Home Textile quilting successful case from Jopalic

Jopalic Background

In today’s globalized economic environment, the international trade of home textile products is becoming increasingly frequent. This time to share a company to follow up the case, Jopalic has cultivated the home textile industry for 10 years, with advanced production equipment and rich production experience. One of its main products is the high quality home textile quilting quilt, with exquisite craftsmanship and high-quality materials, in the domestic and foreign markets have been widely concerned.

The case revolves around the Jopalic export cooperation with an overseas customer. The overseas customer is from the United States, which has a high demand for home textile products, and consumers have certain requirements for product quality and design.

Customer demand analysis

(1) Product quality requirements

Material quality

Customers have very high requirements for quilting quilt filling materials. The filling material must be soft, warm and breathable pure cotton, and there are also requirements for gram weight. Pure cotton materials can not only bring users a comfortable sleep experience, but also have natural and environmental protection characteristics, in line with the pursuit of healthy life of consumers in the country. For example, in the choice of filling cotton, the customer specified to use long staple cotton, because long staple cotton fiber is slender, high strength, good elasticity, making the quilting quilt more fluffy and soft, warm performance is better.

Technological standard

In the quilting process, customers require stitches to be uniform and fine, and the number of stitches per inch must meet certain standards. This is not only to ensure the beauty of the quilting quilt, but also to prevent problems such as displacement and caking of the filling material during use. For example, in the line design of quilting, complex but beautiful geometric patterns are used, which not only increases the three-dimensional sense of quilting quilt, but also ensures the fixed filling materials.

Colour fastness

For the fabric color of quilted quilt, customers require a high level of color fastness. Because home textile products in the daily use and cleaning process, will frequently come into contact with water, detergent, etc., if the color fastness is not high, it is easy to fade, affecting the beauty and service life of the product. For this purpose, the company has specially optimized the dyeing process, adopted environmentally friendly dyes, and strengthened the color fixing treatment after dyeing, to ensure that the product can maintain a bright color after repeated washing.

(2) Product design requirements

Pattern style

Consumers in the countries they live in prefer simple, modern designs. And jopalic’s current pattern is inconsistent, therefore, in the pattern design of quilting quilt, our design team of the company conducted in-depth communication with the customer, the customer issued the requirements and the first draft, jopalic issued the finished pattern and sample, and finally determined the design scheme based on simple lines and geometric graphics. The use of a large area of solid color with a small number of abstract line patterns, both in line with the aesthetic trend of modern simplicity, without losing a sense of fashion.

Size specification

According to the demand of the country’s market and the use habits of consumers, customers have put forward clear requirements for the size specifications of quilting quilt. In addition to the common standard sizes, some special sizes of products are needed to meet the needs of different consumers. For example, for the country’s large beds, specially customized large-size quilted quilt, the size is larger than ordinary products, can completely cover the bed, giving consumers a better experience.

(3) Delivery time requirements

The customer has strict requirements on delivery time. As the selling season in the country and the timing of promotional activities have been determined, customers need to receive the goods within the specified time for timely marketing and sales. For example, in order to catch the holiday promotion of the Christmas season, the customer plans to push the quilting to the market about a month before Christmas, taking advantage of the sales season, so the company must complete the production and delivery before the end of September. If the delivery can not be delivered on time, it will affect the customer’s sales plan, and may even cause the customer to suffer economic losses.

(4) Price requirements

Customers also have certain expectations in terms of price. On the one hand, customers want to get a competitive price to ensure that the product has a price advantage in the country’s market; On the other hand, customers also understand that high-quality products need corresponding cost input, so they show a certain rationality in the price negotiation. Enterprises need to ensure the quality of products and their own profits under the premise of reaching a mutually acceptable price with customers.

Preparation for export

(1) Production arrangements

Raw material purchase

In order to meet customers’ requirements for pure cotton filling materials and high-quality fabrics, jopalic’s purchasing department carefully selects reliable suppliers. We have signed strict quality assurance agreements with suppliers to ensure the supply of raw materials on time, quality and quantity. For example, for the purchase of long staple cotton, we chose a well-known domestic cotton supplier, whose cotton quality is excellent, and has passed strict quality testing, which meets the requirements of enterprises and customers.

In the choice of fabrics, also carried out strict screening. The cotton fabric with high count and high density is selected, which not only feels soft, but also has good wear resistance and can withstand long-term use and multiple washing.

Production process optimization

The company has comprehensively optimized the production process to improve production efficiency and product quality. First of all, in the cutting link, advanced automatic cutting equipment is used to ensure the accuracy and consistency of the cutting size. Secondly, in the quilting link, the technical training of the workers is strengthened, and the uniformity and fineness of the stitches are improved. At the same time, a strict quality inspection system has been established, and quality inspection points have been set up in each production link to carry out strict inspection of products to ensure that unqualified products will not flow into the next production link.

Production schedule monitoring

In order to ensure timely delivery, the company has established a sound production schedule monitoring system. The production department has made a detailed production plan and divided the production tasks into each working day and each production team. At the same time, the use of information management system, real-time tracking of production progress, timely discovery and solution of problems in the production process. For example, if there is a delay in a certain production link, the system will give a timely warning, and the production management will quickly take measures to adjust and ensure that the production schedule is not affected.

(2) Quality control

Raw material inspection

Before the raw materials are stored, the quality inspection department of the enterprise will carry out strict inspection on each batch of raw materials. For cotton filling materials, fiber length, fineness, impurity content and other indicators will be tested. For the fabric, the color fastness, shrinkage, strength and other indicators will be tested. Only the raw materials that pass the inspection can be put into production. For example, in the color fastness test, a professional color fastness tester is used to simulate the color fastness of the product under different washing conditions to ensure that the color fastness of the product meets customer requirements.

Production process inspection

In the production process, the quality inspection personnel will carry out inspection and random inspection for each production link. For example, in the quilting link, the density and evenness of the stitches will be checked regularly, and the workers will be notified to adjust in time when problems are found. At the same time, for each completed semi-finished product, strict quality inspection will be carried out to ensure that the semi-finished product meets the quality standard before entering the next production link.

Inspection of finished product

A thorough inspection of the finished product is carried out before the product is packaged. Including the product size, weight, appearance, process and other aspects of strict inspection. At the same time, sampling tests are also carried out, such as the thermal performance test of filling materials, the breathability test of fabrics, etc. Only products that pass all inspection items can be packaged and shipped.

(3) Packaging design

Inner packing

Considering that the quilting quilt needs to be kept clean and dry during transportation, the company uses waterproof, breathable plastic bags as the inner packaging. This packaging bag can not only effectively prevent dust and moisture from entering, but also has a certain degree of permeability, to avoid the product in the packaging odor. At the same time, the product brand, specifications, washing instructions and other information are printed on the packaging bag to facilitate consumers to use and understand the product.

Outer packing

In order to ensure the safety of the product during transportation, the company has designed a durable carton as the outer packaging. The material of the carton has high strength and compression resistance, which can effectively protect the product from extrusion and collision. On the surface of the carton, exquisite product patterns and enterprise information are printed, which not only plays the role of promoting the product, but also facilitates the identification and management of the logistics transportation process.

(4) Logistics and transportation arrangements

Transport mode selection

According to the requirements of customers and the characteristics of products, the company has chosen sea transportation as the main mode of transportation. Sea transportation has the advantages of low transportation cost and large transportation volume, which is suitable for the export of large quantities of home textile products. At the same time, in order to ensure that the goods can reach the destination on time, the company also cooperated with a number of well-known Marine freight forwarders, compared the transportation time, freight, service quality and other factors of different freight forwarders, and finally chose a reputable and high-quality service freight forwarder.

Transportation time planning

The company and the freight forwarder jointly developed a detailed transportation time plan. Taking into account various factors that may occur during the shipping process, such as weather changes, port congestion, etc., a certain time buffer is reserved. At the same time, pay close attention to the progress of the transportation of goods, and communicate with freight forwarders and customers in a timely manner to ensure that customers can keep abreast of the transportation of goods.

Customs clearance

The customs declaration department of the enterprise has prepared a complete set of customs declaration materials in advance, including commercial invoices, packing lists, bills of lading, certificates of origin, etc. Maintain close communication with customs to ensure the smooth handling of customs clearance procedures. At the same time, understand the customs policies and import requirements of the destination country, and take countermeasures in advance to avoid delays or seizures of goods due to customs clearance problems.

Challenges and solutions in the export process

(1) Quality problems

The filling material is uneven

In the production process, it is found that some quilting quilt has the problem of uneven filling material, which causes the thermal performance and appearance quality of the product to be affected.

Solution: The enterprise immediately organized technical personnel to conduct a comprehensive inspection and debugging of the production equipment, and optimized the filling process of the filling material. The mixing and dispersion of the filling material are increased to ensure that the filling material can be evenly distributed in the quilting quilt. At the same time, the quality inspection of the filling link is strengthened, and the frequency and quantity of sampling are increased to ensure that the filling material of each product is evenly distributed.

Fabric stain defect

When dyeing the fabric, there are some defects such as uneven dyeing and color spots, which affect the appearance quality of the product.

Solution: The enterprise and the dyeing supplier jointly analyzed the cause of the problem and found that the dyeing process parameters were improperly set and the dye quality was unstable. Therefore, the enterprise adjusted the dyeing process parameters, strengthened the control of the dye quality, and required the supplier to provide more stable and high-quality dyes. At the same time, a cleaning and inspection process is added after dyeing to ensure that the dyeing quality of the fabric meets the requirements.

(2) Delay in production schedule

Material delay

Due to the supplier’s production plan adjustment and logistics transportation problems, some raw materials failed to arrive at the enterprise on time, resulting in the production schedule affected.

Solution: The enterprise immediately communicated with the supplier and asked the supplier to speed up the production schedule and take urgent logistics and transportation measures. At the same time, enterprises have adjusted their production plans to prioritize the production of those products with sufficient raw materials to minimize delays in production schedule. For the products that cannot be produced due to the shortage of raw materials, communicate with customers in a timely manner, explain the situation and strive for customers’ understanding and support.

Production equipment failure

During the production process, some production equipment malfunctioned and needed to be repaired and parts replaced, resulting in production stagnation.

Solution: The enterprise immediately launched an emergency plan and organized maintenance personnel to repair the equipment. At the same time, contact the equipment supplier to urgently deploy the required parts. In order to make up for the loss of production time, enterprises arrange workers to work overtime to improve production efficiency. During the maintenance of the equipment, the production plan should be adjusted reasonably, and part of the production tasks should be assigned to other equipment for production to ensure that the production schedule is not greatly affected.

(3) Logistics and transportation problems

Marine delay

Due to factors such as bad weather and port congestion, sea transport time is longer than expected, which may result in customers not receiving goods on time.

Solution: Companies communicate with freight forwarders and customers in a timely manner, explaining the reasons for shipping delays and the expected arrival time. At the same time, assist the freight forwarder to track the progress of cargo transportation and urge the shipping company to speed up the transportation speed. In order to reduce the loss of customers, the company, in consultation with customers, adjusted the sales plan and promotional activity time according to the actual situation to ensure that the product can be introduced to the market at the best time.

Cargo damage

In the process of transportation, some goods due to extrusion and collision, packaging damage and product damage.

Solution: The company worked with freight forwarders and insurance companies to assess and investigate the damage to the goods. According to the insurance clause, the claim application was made to the insurance company. At the same time, the company has repaired and replaced the packaging of the damaged products to ensure that the products can be sold normally. In order to avoid the recurrence of similar problems, the enterprise negotiated with the freight forwarding company, strengthened the packaging and handling management of the goods, and improved the protection measures in the transportation process.

Enlightenment

Focus on customer needs research

In international trade, customer demand is the starting point of enterprise production and service. Enterprises should strengthen the investigation and analysis of customer needs, constantly optimize products and services, meet the personalized needs of customers, and improve customer loyalty.

Strengthen quality awareness and management

Quality is the lifeline of an enterprise and the basis for an enterprise to establish itself in the international market. Enterprises should always put quality in the first place, establish a sound quality control system, strengthen the quality control of the production process, to ensure that product quality is stable and reliable.

Strengthen supply chain management

The supplier is an important part of the supply chain of the enterprise, which has a vital impact on the production and operation of the enterprise. Enterprises should strengthen the management of suppliers, establish long-term and stable cooperative relations, and ensure the quality of raw materials and the timeliness of supply.

Improve emergency response capacity

In international trade, all kinds of emergencies occur from time to time, and Jopalic need to establish perfect emergency plans to improve the ability to deal with emergencies. At the same time, it is necessary to strengthen communication and coordination with relevant parties to jointly deal with problems and reduce losses.

Maintain good communication and cooperation

In international trade, enterprises need to communicate and cooperate with customers, suppliers, freight forwarding companies, customs and other aspects. Enterprises should establish a good communication mechanism, strengthen cooperation with all parties, and jointly promote the smooth progress of trade.

Through this home textile quilting export case, we can see that in international trade, enterprises need to fully consider customer demand, production management, quality control, logistics and other aspects of the factors, and constantly optimize their own operation and management, in order to be in an invincible position in the fierce international market competition. At the same time, enterprises also need to constantly summarize experiences and lessons, improve their resilience and innovation ability, in order to adapt to the changing market environment and customer needs.the market competitiveness of the enterprise, and wins a good reputation for the enterprise.

Effective production management

By optimizing the production process, rationally arranging the production plan, strengthening the monitoring of the production schedule and other measures, the enterprise has improved the production efficiency and ensured the timely delivery of products. At the same time, in the face of various problems in the production process, we can quickly adopt effective solutions to ensure the smooth progress of production.

Good logistics and transportation arrangements

Choosing the right mode of transportation and freight forwarding company, making detailed transportation time planning, handling customs formalities in advance and other measures to ensure that the goods can arrive at the destination safely and timely. When encountering transportation problems, we can actively communicate and coordinate with relevant parties, take effective countermeasures, and reduce the loss of customers.

Deficiencies

The management of suppliers needs to be strengthened

In the problems of raw material supply delay and dyeing defects, there are certain deficiencies in the management of suppliers. Enterprises need to further strengthen the evaluation and supervision of suppliers, establish a closer cooperation relationship, and ensure the quality of raw materials and the timeliness of supply.

Emergency plans need to be perfected

Although Jopalic have taken corresponding emergency measures in the face of problems such as production equipment failure and logistics transportation delay, the emergency plan is not perfect. Enterprises need to further summarize the experience and lessons, improve the emergency plan, and improve the ability to respond to emergencies.

Communication with customers needs to be more timely

When production schedule delays and logistics transportation problems occur, although Jopalic have communicated with customers in a timely manner, the timeliness and initiative of communication need to be improved. Enterprises need to establish a more efficient communication mechanism, timely feedback to customers about the progress of problem solving and the expected completion time, and enhance customer trust and satisfaction.

Enlightenment

Focus on customer needs research

In international trade, customer demand is the starting point of enterprise production and service. Jopalic should strengthen the investigation and analysis of customer needs, constantly optimize products and services, meet the personalized needs of customers, and improve customer loyalty.

Strengthen quality awareness and management

Quality is the lifeline of an enterprise and the basis for an enterprise to establish itself in the international market. Companies should always put quality first