We Audited 100 POs
At HTG, we don't just print shirts. We obsess over what works, what breaks, and how to run smarter every single day.
Earlier this year, we ran an internal audit of 100 recent contract jobs across screen printing, embroidery, and DTF. We wanted to know:
Where do jobs go sideways? What slows things down? And what’s quietly killing profit margins without anyone noticing?
The results were eye-opening. Some of it we expected. Some of it caught us off guard. All of it can help you run a cleaner, faster, more profitable business.
1. 47% of Orders Had PO or Art Issues That Delayed Production
Nearly half the orders we reviewed had incomplete or unclear purchase orders and artwork files.
Missing PMS codes
Vague notes like "center chest" with no dimensions
Raster files instead of vector
Job names that didn’t match the art files
These aren’t small errors. They stall production, trigger email threads, and knock your order out of the press queue.
What no one talks about: These problems don’t just affect your job, they create bottlenecks for everyone behind you.
2. 22% of Client-Supplied Garments Arrived Incorrect or Late
Client-supplied garments are common—but they’re also one of the top sources of chaos.
Wrong styles or colors
Incomplete quantities
Late arrivals
No packing slips or communication
What no one talks about: Every time we have to sort, track, or delay a job due to garment issues, it adds labor cost. That eats your margin, even if you don’t see it directly.
3. 35% of Rush Orders Could Have Been Avoided
We get it—sometimes the client needs it yesterday.
But in over a third of rush jobs, the PO was submitted late even though the art and inventory were ready to go. The rush was self-inflicted.
What no one talks about: Rush fees are real, but so is the strain on production. If you’re not charging your customer for that urgency, it’s coming out of your profit.
4. 61% of POs Included Add-Ons Without Pricing Clarity
We saw all kinds of value-adds on these orders:
Polybagging
Sleeve prints
Neck relabels
Patches
Special effect inks or threads
But in over half the POs, these were listed with no clear breakdown of how they were priced—or even if they were priced.
What no one talks about: If your PO is vague, you're likely absorbing the cost. That’s death by a thousand cuts.
5. The Clients with the Fewest Mistakes Sent the Clearest POs
The cleanest jobs had one thing in common—crystal-clear paperwork. Those clients:
Used structured PO templates
Attached mockups with detailed specs
Sent vector artwork with PMS codes
Listed every finishing detail upfront
They weren’t always our biggest clients, just the most organized.
What no one talks about: You don’t need to print more shirts. You need to print smarter ones.
Final Takeaway: Your Margin Lives or Dies in the Details
These weren’t flukes. They’re patterns. And they’re costing time, money, and client trust every day.
Want:
Faster turnarounds?
Fewer mistakes?
Better margins?
It all starts before your job hits the press.
We’re not here to point fingers, we’re here to help you win.













