Category Archive: Industrial Sewing Services

What is Ultrasonic Cutting?

Ultrasonic CuttingPeoria Production Shop delivers quality industrial sewing services with a highly trained staff and commercial sewing equipment.  We utilize and thoroughly train employees on using all machinery including an ultrasonic cutting machine which is used for many sewing projects.

Ultrasonic cutting is the process of heating materials and then fusing them together. Without any additional thread, glue, or other materials, the seam is finished. This process eliminates any fraying by sealing the edges of the cut.

Ultrasonic cutting is common in the manufacturing of textiles, where fraying is not allowed. This process ensures a high level of accuracy for precision cutting and makes it possible to meet the various cutting constraints for industrial sewing projects.

We use the ultrasonic cutting technique on a variety of sewing products such as seatbelts, straps, webbing, vinyl, cotton, Gait Belts and more.

Benefits of Ultrasonic Cutting

 There are many benefits of using an ultrasonic cutting machine for industrial sewing applications. Ultrasonic cutting guarantees:

      • No fraying
      • No need for thread in seams
      • Shorter production times
      • No burns on fabrics

PPS has the capabilities to take on any commercial or industrial sewing project, big or small. Our ultrasonic cutting machine allows us to change settings like speed or thickness for different sizes of fabric.  For larger size orders, our employees use the ultrasonic cutting technology. For smaller projects, our staff use a heat knife, a smaller tool with the same concept.

Using the ultrasonic cutting machine allows for maximum time savings and increased productivity. Our employees are more efficient when they use this precise, cutting technology.

Our highly-trained staff, modern equipment, and quality practices allow Peoria Production Shop to provide solutions that meet your requirements. The ultrasonic cutting machine is an added capability, making us a one-stop shop for all of your sewing needs.  Request a Quote on our website today.

Quality Operating Procedure

Quality Operating ProcedureWhat is a Quality Operating Procedure? (QOP)

A quality operating procedure (QOP) is a written document composed of step-by-step instructions used to complete a routine operational task. These procedures help to achieve efficiency, performance, and quality control.

Quality Operating Procedures are important to ensure that production operations are performed consistently to maintain the quality of products and processes.

The purpose of operational procedures is to define systems, assign responsibilities and authorities, and provide instructions for carrying out activities comprising the quality system. Operational procedures explain the what, when, who and how for each activity; identify interfaces for the activity; and instruct who should be informed and how the results of the activity should be recorded.

PPS uses specific coding for our operational procedures such as QOP-SS-NN. QOP stands for Quality Operational Procedure, SS is the section in the quality manual to which the procedure pertains, and NN is the consecutive number of a procedure for the section.

Importance of Quality Operating Procedures

1. Increases Business Productivity

QOPs can be beneficial for companies that produce the same product over a long period of time. PPS has been working with a Fortune 100 manufacturer for over 80 years. The procedures help to increase business productivity.

2.Processes Remain Consistent as the Company Expands

PPS is expanding so QOPs can make the work processes portable. Our new employees at the new location can uphold our reputation by using the same QOPs to replicate the products and services provided at the original location.

3.Reduces Errors

Standardized procedures help guide our employees and reduce the possibility of missed steps that impact the quality of the completed product. A QOP ensures that our customers’ products are created in the same way from start to finish every time, creating consistency with high-quality products.

4. Keeps Processes within the Company

Writing down procedures helps to keep key information with the company. This is beneficial when new employees take over a process and for cross-training of employees. It is important for the company to have a physical copy of all work instructions and procedures with documented alterations and continual improvements noted.

5. Better Time Management

QOPs are a valuable component for a new hire, ultimately reducing training time. As PPS expands, we will be hiring more employees. With specific work instructions, the quality operating procedure details the checks for quality personnel.

As an ISO registered company, we use Quality Operating Procedures to remain consistent when following strict quality guidelines. PPS promises to maintain the quality of our customers’ products. Visit our website to join our quality team.

 

In-Process Inspection Report

 

ISO certified companyPeoria Production Shop follows strict quality standards with processes in place to ensure an understanding of the process for high-quality results. As an ISO certified company, you can have confidence in our commitment to meeting your specifications.  We use in-process inspection reports (IPIR) to identify problems as they arise and immediately take corrective action. Our highly trained staff use these reports to streamline the inspection process and ensure work orders are completed accurately.

Prior to the inspection process, the supervisor is responsible for processing the work order and preparing the work station for the operator. During this step, the supervisor will fill out the specific information for the job on the IPIR such as the sales order, part number, quantity of order, package quantity per carton (bag or container), and specific work instructions to be used. The IPIR sheet stays with the product at all times.

After the workstation has been properly set up, the supervisor will inform the quality inspector of the job or new operator. This step can happen at any time of the work day as work orders are completed or operators are shifted around the facility.

The Inspection Process 

  1. Take IPIR Report and random sample of product from operator’s work area
  2. Check a minimum of 5-10 pieces (according to work instruction quality guidelines)
  3. Document findings on IPIR sheet
  4. Communicate those findings with operator
  5. If product is non-conforming, the quality inspector talks to the supervisor. A supervisor must sign off on the IPIR sheet before work can continue.
  6. Quality inspector repeats the process every 30 minutes.

Along with the IPIR sheet, the quality inspector carries a daily report sheet and a work instructions binder to each area that requires inspection. The quality inspector is solely responsible for identifying errors. The supervisor is in charge of correcting any issues with products or processes such as a machine or scale calibration.

The IPIR sheet helps the quality inspector to recognize any patterns. Since the in-process inspection sheet is used for the full duration of the work order, the quality inspector can draw conclusions about an operator’s ability to perform the task or the effectiveness of a machine.

At Peoria Production Shop, we strive to add value to every product we touch. Our quality team follows strict policies and procedures.  If we find that a particular employee is better suited to perform a different task than the one assigned, we place our workers where they excel and perform to the best of their abilities.  This policy has proven to be beneficial to ensure that we provide high-quality products, on-time and with consistency.

At PPS, we use in-process inspection reports and materials to aid in-process inspections  and to ensure finished products meet customer specifications. We promise to do our part and take appropriate action as needed so our customers can succeed. Visit our website to see how we can further your company’s success as a value-added, quality supplier.

 

Partnering with a Quality Industrial Sewing Contractor

Industrial Sewing Contractor

Industrial contract sewing is the process of subcontracting a company to sew products produced by the original manufacturer. Outsourcing your sewing needs has many benefits such as increased space in your facility, reduced cost, and customization. 

Increased Space

An in-house sewing department can take up a lot of space in a warehouse. Original manufacturers have to consider all of the materials required for a sewing department such as tables, products, sewing machines, utensils, measurement tools, and more. Industrial sewing contractors have the ability to accommodate large sewing processes more so than original manufacturers.

Peoria Production Shop has over 160,000 square feet and is currently expanding. Our modern technology allows us to produce high-volume sewing requirements with plenty of current and future capacity.

Reduced Cost

Sewing equipment can be very costly for original manufacturers. Oftentimes, it is better to outsource the work to a contractor who already has the equipment and materials needed for the project. Also, hiring individual sewers and training costs adds up. 

Industrial sewing contractors offer competitive pricing that includes the cost per project, materials needed, and the labor costs. The total of these costs is typically less than setting up an in-house sewing process. At Peoria Production Shop, our motivation is jobs, not profits, allowing us to offer competitive costs in the sewing industry. 

Customization

Industrial sewing contractors offer vast experience in customizing an OEMs sewing project to meet their exact specifications.  Sewing subcontractors can complete custom orders in a timely manner, all for less expenses.  As an industrial sewing contractor, PPS is able to provide customized projects that fit your needs. If a customer needs to change the order size or overall design, we can alter the project to meet any new requirements.

Peoria Production Shop has a highly trained workforce that meticulously follows customer supplied specifications per every project. As an ISO9001:2015  certified company, our staff inspects materials and finished products to ensure they meet customer specifications and our own internal quality standards.  We are dedicated to our customer’s total satisfaction so we work closely to ensure our projects are completed while following a strict quality policy. 

With over 80 years of experience and connections in the industry, PPS is recognized as a leader among the contract sewing companies in the USA. Our success is based on your success. Visit our website to learn more about our industrial sewing capabilities.