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Job Master Checklist for Embroidery

Purpose: Quality Control tool.

Master List File Name: SPECFRME

Format: Two to a Page, 1 Part

According to Scott Ritter, the most frequent question he is asked in seminars or by clients is "How do I reduce errors in the shop?" Obviously, the answer is to have a well run, established, and integral quality control system. That does not have to be a tough task to implement. This form was created to serve as the main quality control tool for most shops. This system works great for any size shop from a one-man (or woman) operation to enormous multi-location companies. Even though the form was created with multi-employee handling in mind, one-person shops find that completing each phase of the checklist helps insure accuracy.

Use: The concept is simple. Initially, the work order for each job issued into production is placed on a clipboard along with one of these checklist forms. At issuance, the header box is filled out, denoting the customer name or account number, the job number and the order date. These items should correspond with the same information on the work order or order form (if a similar field exists)

First stop is digitizing. If the design needs a new tape or disk created, the digitizer will fill out all the particulars for this design as he creates it. If  stock lettering or designs are all that is needed, the person responsible for arranging the design will fill this portion of the form. The form has an area where somebody must initial that the customer has approved the design, and those initials must be on the form before the digitizing department head will sign the section as complete. The order does not go into production until the digitizing department has "signed off" on it's part of the form.

The next step is the embroidery setup section. People completing work on this order must initial or sign as the goods are picked for the order, and as the machine is set up. At each step, the person completing the work should have another individual "co-sign" that the work has been performed correctly. When the operator has the machine ready to go, a second individual co-signs that the thread colors are correct, and that the machine will use them in the correct order. At that point, the operator performs the first run, and then another person inspects the first run, verifying that the design, the colors, and the locations match the work order.  Only then does the operator proceed with the rest of the batch.

After the order is sewn, the packager recounts the order to make certain the correct quantities are being shipped, and checks the garments for defective work. When satisfied, the packager / inspector signs the checklist. He or she also denotes whether any items found defective were replaced with new, so that the shipment is complete per the order, or if the shipment is short (or over) so that the bookkeeping department will be alerted to check the order for billing quantities. When the order is packed into boxes, the packager initials the area denoting this action. Then, the people who enclose the packing list initial their space, and the shippers initial and date the shipment.

When the order is completed, the checklist is stapled to the work order, and filed away for future reference. This way, if a concern should arise about the quality of an order, the individual responsible for each phase becomes accountable.

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