The Embroidery Column
Make your embroidery department more efficient with a few small tweaks
In business, time is money, and sometimes by saving seconds, you could save pennies. A tight-run ship can help bring efficiency, which inevitably leads to less time wasted and more savings, as Liz Woodhouse of the Embroidery Academy explains.
R
unning an embroidery department isn’t only about having skilled operators or state-of-the-art machines; it’s often the subtle, everyday practices that shape productivity and profitability. In a fast-paced production environment, seemingly minor delays accumulate rapidly: seconds wasted searching for a thread, unnecessary trims, poorly planned colour sequencing, or machine stoppages that could have been prevented. The good news? Small strategic adjustments can have a big impact. Here are simple, practical improvements that embroidery departments can implement to increase workflow efficiency, reduce downtime, and improve stitch quality.
Efficient thread storage Thread management is one of the most overlooked areas in embroidery rooms. Threads stored haphazardly or without a system waste time as operators search for the right colour or untangle cones. Establishing a structured thread storage system not only improves workflow but also reduces operator stress and errors. Begin by grouping threads in a logical
Thread management saves time and effort
order. Arranging them by colour families, frequently used shades, or brand number sequence works well. Clearly label shelves or peg boards and assign a consistent spot for each colour, making them easy for operators to reach. Prepare new threads in advance so they’re ready for a quick changeover as soon as the previous run finishes, keeping production flowing smoothly.
Once your threads are organised, the next step is to optimise their placement on the machine to minimise travel time.
Organise for speed and consistency It’s also important to consider that the machine takes time to travel from one needle to the next. By grouping popular colours close together, you can significantly reduce this travel time. For example, if white is on needle one and another frequently used colour is on needle 15, the machine must move across all intermediate needles between colour changes. Depending on your machine’s speed, this can take several seconds each time, which adds up quickly over a large production run. Strategic needle placement keeps the machine stitching more and moving less, improving efficiency on every job.
Position the most commonly used threads, such as black, white, red, and royal, permanently in the centre machine positions, as these are on the machine all the time. Threads that require frequent changes should be placed in the easiest-to-reach spots for the operator, allowing quick swaps without disrupting workflow.
Reduce unnecessary stops Unnecessary trims within a design can dramatically increase run time. Where possible, use travel stitches to move from one section of the same colour to the next, rather than trimming after each segment. For small text or intricate details, always try to use connectors – this not only saves time but also reduces the risk of thread breaks. Each trim can take two to five seconds, depending on your machine. On designs with multiple trims, such as lettering where each letter is cut individually, these seconds add up quickly, potentially doubling run times. Thoughtful digitising and minimising trims keep machines running smoothly, increase throughput, and reduce post-production cleanup.
Small tweaks, big results Boosting efficiency in your embroidery department doesn’t require expensive equipment or major overhauls, just a few well-considered tweaks. By organising thread storage, strategically placing threads on the machine, and minimising unnecessary trims, you can shave valuable seconds off every run, reduce operator stress, and keep production flowing smoothly. Over time, these small changes compound, resulting in faster turnaround, higher output, and a more profitable operation.
Start implementing these simple adjustments today, and watch your embroidery department run smarter, not harder.
www.printwearandpromotion.co.uk February 2026 | 79 |
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