Customer Overview
The customer is a leading American producer of pillows, bedding, and other related products, holding the title of the largest such manufacturer in Minnesota. Their extensive product range includes mattresses, mattress toppers, slippers, comfortable apparel, and bath items. Their flagship product, an ultra-comfortable pillow designed by the founder, aims to deliver superior sleep quality. During the Covid-19 pandemic, they expanded their production to include cotton face masks for medical workers.
Problem: Inefficient Fabric Spreading
The customer needed a fabric spreading machine that could keep pace with its high production demands. Fabric spreading, the process of unrolling and laying out fabric smoothly for manufacturing, typically requires substantial manpower when done manually. Traditional methods are not only slow and labor-intensive but also prone to errors. Workers can become fatigued, leading to uneven fabric tension and increased material waste. Moreover, manual spreading is risky and requires 2-6 workers, making it inefficient and unsustainable for large-scale production.
Solution: OSHIMA’s Heavy-Duty Fabric Spreading Machine
The customer opted for OSHIMA’s multi-roll fabric spreading J3, a precision-engineered, heavy-duty fabric spreading machine. This machine changes the way fabric spreading by automatically processing a substantial volume of fabric with high efficiency. Whereas manual labor could only manage to spread 1200-1500 pieces of fabric over an eight-hour shift, the J3 machine dramatically increases this capacity, spreading 4000-4500 pieces in the same timeframe. Its high travel speed of 90 meters per minute minimizes downtime and maximizes productivity. This machine is not only perfect for handling large volumes but is also ideal for producing sensitive items such as medical isolation gowns and masks due to its precise and consistent fabric handling.
Result: Enhanced Production Efficiency and Precision
By installing the J3, the customer has achieved significant improvements in consistency, accuracy, and speed in the fabric spreading process. This has enabled a notable increase in output and the ability to diversify product offerings effectively. The investment in this fabric spreading machine, substantial though it may be, has paid dividends in terms of increased capacity and enhanced operational efficiency.
