The Success Of a Chinese Shoe Factory,How To Improve Quality
How this shoe factory became the official manufacturer of fashion brands against all odds
Walking into the production workshop of a shoe factory in Dongguan City, Guangdong Province, China, the clean and bright environment and automated assembly lines are refreshing.
General manager Wang Wu seems confident, since 1999, his factory has completed four “transformation and upgrading“, from the initial few used ovens and bottom presses, now, his workshop production line has been more advanced in the industry.
Many domestic shoe factories shift production capacity to Africa or Southeast Asia in recent years,for this,General Manager Wang Wu has his own views.
The success of a shoe factory-Upgrade Equipment
“We have also visited Southeast Asian countries, but after the actual understanding and assessment, we still believe that Dongguan is still the most complete supply chain support for the global women’s footwear industry, including shoe materials, equipment, and even the level of technology.”
After making up his mind,the shoe factory invested nearly ten million dollars in equipment and assembly lines for the fourth renewal.
Invest nearly 10 million, new construction of automated assembly line, labor reduced by half
Wang Wu said that traditionally, a production line like them, probably needs 45 to 50 people, while this line only needs about 25 to 30 people to produce.
Moreover, the energy consumption of the whole line of equipment is only 200 kilowatt-hours a day, which is about 50% less than the energy consumption of other traditional production lines.
Another example is this pen type toe lasting machine, which can store up to 3000 pairs of different shoe models through servo glue feeding system, full data memory and visual photo forming trajectory, etc. It only takes 2 minutes to complete the visual photo forming trajectory, which is a one-stop solution to many production technology barriers.
Wang Wu said, now with this hot melt glue,he does not need people to brush glue.For the environmental protection, glue pen brush glue, completely do not need to consider replacing the glue tray and other problems like other toe lasting machine.
According to reports, shoe processing is often mass-produced.This pipeline design, on the other hand, flexibly addresses the need for small batch production of high-end products and facilitates enterprises to adapt to a more flexible market demand.
It took several months to switch from foreign equipment to domestic assembly lines
The most important process of shoe making lies in wrapping, which was first done by personnel.
The toe lasting machine, middle and back lasting machine and intelligent production line introduced at present have transferred the process responsible by human beings to equipment production, which greatly reduces the influence of human factors and improves the product quality.
General manager Wang Wu spent several months visiting and investigating in order to find an advanced and reasonable production line. Only in the end did he choose this kind of CNC production line that runs on IE production data and forms TT beats.
According to Wang Wu.
We first actually decided to contract with foreign equipment manufacturers, but subsequently looking at many domestic brands of equipment, we found that in fact these domestic manufacturers had better features, cost performance, etc. than foreign equipment, so we finally chose a domestic brand and after a few months of operation, we are also sure that our initial choice was the right one.
This new production line, according to the molding process, extracts the equilibrium time and sets it as the TT beat of production. The employees of the whole production line must then consciously and actively complete their process within the set time. The per capita efficiency can be increased by more than 25%.
At the same time, saving shoe lasts and electricity were also the reasons why Wang Wu chose it.
Producing about 1200 pairs of shoes per day, only 80 pairs of shoe lasts are needed and about 200 kilowatt-hours of electricity.
In this era of labor scarcity, this new production line, which was put into production when more than 10 employees could also run normally, now has more than 30 employees.
And in recent years, the domestic environmental protection requirements are also getting higher and higher, so the choice of equipment also needs to meet the environmental protection regulations as well as the future environmental protection requirements of the equipment and process.
The Success Of a Shoe Factory-Owner’s Goals
In 1999, 22 years ago, Wang Wu stepped into the shoe industry with a determined heart and founded this shoe factory.
The earliest start was to do some low-end brands in Africa, and then received low-end orders from the Middle East and Europe. Later on, we started to contact with European and American mid-range brands, until now we have been cooperating with many American fashion brands.
And recently, gradually replaced the automatic equipment for the whole lines, also attracted many footwear brands and traders to visit to understand.
Wang Wu said, “We provide better quality and efficiency to our customers, so that they can see our strength, and they are more comfortable to place orders. Several large brands and traders have recently made us their main supplier as a result.”
At one time, Wang Wu also wanted to do his own brand, but after a careful evaluation, he felt that he should focus on what he is good at and turn it into the biggest reliance for the company’s growth.
First, a series of reforms and distributions have been carried out inside the company, so that the main backbones can have a certain amount of allotted shares and build up everyone’s sense of belonging.
The second is the renewal of production equipment towards intelligence and automation. We are looking for solutions to replace manpower, we do not rule out the introduction of robotic arms and other equipment that can save manpower and increase efficiency in the future.
Third, focus on the breakthrough of shoe-making technology, some of the difficulties encountered in the past, find ways to break through, and constantly carry out the inheritance of shoe-making technology and learning.
Wang Wu said.
In the depressed environment of these years when the footwear industry was affected by the trade war and the COVID epidemic, many of our customers and suppliers expressed their willingness to support and face the difficulties together.
Therefore, we have instead increased our investment at this time, investing nearly 10 million in upgrading the hardware equipment of our shoe factory. With a complete industrial chain, plus the proper replacement of old equipment, we can keep moving with the times by leveraging on these foundations, so there is no sunset industry, only “sunset thinking”.
Nowadays, with the help of a complete local industry chain, Baoding Shoes has successfully achieved counter-trend development and become the designated manufacturer of many high-end fashion brands in Europe and America.
At the same time, Wang Wu also expects more global high-end footwear brands to flow into Dongguan because it has the most complete footwear industry chain in the world.
Disclaimer:
CQI5 article information from the Internet and contributions, the copyright of which belongs to the original author, and only represents the views of the original author. This website is only responsible for sorting out, typesetting and editing the articles, reproduced for the purpose of spreading more information, does not imply that it endorses its views or proves the truthfulness, completeness and accuracy of its content, and therefore does not assume any legal responsibility.
The information contained in this article is for reference only and is not intended as direct advice for decision-making.
If we inadvertently violate your copyright, please inform us, after verification, we will immediately correct or delete the content according to the requirements of the copyright holder, thank you! Contact, email: copyright@cqipro.com
This website has the final right to interpret this statement.
Welcome to reprint, Please be sure to keep information complete.
