"He who marches out of step hears another drum." ~ Ken Kesey
Thanks Pierre!that's so smart! that's why i love these boards!!
35k hoodies in our shop... Logistically it almost became a disaster... but we powered through, learned a bunch and would do it again in a heartbeat.these all were customer ordered from china, and arrived NOT palletized in a shipping container... upon opening the boxes we found that the shirts were all individually folded and bagged... this started a massive effort requiring 2 people to unbag shirts and stack them on job carts. We thought all was good for the first few days -- we were averaging 550 shirts/hr 3600 shirts/day. Then we get a calll from the customer telling us to "Stop the presses" as all the shirts were the wrong size (they ordered them, so not our responsibility) -- their vendor in china evidently mixed up the womens and youth size tempates, so all the womens shirts were SO tiny that a 2xl womens fit like a small. So we start only printing the mens shirts as they scrambled to get more in. We had 5 people working on the job (2 unbagging, loader, catcher, and a puller/stacker at the end of the belt). It actually didn't go that bad overall... just that the shop was so stacked that we had little 2' walkways to get around the first week. Total production time was around 100 hours (that includes setups, teardowns, switchovers, inking/gluing etc). We were lucky in that the fleece material stuck really well to waterbase tack and we didn't have to use webspray.I'm sure I'm forgetting some parts of this, but it was quite the job for our little 1 auto shop (while keeping all the other orders flowing) <<- this is what a lot of people don't think about... thank god for our 10 color press so we were able to put other jobs 'in between' the heads to keep the big job setup.
