This is basically short-order, short-lead-time, custom textile manufacturing. Our OEM clients typically order in quantities under 250 units. In cases of extreme adornment or customization, an order of a single unit is common. Our OEM clients generally expect an order-to-shipment lead time of 5 to 15 working days. Our OEM/DSOD clients expect same or next-work-day shipment.
- Define the specific objective centered on the client items, equipment or intent.
- Make general determination as to materials, plant machinery, skill levels.
- Are project needs best served within the available range of material types and weights?
- Is the plant machinery capable or configurable to efficiently and economically produce the solution?
- Are the appropriate levels of skill and experience present under a quality control umbrella?
- Clarify Scope and Scales
- Do quantity requirements, high or low, pose client risk or potential plant stress?
- Do time requirements pose client risk or plant stress?
- Is there a general understanding of costs, pricing formulations and financial terms?
The end goal of this process is to present the client with three results:
- Single physical sample of the desired textile solution.
- A price table showing quantity discounts in all possible or requested material options.
- A written overview addressing variables such as expected lead times, potential supply risks, design and function points, applicable variations, etc., etc.
Client collaboration and the physical aspects will drive this initial manufacturing process. Is the item to be built around, or a dummy, available; are there technical drawings; are previous solutions available; are special procurements required? Each case presents its own variables, but the questions of weights, openings, item ingress/egress, portage, protection and overall aesthetics are fleshed out and the beginning pattern or drawing and accoutrement list is created.
A senior production specialist will cut the necessary fabrics, insulations if applicable, zippers, bindings and all other components – and will assemble/sew the entire item alone; secondary or sub processes included. The intent is to 'model' the production process itself, as well as yielding the first rough product for review. Normally, this first product is not presentable and will require considerable alteration. The modeling of the production process may itself drive changes to the pattern or even the overall design, cost efficiencies being a major consideration.
The next production attempt will have assimilated the refined learnings of the initial attempt. A host of factors will dictate the result; it would be desired that it be 'one-away' from a final prototype. In reality, it may well be not much better than the first attempt, especially if the production process model was heavily altered for cost or efficiency reasons. If necessary, the process is repeated – the objective being a prototype one-away from the three-pronged goal.
Depending on complexity, client collaboration may be enlisted at the one-away stage. Minor adjustments, general 'tightening' of pattern and process, and any adornment requirements are forefront and the final pre-production proof is created. The final proof provides all the necessary data for costing formulation, as well as the knowledge/experience to provide an overall assessment.
Variations / Models
Some variations are inherent and are automatically optional. For instance, a solution made of 1,000 denier nylon is optionally made in any color the fabric is available in, as well as possibly other fabrics and their colors. Variations may also include sizes and in some cases functional options. Models might include items that serve the same purpose but in a different manner or for a specific use case. Variations or models, aside from their optional characteristics, are each treated separately and individually in terms of proof development, costing and assessment.
Our goal is to exceed the client's expectations – to have understood the need and objective, to have input our experience and expertise, to have created the correct textile solution; and to have demonstrated the ability to efficiently and economically manufacture the solution.
Client's acceptance and initial order initiates both manufacturing, and importantly, service responses. From procurement and stock levels, all the way to the correct shipping box size; the gears turn (and sometimes grind). Specialized software allows pattern digitization and computerized fabric cutting. This minimizes waste and maintains exact marking and dimensional accuracy insuring every product is uniform. If applicable, the processes of embroidery or etching are created and made available to production at mouse click or button push. Our drop-ship or Drop Ship On Demand (DSOD) services are made available potentially affording significant service and cost savings.
All manufacturing is 'on-demand'. A placed order is immediately scheduled on a production calendar initiating appropriate pre-manufacturing responses. As the completion of older work releases resources the order moves onto the production floor for sub-assemblies and final sewing assemblage. This first order warrants tutelage on the production floor. Considerable time and effort is expended on deploying the production modeling refined in the proofing process. Past the learning curve, the process results in very short lead times and quickness to client's market.
chill-n-go, Inc. has provided textile solutions for over 40 years. Our mentality is long term; our goal to build lasting durable relationships based on trust, transparency and performance. Our products reflect the same mentality – built to serve a purpose, withstand time, and reflect the mission of our client.
We've been providing OEM services to these companies for a number of years. We encourage you to call them – before you call us - and obtain their assessment of the quality of our products, our service level, and our timeliness.
EZ-FX, Inc. Kevin Alarie 1-800-541-5706 firstname.lastname@example.org
Oneness Interfaith Stephanie Guillory 1-916-865-9123 email@example.com
Green Valley Products Monica Loraine 1-916-806-9082 firstname.lastname@example.org
More upon request.
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