CAPACITY EXPANSION
How to Identify an Embroidery Production Bottleneck
Quick Answer
Map the order from file preparation through hooping, sewing, finishing and inspection. Measure queues, processing time and rework. Test the smallest useful change before assuming another machine will solve the delay.
Map the order flow
Map file preparation, materials, hooping, sewing, finishing and inspection. Record where work waits between each step.
Separate demand, sewing time and other workflow limits before adding equipment. Compare options using the same orders, quality standard, working time and staffing. More heads, shifts or operators help only when they address the measured limit and the rest of the process can support them.
- Use accepted output
- Keep scenario assumptions constant
- Expand the measured constraint
Measure queue and process time
Measure both processing time and queue time over representative jobs. One slow sample does not establish the main production limit.
Separate demand, sewing time and other workflow limits before adding equipment. Compare options using the same orders, quality standard, working time and staffing. More heads, shifts or operators help only when they address the measured limit and the rest of the process can support them.
- Use accepted output
- Keep scenario assumptions constant
- Expand the measured constraint
Separate machine and non machine delays
Separate machine stops from missing files, materials, approvals or operators. Another machine may not address delays elsewhere.
Separate demand, sewing time and other workflow limits before adding equipment. Compare options using the same orders, quality standard, working time and staffing. More heads, shifts or operators help only when they address the measured limit and the rest of the process can support them.
- Use accepted output
- Keep scenario assumptions constant
- Expand the measured constraint
Find variability and rework
Record repeated errors and the time spent correcting them. Check which step creates the problem and which step carries the rework.
Define what is checked, when it is checked and which approved file and sample are used. State what stops the batch. Record file, material, thread, needle, backing or setup changes, and require new approval when they can affect placement, appearance or repeatability.
- Compare the same delivered configuration
- Separate included items, options and buyer supplied work
- Keep return assumptions owned by the buyer
Test the smallest useful change
Change one specific process and compare the same work before and after. Check accepted output and quality as well as time.
Separate demand, sewing time and other workflow limits before adding equipment. Compare options using the same orders, quality standard, working time and staffing. More heads, shifts or operators help only when they address the measured limit and the rest of the process can support them.
- Use accepted output
- Keep scenario assumptions constant
- Expand the measured constraint
Expansion decision
Expand only the constraint supported by the measurements. Review staffing and upstream or downstream capacity before committing to equipment.
Separate demand, sewing time and other workflow limits before adding equipment. Compare options using the same orders, quality standard, working time and staffing. More heads, shifts or operators help only when they address the measured limit and the rest of the process can support them.
- Measure a complete job cycle
- Separate machine and workflow constraints
- Compare expansion scenarios under the same assumptions
Frequently asked questions
Does rated speed predict finished pieces per shift?
No. A fast machine cannot remove waiting at other steps. Measure accepted pieces across the shift and include digitizing, hooping, finishing, inspection and rework.
What should I share with FUJA?
Track when each job enters and leaves the main steps. Record waiting, work time, staffing, rejected pieces and repeated delays, then compare the steps under the same order mix.