05:30 — Roll intake
The day starts before the lights go on in the cutting hall. Fabric rolls arrive from the spinner and are logged against the purchase order: supplier, lot number, GSM, and width. Every roll is checked for loom breaks, oil spots, and web defects before it is admitted to the production floor.
Rolls that fail intake are quarantined. They do not go back to the shelf and they do not quietly get used on a smaller job.
07:00 — Die cutting
Dies are mounted and the first pieces are pulled and measured against the spec sheet: handle geometry, panel dimensions, gusset placement. Die setup is checked against the approved artwork and the physical sample the buyer signed off.
The first-off pieces are retained for the run. If the run is later questioned, the retained first-off is the reference.
09:30 — GSM verification
Fabric weight is verified on the floor, not taken on trust from the supplier's certificate. Samples are cut from the running web, weighed, and recorded against the batch. This is the check that catches a sub-weight roll before it becomes a customer complaint.
11:00 — Print setup and strike-off
Flexo plates are mounted, ink is mixed to the specified Pantone reference, and a strike-off is pulled on production substrate. The strike-off is approved against the signed sample before the press runs at speed.
This is the single most important checkpoint in the plant. It is the last point at which a colour problem can be fixed in minutes rather than in weeks.
13:30 — Sealing and handle assembly
Ultrasonic and heat sealing are set and verified on the first pieces of each size. Handle assembly is checked for attachment strength — the same pull test that the finished bag will be subjected to during final inspection, applied on the line so problems surface early.
15:00 — Dimensional audit and count
A random sample across the batch is measured against the size tolerance for every SKU in the order. Counts are reconciled against the production quantity so a shortfall is caught before palletising rather than after delivery.
16:30 — Final dispatch inspection
A final audit pulls finished bags from completed pallets and checks print registration, colour, handle integrity, and packaging. Approved pallets are wrapped and labelled with the lot reference so the batch remains traceable after it leaves the plant.
Why the sequence matters
Each checkpoint exists to catch a failure class that the next stage would make invisible. GSM verification catches a short roll. The strike-off catches a colour mismatch. The seal check catches a bond failure. The final audit catches what the earlier stages missed.
That is the whole argument for in-house production: when a problem appears on the line, the person who can fix it is standing next to it. In an outsourced supply chain, the same problem becomes a phone call, a courier, and a timeline measured in weeks.