Tips for Training Embroidery Operators

September 14, 2009
By Deborah Jones, Contributing Writer

Does your shop have a training program? Even if you are a one-person shop, there will likely come a day when you will need to train a helper, salesperson or machine operator. Start keeping notes now about what your employees need to know and how you want to teach them.

Many shops just hire a new worker and let them learn on the job. This “on-the-job osmosis” method usually results in uneven job skills and does not give your employee the best opportunity to excel.

A defined training program has thresholds that are linked to a schedule, assuring that trainees are presented with all relevant information within a finite time frame. This gives you the ability to make a judgment about whether the trainee has or will likely achieve the necessary competency level to become a permanent employee.

When you train an operator from the ground up, and let them know they can advance in the company they are less likely to leave you to go to another embroidery shop. Also, if you have an established training program, and you lose an employee for any reason, you have a good idea how long it will take to another employee up to speed. Indeed, you are less likely to lose employees because a training program instills a sense of value to your business.

Machine Operation: The Ideal Candidate
A candidate for a machine operator should be bright, reasonably fit, and have good hand-to-eye coordination and dexterity. Many people look for sewing experience. That can be helpful, but keep in mind that commercial sewing machine operators sit while working, while embroiderers must be able to stand on their feet all day. During the interview process, I show the machine area to the prospective employee. I like to hire a prospective trainee who is not intimidated either by the machine or the computer.

Principles of a Good Training Program

The machine does not have a mind of its own.
I stress to trainees is that the machine does only what you tell it to do. Machines rarely malfunction and stitch improperly – a possible result of electrical or electronic problem.  So don't be overly sympathetic when a trainee exclaims,  "I don't know why the machine did that." Reinforce in a gentle way that the machine most likely did what they instructed it to do.

The machine can hurt you.
You don't want to frighten new employees, but they should have a healthy respect for the machine and understand that they could be hurt if safety procedures are not followed. Establish a signal that lets others know the machine is about to be started. Many operators say "Ready" or "Clear" loudly before the machine is engaged. This is a must on multi-head machines, to help assure that no other worker has hands or fingers near any moving parts.

Mistakes happen
Enthusiastic trainees can sometimes persuade managers to accelerate the training program. Resist the temptation. Errors will occur — like hitting a hoop, misplacing embroidery or cutting a shirt. Remain calm; don't undermine the trainee's confidence and try to make it a positive, “What did we learn from this?” experience.

Allow the trainee to operate the machine as soon as possible
Research shows that people retain:
• 25% of what they hear
• 45% of what they see
• 70% of what they see, hear and do

The trainer should observe the trainee for a time, and then reverse the roles. For the first few days, the trainer should be available at all times and never walk away leaving the trainee alone at the machine. Have the trainee repeat instructions, or explain procedures, in their own words. Many trainees want to succeed and say they understand a concept even when they may not understand.

Train operators according to their ability to absorb information
Some large shops have specialists — setup operators and job operators — but most small shops cannot afford this luxury. Small shop operators should be comfortable with the machine as well as its controller. Allow a trainee to make notes to help them through the steps to load a design, assign needles and other controller tasks. Keep a laminated “Quick Start” reference card at the machine.

Getting Started with a Training Program
Set a defined curriculum and schedule. Start trainees with simple tasks, like changing thread over for a new job and progress to teaching tension basics, and identifying good embroidery from poor embroidery. Collect samples with mistakes like embroidery that’s off-register, jagged column stitches or other symptoms.

It's also a good idea to make a short video of operations in your shop that your trainee can take home. This serves a dual purpose; they will learn from it and they can show their family about their interesting new job.

Minimum Training Curriculum for Computerized Embroidery Machine Operators
• Understanding of placement standards
• Understanding how to apply your shop’s standard embroidery placement, such as left chest or full back.
• Selecting suitable techniques for marking garments
• Review of job details 
• Read orders for completeness – thread colors, design, placement
• Ask for verification in the case of questionable spelling
• Inspection of garments
• Counting of garments
• Checking for correct garments
• Checking for defects before applying embroidery
• Selecting appropriate hoop for the job
• Understanding the principle of using the smallest hoop that will accommodate design
• Learning hooping rule exceptions, such as keeping bulky seams out of hoop area
• Hooping various fabric types
• When alternate holding methods are needed
• Avoiding damage to fabric from hooping
• Match stabilizer to fabrics
• Do a test sew-out on similar fabric for a first article
• Evaluate for proper support
• Evaluate when a topping is needed
• Determine when it is necessary to mark garments for placement
• Deciding proper marking technique for each fabric type
• Applying proper marking

Thread Handling
1. Setting up thread for standard jobs
2. (Multi-head) Setting up threads for small quantities or mixed color orders
3. Tying of knot to pull through needle for thread changeover
4. Tying of knot for thread storage
5. Purpose of each component in the thread path (pre-tensioners, tensioners check spring)
6. How a stitch is formed
7. How thread break detector/bobbin sensors work
8. Handling of metallics, polyesters and other specialty threads

Thread Tensioning
1. Tension testing procedures (top and bottom)
2. Troubleshooting tension problems
3. Understanding how to apply logic to balance tensions
4. Adjusting and cleaning of the bobbin case
5. Adjusting of the upper tensioners

Needles
1. Matching the proper needle to goods
2. How and when to change needles
3. Identifying sewing symptoms that are needle related

Troubleshooting and Machine Management
1. When to back up the machine, and when NOT to.
2. Identifying causes of thread breaks
3. Lubricating —  when, where, how and with what
4. Sewing speeds for various jobs and stitch types

Specialty Techniques
1. Producing high quality embroidery on finished caps
2. Producing appliqué products (if applicable)

Minimum Training Curriculum for Supervisors (Multiple Machine Shops)
Pre-Production
1. Scheduling principles
2. Matching job specifics for efficient consecutive job sequence
3. Assigning priorities according to promise date
4. Procedures for ordering digitized designs

Production
1. Sensible, orderly work flow through shop
2. Monitoring of supplies and accessories
3. Matching operators to jobs and machines
4. Tracking of production throughput-maintaining a production log
5. Account daily or weekly losses and cost of nonconformity

Equipment
1. Oversee maintenance
2. Keep a maintenance log for each machine

Training
1. Selecting and organizing recommended reference material for operator trainees
2. Evaluating trainees' progress
3. How to identify underskilled operators and provide assistance

Deborah Jones is a commercial and home embroiderer with more than 30 years experience in the computerized embroidery field. For more information or comment on this article, e-mail Deborah at deborah_jones247@yahoo.com.

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