Going into production. How bags and backpacks are made. E02

Summary

This documentary offers an insightful look into the meticulous process of bag production in Semarang, Indonesia. From design and material selection to cost analysis and production logistics, the video details the importance of preparation and the role of skilled labor in creating high-quality bags. It also highlights the various stages, including cutting materials, assembly lines, quality checks, and the final packaging before shipping to warehouses, revealing the complexity behind crafting a simple bag.

Takeaways

• 🎨 The process of bag making starts with design, fabric selection, and color choices.
• 📝 An analyst team is crucial for cost breakdown and material requirements to avoid production delays.
• 🚢 Sourcing materials can involve decisions on transportation methods like air or sea freight.
• ⏱ Time studies are conducted to determine the duration of each step in the production process.
• 🔍 Operation breakdown involves dividing the bag-making process into specific operations for each worker.
• 🧵 The factory uses a line system with 26 operations for a standard bag, with more complex bags requiring additional operations.
• 🛠 Machine allocation and specialist allocation are key to assigning the right tools and skilled workers to specific tasks.
• 📏 Preparation of base materials includes cutting fabrics, webbings, zippers, and modifying accessories.
• 👜 The stitching process involves creating small accessory pouches and assembling the main bag structure.
• 🔍 Quality control involves checking finished bags and categorizing them into approved, repairable, or reject boxes.
• 🛂 Post-production processes include cleaning, x-ray checks for leftover needles, and a final quality check before packaging.
• 🚚 After passing quality checks, bags are packed and shipped to warehouses for distribution to customers.

Q & A

What is the main focus of this short blog-style documentary?

The documentary focuses on the process of bag production, detailing the steps from design to final product.

Why is it important to have an analyst team involved in the production process?

The analyst team is crucial for cost breakdown, determining the amount of materials needed, and ensuring the production process is efficient and cost-effective.

What factors does the analyst team consider when sourcing materials?

They consider the cost, the method of transportation (air or sea), and the time required for sourcing.

How does the time study in the production process help in bag making?

Time study helps in determining the duration it takes to make one bag, which aids in operational breakdown and efficiency.

What is the significance of the 26 operations in the factory's production line?

Each operation represents a specific task in the bag-making process, such as stitching a zipper, and is crucial for breaking down the production into manageable parts.

Why is machine allocation important in the production process?

Machine allocation ensures that each process in bag making uses the appropriate machinery, which is essential for the quality and efficiency of the final product.

What challenges do zippers pose in the bag-making process?

Zippers can be difficult to stitch, especially curved ones, and require trained workers to ensure they are correctly implemented in the bag.

What is the role of the specialist allocation in the production line?

Specialist allocation involves placing skilled workers in the right areas of the production line to handle complex tasks, such as zipper installation.

What happens to bags that pass the initial quality check?

Bags that pass the initial quality check are placed in a blue box and proceed to the cleaning process, followed by an x-ray check for any leftover needles.

What is the purpose of the final quality check after the cleaning process?

The final quality check ensures that the bags are free of any defects such as extra threads, and that they meet the build quality standards before being packed and shipped.

How are the bags distributed to customers after leaving the factory?

The bags are shipped from the factory to warehouses, where they are stored and then individually shipped to customers.