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An early ride on bullet train lead us the coveted factory –
Wacoal.
All of us braved the cold weather to get to the factories to
witness how the products are made.
A warm Japanese ambience welcomed us as we get inside the
factory. We were asked to take off our shoes as we entered the area which is
part of the manufacturing practices and standards.
We have been introduced to
the Japanese production team, the hardworking people behind these beautiful
undergarments.
Once we have finished the orientation and introduction about
the company, the factory tour started. Welcome to Hokuriku Wacoal Sewing
Corporation!
Production process,
developments, designs - the works!
The manufacturing processes of Wacoal products go through a
very tedious work. It doesn’t stop on creating a desired pattern. There is a
series of step by step process that needs to be followed.
We were shown first at the area where prototype of
undergarments are made. These prototypes are not the final designs. It has to
be approved first and several concerns are to be considered before sending for
production.
The process begins as follows. Fabrics and laces are
prepared for cutting based on each material feature. It will be relaxed
in the machine for atleast one day to avoid shrinkage based on the pattern and
will proceed to spreading the fabric.
Different processes are used for cutting of fabrics and laces.
Automatic cutting machine is used for cutting of fabrics. Whereas laces are cut
by two methods – rotary cutter and press cutting. Next would be combining some
parts and checking if its cut correctly based on the pattern.
Then its time for the sewing process! Both lingerie and
brassiere have different specs and instructions to follow. It’s hand-sewn with
skilled techniques to produce high quality products based on design. Imagine
how the skilled workers would sew all of it manually.
Then there goes the high quality of maintenance which repair
machines and arrangement which would enhance the quality and the productivity
that is required.
For every finished product, there goes the quality control.
Wacoal has high quality standards and methods that they follow. Making sure
each product goes through proper inspection and right output.
When it comes to packaging, set of procedures are observed
as well. There is a standard folding and presentation per final product.
Each process undergo a meticulously set of standards and
procedures. Each worker is trained to provide their best skills
in finishing the product.
Another beauty, here
comes the lace!
When we get to the material factory, we were
able to get a closer look where the fabrics are designed and made. The laces
are designed by a lace designer, considered as an artist who makes and starts
everything from scratch. The designer thinks of its own unique design, fabric,
pattern, thread to be used, etc.
Laces also go through a series of steps to be able to arrive
in its own form. Artist will have to create pattern design then proceed to
drafting. After this has been approved, it will start to go on manufacturing.
Wacoal don’t outsource their materials because they
themselves make it then proceed to creating the products. They exhibit a high
level of craftsmanship in each of the product that they make and has ushered
into a merchandise of strength, comfortability which has earned them
distinction and setting standard for customers around the world.
It carries with it a heritage of trust from Japanese people
and customers worldwide a strong reputation of quality products becoming a pillar in the
undergarments business.
Capping the night
After touring the factories, we were treated to a sumptuous
Japanese dinner at The Sodoh Higashiyama Kyoto. We were delighted to see the ninja show which provided
entertainment for all of us. Fun day indeed! Thank you so much Wacoal!
I'll be posting my last day in Kyoto on my next blog. Hope to share with you more of Kyoto and Wacoal products.
Also, follow my vlog on YouTube (https://www.youtube.com/rochellemikorivera) to give you more glimpses of the trip.
I'll be posting my last day in Kyoto on my next blog. Hope to share with you more of Kyoto and Wacoal products.
Also, follow my vlog on YouTube (https://www.youtube.com/rochellemikorivera) to give you more glimpses of the trip.
Photos by: Gerry Baclagon
