In the business of screen printing, achieving faster screen printing set ups can make a huge difference in efficiency and profitability. During a recent Shop Talk at Impressions Long Beach, industry experts Tony Palmer of Palmprint Consulting and Brian Lessard of MADE Lab shared their insights on how to streamline the setup process in screen printing shops. Here’s a detailed look at their discussion.

Preparation is Key

As Tony Palmer aptly stated, “If you fail to prepare, prepare to fail.” The importance of preparation cannot be overstated. Having everything ready before the setup begins can drastically reduce downtime. Both Tony and Brian emphasized that the vast majority of time lost during production isn’t due to the speed of the machines but rather due to ineffective preparation.

• Reduce Variables: Tony mentioned the need to minimize variables during setup. This includes ensuring that the pre-registration system is perfectly aligned to avoid complications later on.
• Organized Workspaces: Brian highlighted the necessity of having all materials—inks, screens, shirts—organized and easily accessible. “The humble shop cart saves so much time,” he noted. Having everything in one place prevents delays caused by searching for missing items.
• Clear Communication: Establishing clear communication among team members is crucial. Everyone should know their roles and responsibilities to avoid confusion during setups.

Understanding Quality Standards

One of the more philosophical discussions centered around quality standards. “The most valuable person in your shop is the person that knows when the print is good enough,” Tony remarked. This perspective encourages a balance between striving for perfection and recognizing when to move forward without getting bogged down in minor details.

Investing in Pre-Press Equipment

Investing in high-quality pre-press equipment was another essential point made during the talk. “People want to get the bigger press, the faster press, but they’re still using film and positioning by eye,” Tony explained. Upgrading pre-press equipment can significantly enhance overall efficiency, allowing for quicker and more accurate setups.

Creating a Sense of Urgency

Establishing a culture that values speed and efficiency is vital. Brian shared an example from a large shop where a system was implemented to create urgency during setups. “As soon as the press was set up, a light would turn on, and if it stayed on for fifteen minutes, the most experienced person would step in to troubleshoot,” he explained. This approach fosters a proactive attitude towards setup times.

Best Practices for Setup

• Have Everything Ready: Ensure that all materials and tools are ready before starting the setup. This includes swatching inks and confirming the availability of shirts.
• Streamlined Processes: Establish standardized procedures for common tasks, such as cleaning screens and preparing inks, to minimize delays.
• Monitor Setup Times: Keep track of how long setups take and identify areas for improvement. Tony suggested that setups should ideally be under thirty minutes for a standard job.
• Training and Cross-Training: Train staff not only on their specific roles but also on others’ roles to create a more flexible and responsive team.

Final Thoughts

Both Tony Palmer and Brian Lessard provided a wealth of knowledge on faster screen printing set ups. The key takeaways are clear: prioritize preparation, reduce variables, and invest in quality pre-press equipment. By fostering a culture of efficiency and communication, screen printing shops can significantly enhance their productivity and profitability.