Impressions - March 2025 - 47

3. Automation and technology
According to Stakes' Seifert, his
company's quality-control process
combines the efficiency of technology
and the precision of manual tools,
supported by a team of experienced
professionals who undergo thorough
training and education. Again,
his shop's products receive multiple
QC checks over the course of the
decorating process, during receiving,
staging, pre-production and post-production,
as every item is QR-coded
and scanned at every touchpoint, with
screens showcasing product mock-ups
and product/garment details.
" We report internal QC fails in
real time to isolate and resolve any
equipment and human errors, " Seifert says. " Every order is meticulously
tracked throughout the production, QC and fulfillment
processes, allowing us to identify the root cause and trends of quality
issues. We address all individual instances where items are shipped
without meeting our quality standards. In such cases, we provide
corrective training to the responsible employees. This approach
ensures we consistently deliver high-quality products while fostering
a continuous improvement culture. "
Automating the ordering process, in particular, can help ensure
smoother operations and more straightforward customer communication,
since shops can both streamline production and set clear
expectations by having systems to guide customers through the
specifics of order entry.
" Our systems ask the questions as customers input their information, "
McDonald says. " When customers receive a proof,
it includes their timeline. Setting these expectations is important
because it keeps customers informed about what to expect at each
step of the process. "
For smaller shops that don't yet have the resources for this kind of
automation, McDonald suggests creating a similar manual approach.
" If you're not big enough to do automation, have a list of questions
you want to ask for every order, " he says. " Have a process for order
entry and order taking early on to prevent problems and manage
expectations effectively. "
By way of an example, while the Precision 1 Concepts team
uses shop management software to track orders, it also relies on
paper checklists to ensure accuracy from start to finish. " We still
use paper check-off sheets from receiving and shipping and into
production start to finish, " Burwell says. The resulting blend of digital
and manual systems allows the shop to maintain tight control over
timelines and production.
4. Developing specific processes
As part of its production processes, US Colorworks operates a highly
structured and thorough QC program. " Every time a person touches
a step in the process, there needs to be quality control to verify
that step was executed correctly, " McDonald says. For example,
the team sends an art proof to customers for every order-even
for repeat jobs-to prevent mistakes when selecting the correct
artwork from a client's portfolio.
Additionally, McDonald says his production team relies heavily
on visual aids. " When our production people print garments, either
digital or traditional screen print, there's a visual of exactly what
that product should look like on a screen next to their operating
position, " he says. " Our operators and supervisors sign off on each
Among the challenges when it comes to quality control
is ensuring employees recognize the importance of high
standards. Image by studioworkstock - stock.adobe.com
order, ensuring that there are always two signatures for verification. "
In addition, he says, every US Colorworks operator can stop a job
if something seems off. " Any of our operators can pull a garment
or a job for a quality reason, " McDonald explains, emphasizing
the fact the ability to do so is not limited to supervisors or managers.
" We encourage people to ask questions. That's what quality
control comes down to-forcing yourself to ask questions when
something doesn't seem right. "
The resulting open culture of responsibility enables the team
to catch and correct errors quickly, leading to fewer issues and a
higher quality standard for each order, McDonald says, noting the
processes for QC in screen printing and embroidery differ due
to the unique nature of each method. " For screen printing, a lot
of our quality control checks will come down to the following:
Are we using the correct PMS colors for the ink? " he says. " Or
did the ink get mixed correctly? Are we putting the decoration
on the right garment? "
McDonald also emphasizes the importance of following a " recipe "
for each job, including everything from the order of the screens
being used things like squeegee angles or the pressure that need to
be applied. " Our goal is to be able to print a shirt today, tomorrow,
six months from now or five years from now, and it's the same
result every time, " he says, noting the fact that approximately 20
percent of his business comes from reorders only underscores the
need for consistency.
Along these same lines, Precision 1 Concepts' Burwell says that
when it comes to embroidery work his company limits thread colors
for efficiency. " We've developed our most popular thread colors
and try to stay with those unless a customer requires something
different, " he says. " We have three shades of red in stock vs. 15, but
only our primary stays on the machine all the time. "
Conclusion
Ultimately, an effective quality-control process plays a key role
in determining the output from your facility, directly impacting
client and customer satisfaction.
" Quality is not only a representation of your company but an
extension of the brand, company or person you're printing for,
which is a responsibility that shouldn't be taken lightly, " Seifert says.
Focusing on quality enhances your reputation while building
strong, lifelong customer relationships. 
Nicole Rollender is an award-winning writer and heads up the copywriting and
content-creation firm strandwritingservices.com. For more information or to comment
on this article, email Nicole at nicolerollender@strandwritingservices.com.
March 2025
P.47
http://stock.adobe.com http://www.strandwritingservices.com
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