PAIHO, a preeminent global supplier in the footwear industry established in 1979, faces the quintessential challenges of maintaining quality and efficiency in its production processes. With over 10,000 employees worldwide and a commitment to supplying top-tier materials such as velcro, elastic, webbing, shoelaces, and reflective materials to the leading 20 international sports shoe brands, the stakes for operational excellence are high. The company's factories, strategically located in Taiwan, China, Vietnam, and Indonesia, complemented by sales offices and warehouses in the United States, stand testament to its global footprint and industry leadership. However, two significant challenges threatened to undermine this esteemed reputation: fabric shrinkage due to inaccuracies in the fabric fusing process and the risk posed by undetected needles in finished products.
Challenge 1: Fabric Shrinkage and Defective Products
The fabric fusing machines, a crucial component of PAIHO's production, necessitate accurate calibration of heat, pressure, and time. There were some issues that arose due to alterations in these factors, such as fabric shrinkage and other related problems.This resulted in the inefficient use of resources and created challenges in the supply chain, leading to product recalls in some instances. Issues like these can have financial implications for the company and negatively impact its reputation in the market, as well as the satisfaction of its customers.
Challenge 2: Inaccurate Needle Detection
Ensuring the safety of the end products is of utmost importance. PAIHO relied on needle detectors to detect and remove sharp metal contaminants, but the tools they had at the time were not always effective in locating all needles. There were potential consequences that could have arisen from this mistake, including harm to individuals who used the product, the possibility of legal action against the company, and potential damage to its reputation. There was a pressing need for a prompt and efficient resolution.
The Solution with OSHIMA Machinery
In response to these issues, PAIHO collaborated with OSHIMA to obtain fabric fusing machines with a unique automatic shutdown mechanism to keep them from overheating. OSHIMA ensures that heat and pressure are distributed evenly, resulting in a significant reduction in fabric shrinkage. Also, OSHIMA's regular calibration every 2 hours guarantees accurate scanning of the needle.
Outcomes
The use of OSHIMA technology has transformed PAIHO's manufacturing capacity, allowing the company to maintain its commitment to quality and safety. The improved efficiency and dependability of the production processes have not only increased PAIHO's ROI, but have also restored and reinforced the company's market position and consumer confidence.
Discover how OSHIMA's garment machinery products may improve your production standards while reducing operational risks. With OSHIMA's proven solutions and dedicated after-sales service, your company can focus on what it does best: producing high-quality footwear components for the worldwide sports industry. Contact to us today.
