In the first part we have seen how sewing machines are developed and how they get tested. After the official style and functional approval the next task is to produce the machines for the customers.
Here we learned that especially in this field of machinery supply the regular production system is dominated by pull principles. Dürkopp-Adler works a lot for projects like setting up a complete new factory and as such produces the machines according to the customer’s needs. This reduces massively the inventory and working capital but is only doable when the processes are aligned. Speed in production needs modular design and a well structured supply chain. In the raw material warehouse they store more than 30000 different pieces and modules to be prepared for the various customer’s needs.
Interesting to see that also here they borrowed some technics form the car industry. Many parts of the machines are delivered pre-made, some half-made, some arrive completely in single parts.
In a single-piece-flow the machines are put together and are tested after the assembling. With this in mind why not have a closer look to your own production facilities next time you visit one? How do you produce? How do you organise your assembling and how do you make sure to have a proper quality check inside the production and not only after finishing ?
Next was the department for electronics. Dürkopp-Adler produces a lot of their machine control systems by themselves because of various reasons. First up is the resilience and durability. These systems have to be sustainable and easy to use. Not many of us buy sewing machines and sign a 10 years contract for further maintenance. And not many shop floors have air-condition. So what they do is test the components in climatized ( high temp and humidity ) rooms and build them from very solid components.
Finally after having passed more rooms, more departments and more interesting process steps we reached the show room of their various machinery offers. Again, we were thrilled by the variations of devices and needs. Starting from our own industries need with automated pocket machines, button hole machines and the twin setup for padded lapels together with Strobel, there were even more specialties.
A big and solid one was for the assembling of safety belts and lifter belts for bigger ships and vessels. Also impressive was the Needle – up to size 300. While we use normally 60 for womenswear over 80 – 100 for menswear until 110 -160 in jeanswear the amazing 300 was really heavy. Also the motor was quite strong and the machine would shiver when started. Not to mention about the belt itself and to hold and steer it during sewing 🙂
Some other examples, it was endless and inspiring at the same time:
Here are some ideas about car seating and a harness for paragliding.
All in all it was a fantastic experience to see how much effort and innovation is behind “just a sewing machine company”. Not to mention about all the other services they offer but this here is not a marketing blog 🙂 and if you are more interested in the details I suggest to visit the TexProcess in Frankfurt in May and have a closer look and maybe walk through the halls with a little bit more respect or empathy than you would normally do – they all deserve it.
The overall topic of this years meeting of the IACDE german chapter was “Reality check 3D” and we asked our CAD suppliers to develop in 3D the same prototype than we did in 2D and real prototyping. In was fascinating to see the results – more to come in further blogs…