Finishing Inspector Lead

Job Title

Position Overview

This position is Monday - Friday 3pm-11pm.

POSITION OBJECTIVE:

The Lead Inspector plays a critical role in supporting quality operations across two continuous finishing lines. This position is responsible for assisting with carpet inspection, making decisions on carpet grading, and guiding inspection team members to ensure consistent quality standards. The Lead Inspector will move between lines as needed to provide real-time support, resolve grading concerns, and help identify off-quality issues.

ESSENTIAL DUTIES:

1. Lead Inspector

o Make informed grading decisions based on established quality standards.

o Assist inspectors on both lines with difficult calls or uncertain grading situations.

o Provide on-the-spot training and feedback to support consistent inspection and grading practices.

o Communicate with quality, supervisors, operators, and other team members to ensure proper handling of product.

o Document inspection findings and assist in tracking trends or recurring quality issues.

o Ensure all Flashbacks are submitted, and photos are communicated of carpet downgraded on the line.

o Support continuous improvement efforts by identifying and reporting issues that may affect product quality.

o Serve as a liaison between inspectors and supervisors when grading discrepancies arise.

o Serve as a liaison between inspectors and supervisors when grading discrepancies arise.

2. Routine Inspection

A. Constantly observe carpet on inspection table for any defects including tufting, yarn, backing defects.

1. Yarn defects

a) Yarn problems usually appear in the form of a single end streak.

b) These types of problems create either straight or shifted streaks depending on the tuft pattern.

c) If a yarn problem is found, one roll(s) will be held for review if the defect is 75 feet or more. If the defect is less than 75 feet, the carpet will be downgraded according to the grading system and a representative cut made for yarn technical evaluation. This cut should be 9”x9”.

d) At this point, perform the streak evaluation (scale 1-10).

(1) 1-4 represents the worst possible case (heavy streaking)

(2) 5 represents marginal goods

(3) 6-10 represents grade “A”- some light streaking, but still first quality

e) Carpet rated 5 or higher is acceptable for shipment, assuming there are no other defects.

f) Any carpet rated lower than 5 will be as follows:

(1) More than 75 feet- hold roll for review

(2) Less than 75 feet- downgrade

g) All yarn problems are listed on the Defect Code Sheet for use. It is the Inspector’s responsibility to know and recognize the defects.

2. Dye defects

a) Dye streaks will usually appear as a dark, light, or off-shade area on the face of the carpet.

b) Other problems resulting from the dyeing processes include wrinkles, dye spots, dye smears, and any others listed on the defects code sheet. It is the inspector’s responsibility to know and recognize these defects.

c) Any carpet with dye problems should be held if the defect will cause a short first or off quality.

3. Coating defects

a) Defects caused by coating are listed on the defect code sheet. It is the inspector’s responsibility to know and recognize these defects.

b) The inspector clerk should be informed of any coating defects in order to make note on the roll ticket.

c) Rolls should be held for repair when a repair is possible.

d) If the defect cannot be repaired (latex on face, holes, etc), the carpet should be downgraded according to the system or the defects cut out.

B. Assign proper hold code for defects noticed.

C. Communicate issues to supervisor and responsible party in a timely manner.

D. Escalate any off quality downgraded that is over 100 ft.

E. Mark area affected by defect with tape if possible.

F. Check each seam to cut out all loose secondary backing while minimizing scrap waste.

G. Check secondary backing periodically and report any defects in the backing itself or its application. Report issues to supervisor.

H. Check carpet for moisture or any other defects. If any defects are observed complete the flashback Google Doc and consult supervisor.

3. Performing the Width Check

A. The width of the carpet should be monitored constantly via the digital readout.

B. On each MO, lay the tape measure across the width of the carpet and note the resulting measurement. Notify supervisor if digital readout is more than ¼“ difference.

C. Width limitations on carpet grade are as follows:

1. “A” grade carpet must be at least 11’11” (143.0”).

2. Carpet that is 10’⅞”-11’6” and otherwise first quality will be considered “B1” grade. B1 is narrow, first quality carpet. Width must be recorded on the ticket.

D. Record width checks and quality flashbacks in the appropriate Google Doc.

4. Obtaining Finished Standards for Shear Evaluation

A. Deck boards filed by style located on the wall side of the inspection area

B. Evaluate the shear level using the correct shear standard for the given finished style.

C. Placing the shear standard on the carpet, visually inspect the carpet to determine if the shear level is comparable to the standard.

D. If the shear level is acceptable, continue the inspection process.

E. If the shear level is unacceptable at any point, the roll should be held for re-shear.

F. All rolls having shear gouges of shear pulls will be held unwrapped and shipped for re-shear.

G. Immediately notify the shearing machine operator of any problem with shear quality.

5. Checking for Backprint

A. It is the inspector’s responsibility to check the back side of the carpet for proper backprint. This may mean using the computer screen or physically checking the backprint application.

B. The spec sheet will state the correct backprint number.

C. If the backprint is incorrect, notify your supervisor. Any carpet not printed or incorrectly printed will be held.

D. The backprint must be easily legible.

6. Perform Duties of Inspector

7. Attendance Policy

A. Must adhere to the Corporate Attendance Policy

B. Must notify the previous shift supervisor of an imminent absence 1 to 2 hours before shift change

C. Must speak personally with supervisor detailing the reason for absence

8. Work Schedule

A. Must work all scheduled work hours for your shift

B. Must be able to work weekends

C. Must be able to work 12-hour shifts

D. Must be able to work holidays as necessary

Shaw benefits include:

Medical, dental, vision insurance

Life insurance and disability coverage

Tuition reimbursement

Employee assistance program

Health savings account

Paid time off

Parental leave

401K and Retirement plans

Product discounts for employees

Adoption assistance

Shaw Family Health Center (Dalton, GA and Cartersville, GA locations)

And much more!

Work Shift