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Wrinkled tongue – Case #652

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: wrinkles on the tongue because the factory was applying glue to the lining.

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Impactiva solution: we got the factory to stop using glue at the lining as it is not necessary for the construction, and in this way the wrinkles are avoid at the same time that they save materials, labor and time.

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Stay tuned for more Impactiva technical solutions to every day production problems.

shoe quality control

Knitted upper – Case #651

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: the toe puff can be seen through the knitted upper after lasting.

shoe quality control

Impactiva solution: we got the factory to attach two pieces of black cotton drill backer to the toe puff in order to prevent the problem.

shoe quality control

shoe quality control

Stay tuned for more Impactiva technical solutions to every day production problems.

impactiva shoe quality control

Glue application on straps – Case #650

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: the strap lining gets glue stains because applying the glue on the table stains it and transfers it to the strap.

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Impactiva solution: we got the factory to hang the strap above the table during glue application in order to avoid stains on the lining.

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Stay tuned for more Impactiva technical solutions to every day production problems.

shoe quality control

Decorative buckle attachment – Case #649

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: the non-functional buckle wasn’t secured with a strap, and being kids shoes, it can fall or be removed by the children easily.

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Impactiva solution: we got the factory to secure the buckle between the upper and lining strap in order to avoid this potential problem.

shoe quality control shoe quality control shoe quality control

Stay tuned for more Impactiva technical solutions to every day production problems.

 

shoe quality control

Auto-vanishing pens risk – Case #648

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: the factory was using auto-vanishing pens for outsole marking. There are chances that the pen markings can reappear in cold weather.

shoe quality control

shoe quality control

Impactiva solution: we got the factory to do the sole marking with needle impressions instead of auto-vanishing pens.

shoe quality control

case 648 pic 4 impactiva footwear qa

shoe quality control

Stay tuned for more Impactiva technical solutions to every day production problems.

shoe quality control

Open stitching – Case #646

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: the lining zig-zag stitching opens because the material does not have enough strength.

shoe quality control

case 646 pic 2 impactiva footwear qa

Impactiva solution: we got the factory to add cotton tape along the zig-zag stitching to avoid the stitching opening.

shoe quality control

shoe quality control

Stay tuned for more Impactiva technical solutions to every day production problems.

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Inconsistent pleats – Case #644

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: the pleats look inconsistent and they open due to insufficient glue application at the edges.

shoe quality control

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Impactiva solution: we got the factory to change the glue application cut-outs shape (wider at edges) in order to improve the glue application and achieve a good pleating shape.

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Stay tuned for more Impactiva technical solutions to every day production problems.

 

 

impactiva footwear quality control

Kicking in – Case #642

“A picture is worth a thousand words”. Practical solutions to problems encountered in the manufacturing process that demonstrate how we assist our customers’ factories to produce Right from the Start TM.

Problem: outsole was kicking in

impactiva footwear quality control

 

Impactiva solution: we got the factory to add a 2 mm. texon board at the heel part of the sole. This solved the heel kicking problem.

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Stay tuned for more Impactiva technical solutions to every day production problems.

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Eliminating Waste – Excessive work in process

“A picture is worth a thousand words”. What do we mean when we talk about eliminating waste? These are real pictures taken during different process optimization projects that illustrate how we assist our customers’ factories to produce more efficiently.

Type of waste: excessive work in process. Workers have piles of components and semi-processed product. This conspires against a proper production flow. Defects and problems (e.g. machine breakdown, invisible bottleneck processes) get hidden inside the piles and bunches. Components deteriorate or get damaged. This creates a waste in materials. It causes reworks. It adds counting / re-counting – packing / re-packing tasks. It takes more room in the factory floor. All this is a waste of time, labor and space. If this is a usual view of your factory, there are huge opportunities for improvement.

impactiva process optimizaton footwear apparel shoe garment

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Stay tuned for more Impactiva optimization solutions.

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Eliminating Waste Series – Time (machines breakdown)

“A picture is worth a thousand words”. What do we mean when we talk about eliminating waste? These are real pictures taken during different process optimization projects that illustrate how we assist our customers’ factories to produce more efficiently.

Type of waste: time, not to mention the complications of production stoppage caused by machines downtime. Or the quality defects a malfunctioning machine can cause. When a machine breaks down, it ruins the whole production planning and flow. Sometimes the solution is as simple as using another machine, or as difficult as having to buy spare parts abroad, wait for the authorized service, or other similarly frustrating circumstances.

As always, our advice is Prevention. Set up a machinery preventive maintenance program instead of resourcing to quick fixes that save you today and get you into trouble tomorrow. Have inhouse a mechanic with the necessary skills and training to service the factory machinery. If dirty, not lubricated, unreliable machines is an usual view of your factory, there are huge opportunities for improvement.

impactiva process optimization footwear apparel shoe garment

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Stay tuned for more Impactiva optimization solutions.