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I & J Trading in partnership with Samduk Tongsang CO., LTD specializes in OEM/ODM to satisfy all levels of costumer demands through a thor-ough observance of deadlines and outstanding quality control.
I & J Trading Company and Samduk Tongsan’s Partnership and Strategy for Innovative Production in Out-sourcing Topper
2. FACTORY IN PUSAN
3. EXTERNAL FACTORIES
4. SPECIFICS AND THE DIRECTION OF PARTNERSHIPS
5. MANAGEMENT STRATEGIES FOR EACH SECTOR
6. EXPECTED EFFECTSIND
EX
1. KOREAN MANUFACTURING AND FINAL ASSEMBLY SITES BRIEF SUMMARY
KOREAN MANUFACTURING SITES
PUSAN MAIN FACTORY EXTERNAL FACTORY
PUSAN, KOREA KOREAN INDUSTRIAL COMPLEX
Name SAMDUK TONGSANG CO., LTD. SAMDUK STAFILD CO., LTD.
EmployeesManagement : 80
Production : 100PERSONSManagement : 20PERSONSProduction : 2,700PERSONS
ScaleLand : 6,600 m2
Structure : 5,600 m2
Land : 26,400 m2
Structure : 20,000 m2
Production Capacity
ASSEMBLY : 75,000PRS/MONTHSEWING : 200,000PRS/MONTH
ASSEMBLY : 130,000PRS/MONTH
ItemCasual Shoes, Semi Athletic/Athletic Shoes, Walking Shoes, Sports Shoes, Safety Shoes , Trekking Function Shoes, Military Boots, Law Enforcement Footwear, Utility Boots, Hiking Boots,
ORGANIZATION CHART
FACTORY PRESIDENT
Vice President
Planning & Coordination
Executives
Production/Plan-ning Q.C
Manage-ment
R&D Insti-tute
Marketing
MANAGEMENT DEPT.
Production TeamManagement
Team
Quality Team
(Inspec-tion,
Quality)
Manage-ment
(Planning)
Research Team
(Analysis)Tailoring
TeamSewing
Team
Manufac-tureTeam
(Prepara-tion)
Technology Team
(Press)Tailoring
Team
Materials
HISTORY
1999. OCT Superb Small Businessmen Award(Exports)
1999. NOV 36th Trade Day, 5 Million Dollars Exports award
2000. NOV37th Trade Day, 10 Million Dollars Exports award
2000. DEC ISO 14001(Environmental Management Sys-tem Certification)
2003. APRAppointed as a Quality Assured Company, Achieved the ‘Q’ Mark
2005. OCT Presidential Award (Industrial Technology Development Merit)
2008. JUN INNO-BIZ Certification
2008. OCT Establishment of Samduk Tongsang’s Re-search Institute
2008. NOV 2nd External Industrial Complex relocated af-ter expansion
2009. JUL Appointed as a Venture Firm (Technology Rat-ing Star Company)
2009. SEP CERTTIFIED AND AWARDED (IMS)
2009. NOVNew Art of Shoe Technology Competition – Grand Prize in Functionality
2011. SEP CERTIFICATED BEST HRD
2011. SEP AWARDED FIRST S-OJT
2012. SEP SET UP EXT. FACTORY IN INDONESIA
MAIN PRODUCT
We are manufacturing/supplying products under OEM/ODM manufacturing alliances with numerous firms such as NEW BALANCE, OTB FOOTWEAR, PRO-SPECS, ASICS, K2, Z-COIL, and CHUNG-SI. Not only high-functionality sports, lifestyle and casual footwear icorporating Gore-tex technology, but also military and industrial/utility footwear. We manufacture/supply high quality products with R&D Technology as our base. We strive to reduce overhead and supplementary costs and to meet production and delivery deadlines.
OEM ODM
K2(Gore-Tex)
MAIN PRODUCT
PROSPECS
ASICS
OTB ABYSS Boots were designed and engineered at the request of the U.S. Navy SEALS. A maritime boot for use in any rocky or muddy situation,
the sole unit also works well in dry conditions. With its superior fit and drainage features this boot also works great with a pair of waders.
MAIN PRODUCT : OTB BOOTS
High abrasion TPU upper material resists scuffs for outlasting conventional leather
Upper material is treated with a DWR (durable water repellant) having minimal water absorption characteristics
Tactical Rubber Technology™ for superior silent traction on both wet and dry surfaces
Lugged and razor siped sole to help facilitate water dispersion
Perforated lugged jungle sole unit allow for instant water drainage
Recessed arch on the outsole helps identify center of gravity when climbing ladder rungs
Ballistic mesh placed between the outsole and upper prevents small stones and debris from entering the boot, yet still allows for water to drain freely
Rubber reinforced toe and heel help aid in climbing maneuvers
Mesh ports throughout the boot allows for water drainage and breathability resulting in quick dry comfort for increased foot health
Reticulated foam used for all upper padding will not absorb water under any circumstances
Mesh tongue pocket holds tied laces in place preventing snags on out-croppings
Sea/Air/Land - SEAL footbed™ aids in water drainage as well as breathability for unsurpassed foot health in a wide variety of conditions
The SEAL footbed has a patented removable shank that allows the user to customize the fit for any condition, wet or dry - eliminating the need for half sizes
PRODUCT SPEC SHEET STYLE: DESERT LITE COLOR: DESERT TAN
PARTS COL 3 Y`STICK MATERIALS
BACK WEBBING REINF, NAT NY 210D/A+ADHESIVE(W/12MM)
TONGUE REINF, " "
TOE BOX REINF, WHT CAMBULLAR+ADHESIVE(W/23M/M)
EYELET OVERLAY TAN 1 COLOR WEBBING TAPE(W/12MM)
COLLAR TAPE " 1 COLOR WEBBING TAPE(W/35MM)
HEEL TAPE " 1 COLOR WEBBING TAPE(W/20MM)
EYELET TOP TAN INJECTED NYLON 66(HOOK)
EYELET BOTTOM " INJECTED NYLON 66(EYELET)
VAMP MEDIAL PATCH " synthetic leather(toppicol)
TONGUE LOGO TAN 1 COLOR EMBROIDERY
EYESTAY(LATERAL)LOGO --- HEAT PRESS
THREAD NY 210D/3P
ZIGZAG THREAD --- P 30S/3P
ARIANCE THREAD TAN NY840D/4P
SHOE LACE TAN 1 COLOR (NEW ROUND LACE)
INSOLE TAN GAUZE MESH+CUP INSOLE
INSOLE LOGO HEAT TRANSFER
INSOLE BOARD --- JV170 PG-031H FROM J&V
MIDSOLE TAN 1 COLOR PHYLON SOLE(Hardness:63+-2)
OUTSOLE TAN 1 COLOR RUB SOLE(sticky)
SIZE LABEL WHT HEAT TRANSFER
PARTS COL 1 THICKNESS MATERIALS
BACK WEBBING REINF, BLK NY 210D/A+ADHESIVE(W/12MM)
TONGUE REINF, " "
TOE BOX REINF, " CAMBRELLA+ADHESIVE(W/23M/M)
EYELET OVERLAY BLK 1 COLOR WEBBING TAPE(W/12MM)
COLLAR TAPE " 1 COLOR WEBBING TAPE(W/35MM)
HEEL TAPE " 1 COLOR WEBBING TAPE(W/20MM)
EYELET TOP " INJECTED NYLON 66 (HOOK)
EYELET BOTTOM " INJECTED NYLON 66(ROUND SHAPE)
VAMP MEDIAL PATCH " synthetic leather(toppicol)
TONGUE LOGO BLK 1 COLOR EMBROIDERY
EYESTAY(LATERAL)LOGO --- HEAT PRESS
THREAD NY 210D/4P
ZIGZAG THREAD --- P 30S/4P
ARIANCE THREAD BLK NY840D/4P
SHOE LACE BLK 1 COLOR (NEW ROUND LACE)
INSOLE BLK GUAGE MESH+CUP INSOLE
INSOLE LOGO WHT HEAT TRANSFER
INSOLE BOARD --- JV170 PG-031H FROM J&V
MIDSOLE BLK 1 COLOR PHYLON M/SOLE(HARDNESS:63+-2)
OUTSOLE BLK 1 COLOR RUB SOLE(sticky)
SIZE LABEL WHT HEAT TRANSFER
PRODUCT SPEC SHEET STYLE: JUNGLE LITE COLOR: BLK/BLK
MAIN OFFICE INFRASTRUCTURE
Production Ca-pacity
Busan : Land 6,600 m2, Structure 5,600 m2 , 2 manufacture lines(75,000pairs/m)
Total Number of workers
185 ( 50 management, 35 R&D, Production 100)
R&DSamduk Research Institute : Within Samduk Tongsang CO., LTD. (Officially Approved)PATTERN, PRE-PRODUCTION, PU SCREEN, NO SEWING, ETC TOTAL 35PERSONS
ADDVANTAGE
HIGH LEVEL OF TECHNICAL WITH USE IN GORE-TEX & OUTDOORCAD/CAM PU SCREEN/HIGH FREQUCNCY/NO/SEWING FACILITIES IN R&DA/S SYSTEMFOCUSING ON Q.C
PRODUCTION FLOW
Samduk(Busan)BuyerOrder Placed(Order sheet)
Order sheet placed
Delivery
Delivery after fixation
Depending on difficulty and time constraints, direct production/delivery
Shipment
Purchase domestic subsidiary materials
Sorting/Inspection/Sampling/transferring1. Subsidiary Materials Stocked
2. Prototypes created (Dyed, processed)3. Partly-manufactured Goods Stocked4. Processing/Needlework/Completion5. Quality Management/Sampling/ Packaging/
By establishing a collaboration of factories, an in house production sys-tem and a dramatic reduction of distribution terms are achieved
Transportation to External Factory for A/S purposes only takes 1 day
ONE STOP TOTAL -
1
2
3
4
5
6
7
8
9
10
A/S requestSamduk(External
Factory)
GORE-TEX
We are the proud producer of Gore-tex. As a
licensed factory we strive for excellence in all
areas of footwear production.
We will continue to improve Gore-tex with
utmost attention to detail new application of
emerging technology.
FACTORY INFRASTRUCTURE
PersonsEquip-ment
CAPA( 月 )
Cutting 160 80 200,000
Saw 1050 22lines 200,000
Prepare 250 99 120,000
Press 370 44 200,000
PersonsEquip-ment
CAPA( 月 )
Pyron 80 24 100,000
Prepare 250 4lines 200,000
Make 250 4lines 130,000
ETC 290
FROM RAW MATERIAL, CUTTING TO ASSEMBLY, In-House System
FACTORY INFRASTRUCTURE
PROCESS
FACILITY Q’TIES CAPA/DAYHOUR/
DAYPERSONS
EXAMNI-NATION
LEATHER METER 1 5,000 8 4
TEXTILE METER 1 5,000 8 4
CUTTINGOIL PRESSURE
MACHINE75 8,500 8 152
TOTAL 77 160
PROCESS
FACILITY Q’TIES CAPA/DAYHOUR/
DAYPERSONS
LINE
PREPARATION LINE
4 8,5008
250
ASSEMBLY LINE 4 5,400 250
TOTAL 8 500
ASSEMBLY & PREPARATION FOR ASSEMBLY
CUTTING
FACTORY INFRASTRUCTURE
PROCESS FACILITY Q’TIES CAPA/DAYHOUR/
DAYPERSONS
SEWINGLINE 2
8,500 8 900MACHINE 650
STRAWBELLGATHERING 3 6,000
16
6
MACHINE 14 7,000 20
EYELET
D-RING 11 5,500
20AUTO RIVET 10 5,000
AUTO D-RING 4 2,000
INNER SOCKER
SEAMSEALING 6 2,000
8
20TESTER 2 2,000
SEW. MACHINE 20 2,000
PARTS
HOT MELT 60 14
MAMMER 30 30
MOLDING(C/H) 10 10
COMPUTER(G) 430
COMPUTER(N) 30
TOTAL 719 1050
SEWING
FACTORY INFRASTRUCTURE
PROCESS FACILITY Q’TIES CAPA/DAYHOUR/
DAYPERSONS
EMBROI-DERY
MACHINE 2 5,000 24 15
HIGHFREQENCY
CUT.PRESS(G) 45,000
16
5
CUT. H.FRE. 48 119
WINSEALNO SEWING
PRESS 10 5,000 26
HOT MELTPRESS MA-
CHINE2 8,500 14
SCREEN 20M TABLE 6 5,000 29
SHARPEN-ING
MACHINE 24 8,500 43
TOTAL 99 250
PREPARATION FOR SEWING
FACTORY INFRASTRUCTURE
PROCESS
FACILITY Q’TIES CAPA/DAYHOUR/
DAYPERSONS
ROLLER
KNEADER 2 15,000
21
60CALENDER 1
MIXING ROLLER 3 15,000
CUTTING 5 12,000
PRESSOIL PRESSURE 44 12,000
160AUTO CUTITNG 2 3,000
TRIMMING MACHINE 16 12,000 90
BUFFING GRINDER 20 12,000 60
TOTAL 95 370
PRESS
FACTORY INFRASTRUCTURE
PROCESS
FACILITY Q’TIES CAPA/DAYHOUR/
DAYPERSONS
PRESSOIL
PRESSURE(H/C)16 3,850
21 62
UV
UV LINE 1 8,500
UV MACHINE 2
COOLING MAC. 1
TOLUENE WASH. 3
8 18WASHER 1 5,000
DRYER 1 5,000
TRIMMING 10 7,000
TOTAL 31 80
PHYLONE MIDSOLE
FACTORY INFRASTRUCTURE
PROCESS FACILITY CAPA/DAY HOUR/DAY PERSONS
MODEL MACHINE 5SET 8 7
MODEL, PATERN, FRAME
FACILITY Q’TIES
SUN LAMP TESTER 1
FORCE CONVECTION OVEN 1
WASH TESTER 1
UNIVERSAL WEAR TESTER 1
DIGITAL BURSTING STERNGTH TESTER
1
DENSIMERTER / MD300S 1
SHOE FLEXING TESTER 1
NBS ABRASION TESTER 1
UNIVERSAL TENSILE STRENGTH TESTER
1
TIME SLICE TESTER 1
CROCK METER 1
LAB.
PLAN
SHORT TERM BASE : SET UP WITHIN DEC. 2011
INSOLE : 200,000PRS/MONTHIP MIDSOLE : 120,000PRS/MONTH
99% IN HOUSE SYS-
TEM
CUTTINGSEWING
DECORATION(PU SCREEN, HIGH
FREQUENCYNO SEWING, TPR,)
INSOLEMIDSOLEOUTSOLEASSEMBLY
MIDDLE TERM BASE : SEP UP WITHIN MAR. .2011
HO-SKIN : 120,000PRS/MONTHTPR : 100,000PRS/MONTH
PRODUCTS COMPETITIVE POWER AND TECH-NIQUE COMPETITIVE POWER
PLAN
Tianjin, China Factory
PROCESS FACILITY Q’TIES CAPA/DAYHOUR/
DAYPERSONS
SEWING LINE 4 1,200 8 300
ANALYSIS ON EFFECT
Each year, Samduk’s quality and productivity increases through
continuous quality control and educational training. High level
intensive management training courses are provided and at-
tendance required by all levels of management
Division
2007 2008 2009 2010
QualityProductiv-
ityQuality
Productiv-ity
QualityProductiv-
ityQuality
Productiv-ity
China 80% 90% 90% 95% 85% 85% 80% 80%
Korea 70% 100% 70% 95% 70% 95% 75% 95%
Ext. Fcty 90% 70% 95% 90% 100% 95% 100% 100%
PARTNERSHIP PRODUCTS
Establish a strategic manufacturing system for a more stabilized and efficient production
ManufactureManufacturing
in External FactoriesSewing
Supply for Domestic Demand as a base
Maximum 900,000pairs/year
Maximum 2,400,000pairs/year
Maximum 1,500,000 Pairs/Year
COMPETITIVENESS
Creation of a prepared Manufacture infrastructure for Outsourcing Production
Moral Management ▶ ① Employment practice ② Human Rights ③ Environmental Pollution ④ Corruption Determent ⑤ Moral Responsibilities
Operation Research Team ▶Process Analysis, Manufacture Quality Research
Technical Support Team ▶Standards, Technical Support, R&D
A/S : Quality Control and Costumer Satisfaction achieved through operating A/S Centers.
Establishment of a Gore-tex shoemaking system
External Factory Line : Establishment of a manufacturing line for Skechers
Establishment one of the world’s best environmental management system1
2
3
4
5
6
7
WHAT’S DIFFERENT
ExistingSituation
Limitations are created as products are produced domestically or produced abroad
Utilizing Busan HQ Factory Utilizing External Factory+
Country of Origin Problem Solved(100% Made in Korea)
- Delivery Term Reduced- Stabilized distribution
system achieved
- Cost Competitiveness - Exclusive manufacturing
System created
Contributes to reputation of high quality and reliability by acquiring Quality Products and Delivery priority using brand’s Exclusive Manufacturing Lines
Using Cost Reduction as a foundation, a strategic viewpoint can be implemented through securing core capabilities and competitive superiority.
Effect
WHAT’S DIFFERENT
Classification Company A Company B Company C Samduk
In House system
Sewing(Semi-manu-
factured prod-ucts)
Outsourcing China / Vietnam Outsourcing Ext. Factory
Shoemaking(Complete Products)
Busan China / Vietnam Outsourcing Busan, Ext. Factory
Materials and partial pro-
cessingOutsourcing Outsourcing Outsourcing External Factory
Quality of Labor
Pros High Quality Average Average High Quality
ConsWages burden,
rapid aging of la-bor force.
Frequent job changes, wage raises, Quality
Competitiveness deterioration
immeasurable Stabilized employment
Prime CostCompetitive-
nessRelatively Low Average Average High Quality
Price Reasoning
1. All processes beside completion
is done through outsourcing
1. Can’t label as Made in Korea as
the product is completed abroad
1. Lack of man-agement due to a
lack of an In-house System
1. In House System – Price competitiveness
2. Limitations on domestic produc-
tion
2. Deindustrializa-tion occurs even
Locally,
2. Limitations of Outsourcing Pro-
duction
2. Stabilized production through Salary Caps(less than 5%) and the fact that it is impossible to change jobs
3. When an out-sourcing problem occurs, there isn’t a countermeasure
3. Impossible to reduce delivery
term
3. Lack of a sense of ownership
(Responsibility )
3. Through non-price com-petitiveness, extra com-
petitiveness expected (De-livery, origin of produc-
tion)
DELIVERY
• Distribution Period, includ-ing customs procedures, takes only 1 day (24Hours)
• Containers 3times/weekDelivery Service 6times/week
• EX) Departure from Ext. Factory at 2pm → Arrival at a distribution center in Seoul at 4pm
• High-difficulty products
or products that are
tight on schedule are
processed at the head
office (Same Price Ap-
plied)
China(and other Southeast Asian Countries)
Excessive Distribution Term
Wages are ona rising Trend
Korea ↔ China
Total Delivery Date : 25~40 Days
Busan ↔ External Factory
I & J Trading Company and its partner Samduk’s business philosophy is
to fulfill customer satisfaction by a thorough observance of delivery
deadlines, created by sending orders to adequate sources of supply and
setting plausible delivery deadlines.
1dayTotal Delivery Date : 60~70days
LABOUR MANAGEMENT
Early StageSimple LaborManpower-
focused
Quality
Enhancement
of Productive
Capability!!
• Productivity improvement
• Task Division
• Management Skills
• Safety Education
• Health/Environment
• Cost reduction
• Theory education
• Skill education
• Hands-on education
Job DutyUnderstanding
Job DutyCompletion
Job Duty
Improvement
• Utilization of high quality labor force.• Implementing Incentives: By implementing a separate incentive system other than the basic paycheck, productivity/quality enhancement is shown
Great emphasis is placed on providing extra training to employees to maximize smooth and continuous production
Acquire skillful workers by implementing regular employee
training sessions and continuous individual training sessions.
PRODUCTION MANAGEMENT
Our Core Competitiveness is to operate an operational research
team, technical support team, and state of the art laboratories.
Also, we will operate a separate STAFF team for processing Skech-
ers’ orders.
Operation Research Team Technical Support Team
Elimination of the source of quality defect → Production Efficiency Enhancement
Laboratories
Guarantees Credibility through various Experiments of (Material) Properties
Creation of A system that can evaluate the R&D and effectiveness of a product in one-stop
All details related to experiments are managed systematically
Gore-tex exclusive Labs
Operation Research Team takes exclu-sive responsibility of process analysis(production/quality/research)Technical Support Team supports standards,technological backup, and SPEC
Qualitative Quality Enhancement through efficient FEED-BACK activities
QUANTITATIVE EFFECTS
- The reduction effect increases gradually in proportion to the increase of orders. - Expectations of a self-owned factory creation effect without implementing separate training sessions or tangible/intangible investments.
- Processing Prices reduced - Completed Product Prices rise as the products are now labeled as Made in Korea
- Delivery Costs are reduced by using professional delivery business vehicles. - Cost reduction by minimization of warehouse storage costs due to immediate payment system - Business Travel Costs are reduced by running Shuttle Busses.
Problems of Diminishing Production rate and Risk reduced
Price Competitiveness Increase
Cost Reduction
QUALITATIVE EFFECTS
Category Detail
Delivery TermTime/Money saving is possible through shortening of the delivery term.
Quality Competi-tiveness
With skilled/educated workers, high quality prod-ucts are manufactured. Contracted Brands’ Quality Competitiveness is enhanced
Outsourcing Ef-fect
Fundamental Cost reduction from removing addi-tional personnel management/labor management administration
Securing Market Competitiveness
Market Competitiveness is secured by labeling Made in Korea
ZERO-Defect Ef-fect
Defects are returned to Samduk Tongsang’s A/S Center to be fixed and delivered back –> Zero-De-fect Effect