INSIGHT INTO MATCHORY BAGS AND BACKPACK FACTORIES
To prevent interruption to the productions we have specifically trained warehouse staff who collect all parts and materials in advance. We are using visual and audio communication systems. When a production line needs materials a push on a button will sound and light the system in the warehouse. A warehouse staff-member will then send pre collected materials to the production line. Our production lines run LEAN manufacturing. The purposes are to make only what are needed at the time when it’s needed and reduce no value-added processes. This practice creates a push-and-pull production flow. By maximizing the production line balance, the production flow between the beginning and the end is so designed that each process is carefully either combined or balanced with the entire production line, creating the least waste of time and labor. Data boards are being used to show the production details, plus an advanced computer visual data system allows production leaders and quality control staff to instantly view and know the production efficiency and quality statistics. All data are instantly saved in the system for future analysis and continuous improvement drives. This data visual system enables input of quality, quantity, efficiency at the same time, facilitating supervisorsto understand the full extent of the production status.
The benefits from low production costs to shortened lead time and to product quality, are easy to spot. This helps our clients to win market shares and profits.
Electronic pattern creation system is being used to shorten sample development lead time. Sample masters use the software to create patterns for each parts of a bag or backpack. After editing the electronic pattern is saved on file for future modifications. After a complete set of patterns is created, a platter draws and cuts all patterns, saving development time and ensuring accuracy. Modern computers and a proprietary ERP software system are extensively being used in our factories. The specially tailored ERP system kicks in after receiving orders from our clients. Before ordering materials the system automatically optimizes material usage at a click of a button. Improving material usage rate and reducing wastes. It than tracks all material available arrival status and accurately reports to the Production Control. This greatly improves the work efficiency of the staff and reduces the risks of human errors. The system manages in-house material inventories, reduces the procurement lead time and ensures production orders being shipped out correctly. This state of the art computer system is simply one of the best in the industry.
Becoming a Smart-Factory and meet the Industry 4.0 standard – the future of productivity and growth in manufacturing industries. Our factory partners using automated production processes which lower the costs on the one hand, and increases the product quality on the other hand. One example for the pursuit of automation in our factories is a self-developed automatic fabric unroll machine. This machine automatically unrolls fabrics, cut to designated lengths and number of sheets. This makes the cutting of the fabrics very accurate and the whole process much more efficient due to saving a great amount of manpower while increasing the processing-speed.
Computerized sewing machines are known to be efficient and consistent. We are using high-tech applications that were specially designed for our machines to support the employees during their work. These applications creating consistently high-quality sewing patterns at low labor input and high product output. Large dimensioned programmable sewing machines are being used to sew oversized panels that are required to have specific stitching patterns. The purpose is to finish the stitching in one process, saving time and labor and increasing efficiency. Two easy swap-templates allow workers to prepare materials while the sewing machine is running. Smaller programmable sewing machines are equipped with hold-down plates so that workers do not need to keep fingers near the needles, improving the safety of workers.High speed automatic sticker application machine uses laser to accurately position and apply sticker on the designated area. One such high-speed machine saves five workers applying stickers by hand.
Another automated system prevent container loading errors. A scanner reads and compares each carton code with the shipping order in the system and automatically removes any cartons that are not in the system for the order. This high-tech application ensures 100% shipping accuracy during loading process.
In order to guarantee the quality of the productions conform to the standards of our clients set up a special quality assurance system. Starting from the incoming materials inspection until outgoing final product shipments detailed procedures are in place to ensure our productions comply with clients expectations.
For example from the beginning of productions, our sewers check the work of the previous process. If any substandard workmanship is found, the work piece/parts will be turned back to the previous station for rework. This special design of this inspection structure prevents non-compliant parts from being passed to the final stage.
During the production, there are inspectors randomly check the quality of work piece. If the number of defects passes a preset limit, production leaders will be called in and the work of the station will be halted until the root causes are found and problems resolved. After completion, every single product must pass a meticulous quality inspection before packaged.
All fabrics pass through inspection machines to locate defects. We operate a test laboratory which carries out a variety of physical tests to make sure that all products fulfill our high quality standard. For example weight carrying parts are often cut and put on the tensile strength tests to ensure final products will sustain abuse from customers.
When it comes to product durability tests are done on parts that often sustain high tear and wear. Such as trolley wheels or handles. Even some seemingly less important parts, such as cartons are tested for burst strength.
Sharp Metal Detection:
Based on customer requests our factories pass finished products through metal detectors to spot any metal parts hidden inside any bags. When needed our system will automatically flip the product so that both front and back sides can be easily scanned.
Waterproof and no-stitching Technologies:
We are using water-proof tape machines which glue strips of tapes on top of needle holes in order to produce waterproof soft fabric bags and backpacks. We are also capable of producing no-stitching products. Using special glue and fabrics, sheets of fabrics or zipper can be bound together without sewing, creating smooth and clean product appearance.