Posts

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.

impactiva shoe quality control impactiva shoe quality control

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

case 650 pic 3 impactiva footwear qa

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.

shoe quality control case 649 pic 2 impactiva footwear qa shoe quality control shoe quality control

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.

case 647 pic 2 impactiva footwear qa

Components storing: a mold risk – Case #647

“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: shoes uppers placed on the floor and touching the walls that might lead to mold growth.

mold prevention impactiva

case 647 pic 2 impactiva footwear qa

Impactiva solution: we got the factory to store the uppers in plastic trays, avoiding contact with floor and walls.

mold prevention impactiva

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

mold prevention impactiva

Shoe boxes: a mold risk – Case #645

“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 shoes boxes are stored on floor. Not only they can get dirty or stained, they can catch humidity that can later develop mold.

mold prevention impactiva

Impactiva solution: we got the factory to store the shoe boxes on pallets and in cartons in order to avoid direct contact with the floor.

mold prevention impactiva

mold prevention impactiva

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

case 644 pic 4 impactiva footwear qa

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

case 644 pic 2 impactiva footwear qa

case 644 pic 3 impactiva footwear qa

case 644 pic 4 impactiva footwear qa

 

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.

case 644 pic 5 impactiva footwear qa

case 644 pic 6 impactiva footwear qa

case 644 pic 7 impactiva footwear qa

case 644 pic 8 impactiva footwear qa

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.

case 642 pic 2 impactiva footwear qa

case 642 pic 3 impactiva footwear qa

 

 

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

case 010 PO pic 7 impactiva lean manufacturing.png

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

case 010 PO pic 2 impactiva lean manufacturing.png

case 010 PO pic 3 impactiva lean manufacturing.png

case 010 PO pic 4 impactiva lean manufacturing.png

case 010 PO pic 5 impactiva lean manufacturing.png

case 010 PO pic 6 impactiva lean manufacturing.png

case 010 PO pic 8 impactiva lean manufacturing.png

Stay tuned for more Impactiva optimization solutions.

impactiva process optimization footwear

Eliminating Waste Series – Time and Labor

“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: direct labor (workers losing time). If the materials are not easily available to the workers at the right production moment, they waste time searching them, delaying the whole manufacturing process or having to deploy workers specifically for the task of finding components / materials. If this is a usual view of your factory, there are huge opportunities for improvement.

impactiva process optimization footwear

case 009 PO pic 2 impactiva lean manufacturing

case 009 PO pic 3 impactiva lean manufacturing

case 009 PO pic 4 impactiva lean manufacturing

case 009 PO pic 5 impactiva lean manufacturing

case 009 PO pic 6 impactiva lean manufacturing

 

 

Stay tuned for more Impactiva optimization solutions.