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Small Order Dilemma Plaguing China'S Textile Industry

2013/7/24 18:51:00 12

Apparel Industry Apparel Orders Textile Industry Garment Manufacturing

in the workshop of the novelty handbag factory in Shijie, Dongguan, Zhou Xiang, a 31 year old woman worker in Hunan, sits next to the a href= "//www.sjfzxm.com/news/index_c.asp" > sewing machine "/a". One end of the zipper is pressed one by one, and the two inch long zipper is sewn into the inside of the cosmetic bag by the clothes.

A big cosmetic bag is produced here, and is decomposed into 50 processes: cutting, sewing, bonding.

After entering the factory for 9 years, Zhou Xiang did just one thing: Car zipper.

"car zipper is the biggest efficiency". In the handbag factory owner Han Changwei, it is efficiency to keep workers repeating the simplest and faster.

However, after turning around to open up the domestic market, each handbag can only produce hundreds or even dozens of new products. This smart boss is puzzled: "how should I arrange my production line?"

Deng Pingli, who is just as confused as the P mattress, is tired of picking up domestic customers: "a client, a water mattress", which means that the size, appearance, hardness and other indicators of customers are different. "Such an order can no longer be placed on the original production line."

Zeng Ming, chief strategist of Alibaba group, wrote that under the help of the Internet, the wave of personalized consumption of mass consumers has arrived. P

The traditional production mode, equipment and process will be faced with challenges. A quiet production revolution has been carried out in the workshop of enterprises.

the new order is no longer the mass production of mass production in the past. It is showing more and more characteristics of "small batch, multi variety and quick refurbishment".

Under the help of the Internet, the wave of personalized consumption of mass consumers has arrived.

the evolution of supply chain

more and more Taobao brands have grown up and have started their own factories.

The final choice is to finalize the Pearl River Delta area, which is well established in Dongguan and other industrial chains.

In this change, Taobao business has become active and active.

At the end of 2012, Cheng Bao Yan, who had been in Beijing for many years, began to expand South and set up factories in Dongguan with only one purpose: "controlling the supply chain".

In the past 9 years, Mika's makeup mirror has been the sales champion of Taobao.

This cosmetic mirror brand from the Internet does not have its own production line.

Cheng Baoyan has been working with manufacturers in the Pearl River Delta region to outsource cosmetic mirrors.

Less than p years ago, sales of cosmetic mirrors had not risen in the past few years, and Mika was in a completely passive situation.

"When someone else's production line is opened, the purchase volume of a single cosmetic mirror is hundreds of faces and thousands of faces, but I have only 10 or 5 sides of the trial list, and the quantity is up, plus the single production."

Many traditional manufacturers do not know how to arrange the production of 10 cosmetic mirrors on a large production line.

Cheng Baoyan ran into the wall, and in the final cooperation, the price of each mirror was up to one or two, and some even reached 40%.

even now, Mika's turnover has reached tens of millions a year, but most of the styles are still difficult to release.

Cheng Baoyan explained that the "Taobao race" hobby quickly updated, in order to meet the young consumer habits, Mika needs to save the cosmetic mirror has more than 1000, and constantly eliminated, in the shop sales of about 200.

Others keep the mold, and the order can be reproduced.

In addition, online stores are pushing ahead with the speed of around 20 per month.

outsourced orders /p >

In the past year, all the handbags of domestic brands have been outsourced to small factories. The huge production line in the novelty handbag factory is still open, and the P is still the foreign trade list.

Shijie novelty > a href= "//www.sjfzxm.com/news/" > handbag factory < /a > boss Han Changwei has felt the wave first.

In 2004, he opened his own handbag factory.

The factories that used to be over 1000 square meters are always busy.

The order coming from Europe was initially made of thousands of thousands of styles and tens of thousands or even hundreds of thousands of them.

"Workers do it over and over, and then they can do it with their eyes closed".

From P to 2010, he began to feel anxious: every time a foreign businessman orders two thousand or three thousand or so, he seldom returns the same style.

Han Changwei turned to open up the domestic market and founded his own brand, "Lake Yi".

But after a round of falling down, he found that the biggest problem remained unsolved: how to arrange the huge production line? The domestic sales did not open, and the maximum number of handbags produced in one style was only 300 to 500.

In order to find out the preferences of domestic consumers, designers have launched five or six new models in one month, each time just a "trial list".

"Even if these dozens of colors are different, how can the production line be opened?"

Zhou Xiang, the most senior zipper in handbag factory, is also worried about P.

Every time a new order comes from foreign businessmen, a new zipper is required. On the first day, she can take 500 cars, second days, 600 pieces, and fourth days later, she can maintain 900 cars per day.

But the domestic orders, the first day just finished 500 cars, have not yet started, the new style, and new zippers, "constantly changing, I can only 500 cars per day."

Zhou Xiang was worried about his own income, and his boss Han Changwei was worried about efficiency. "In this way, wages are rising, and the output of every worker is decreasing."

procurement is also difficult.

To produce a handbag, we need to buy leather, hardware, < a href= "//www.sjfzxm.com" > printing > /a > etc., foreign orders are large, large quantities of raw material procurement will undoubtedly have more bargaining advantages, and the cost can be reduced even lower.

The cost of purchase is also low, and the production cost has been raised. "The manufacturers of stamping hardware used to avoid model fees, and the amount of purchase was limited, and they were required to be charged, one for one thousand or two thousand yuan!"

Han Changwei decided to set up another production line.

However, in the factory turned around, hundreds of workers were just "zipper" or zipper "singles champion". The workers who can make the complete handbag independently have only 10 workers in the design workshop.

"P >" can only be outsourced.

Han Changwei began searching for small factories in Dongguan and Guangzhou, running around several times and picking 10.

In these small factories, every worker can make a complete handbag individually.

Han Changwei has outsourced all the production processes, retaining only the ends of the production line, product design and testing.

In the past year, all the handbags of domestic brands have been outsourced to small factories. The huge production line in the novelty handbag factory is still open.

however, in the past year, there were only two or three factories in the 10 small factories that were originally co operated.

The novelty handbag factory dedicated hundreds of square meters of testing room, stacked the goods sent from the cooperative factory, and Han Changwei pulled out an orange lady's handbag from one of the big paper suitcases, and the zipper was pulled in half, and it could no longer be opened.

"How can this handbag be sold to consumers?"

new production line /p >

in the reformed new production line, every product produced by the company comes with a "chip".

The detection personnel only need to read the chip through the detection equipment, and the production process and indicators are clear at a glance.

the original large-scale, standardized and pipelined production system is facing pformation. What is the way out for the traditional manufacturing industry? Alibaba chief strategist Zeng Ming pointed out that the way out lies in the flexible pformation of the production side.

For example, at the equipment level, it can support mass customization technology equipment.

For example, because of the convergence of the Internet to personalized demand, he has accelerated the popularization of CNC bed cutting, digital printing and three-dimensional anthropometry, which can support flexible production.

Emma P CNC Technology Co., Ltd., located in Dongguan Goldman Sachs science and Technology Park, is an example of this theory.

In the exhibition hall of hundreds of square meters, the company demonstrated the new production line that Zeng Ming's definition is: at the front end of the production line is a three-dimensional foot laser scanner.

This machine was first used in Germany and Japan. In 2007, Emma carried out technological development and launched his own foot scanner. As long as the client stretched his feet into a machine box of four sides, 45 data about this foot were input into the computer, specifically to the width of the baseboard, the length of each toe and the center of the ankle bone.

this is quite different from the old mode of production: the existing "a target=" _blank "href=" //www.sjfzxm.com/ "shoes" /a "factory in Dongguan, after the design and setting of a pair of new shoes, all are manual typesetting: workers take a ruler and a pen, spend half a day, draw circles on a large leather material, and then pfer them to the cutting bed and use the knife mould to cut.

This means that 16 small cowhide made vamp should have 16 different shapes.

Every time there is a new design, if the manufacturer does not have the shape needed to store the knife die, it will take two or three days to order the new knife mold, and the cost of a knife die will be from hundreds to thousands, or circles, or triangles.

however, the cost of using this technology is not low.

Take the most front-end 3D foot laser scanner as an example, the external price is about 300000.

From 2007 to the present, Emma has only sold 5 scanners in China, all of which are bought by brand enterprises in Qingdao and Guangzhou.

NC machine tools which are convenient for many varieties and small batch production are seldom applied in Dongguan.

The price of a CNC machine tool ranges from hundreds of thousands to millions, and can be widely used in various kinds of production such as footwear, leather goods, bags and soft furniture. However, the staff members say that the machines that they order are domestic powerful enterprises, such as the large factory in Dongguan for LV foundry.