Industrial Laundry - Production Problems

Production Problems

Communication

Like any good business, a laundry's operation depends on good communication. Customers must file their orders in a timely manner. Delivery people and order fillers must keep records of the types and quantities of linens used. Managers must be informed of production difficulties and attitude problems. Any breakdown in communication will hinder the laundry's productivity.

Cross-contamination.

Clean linen and soiled linen should never be mixed. For this reason, most laundry facilities have two major work areas, the "soiled area" and the "clean area". These areas are usually separated by a wall. Separate carts are designated for clean and soiled linen. Linen usually passes from the soiled area to the clean area through the washers. Any clean linen that comes into contact with soiled linen or with carts used to transport soiled linen is considered soiled and must be re-washed. Laundry workers who handle soiled linen are required to wash their hands before working with clean linen.

Wet linen storage.

Wet or soiled linen that is allowed to sit for an extended period of time may become permanently wrinkled. Worse, wet linen stored in a humid area may mildew, requiring replacement.

Dust

Dust can and does settle on clean linen. For this reason, clean linen left on shelves and in delivery carts should be covered. While many laundries use dust covers specifically made for this purpose, others will improvise, using sheets or blankets.

Cart Space

Every laundry, regardless of size, has a limited amount of cart space for storing linen. For this reason, the laundry's carts must be constantly recycled. The moment a cart is emptied, it is returned to the laundry to be filled with another order. If it is designated for soiled linen, it should be emptied at the laundry facility, then sent back to the collection point for another load.

Replacement linens

Each trip through the wash cycle places wear and tear on the linen. Thus, a major laundry facility needs a constant stream of new linens coming in to replace worn-out items. Items that are not too badly damaged may be set aside for something other than their original purpose. (Permanently stained or torn blankets, for instance, may be used to line floor areas being waxed.) However, they will still need to be replaced in the linen stream.

Maintenance

From its major computerized machines down to the wheels on its carts, every laundry facility depends on mechanical and electric devices. These devices require a range of constant maintenance by skilled and certified technicians. Poorly maintained equipment can limit productivity and may even cause or contribute to injuries.

Rework

As in any business, any job that was not done properly the first time must be redone. Items that weren't thoroughly cleaned must be rewashed. Orders that were filled using the wrong supplies must be re-filled. These are two of the many examples of rework in a laundry.

Overstuffing

In recent years, it has become standard practice in prisons for prisoners to deposit personal laundry in mesh bags. The advantage of this system is that the mesh bags keep personal items separate in large loads during the wash cycle. The disadvantage is that prisoners tend to overstuff the bags. This inhibits mechanical agitation while preventing water and chemicals from reaching soiled linen. The result is poorer quality linen.

Tunnel jams

If tunnel washers have one noteworthy defect, it is the tendency for the tunnel to become blocked when the washer is overloaded. When the tunnel is blocked, the washer must be stopped and allowed to drain, then the blockage must be removed manually. A tunnel jam may cost the laundry several hours of production time. Operators can prevent tunnel jams by paying strict attention to the washer's load limits.