Huge rush case-4million backpacks
Please deliver 4 million backpacks within 3 months! 
Can it be possible?
We can say yes, actually we have made it!
Case summary
We succeed to handling with the really big case for 4,000,000 pcs backpacks within required delivery time (3 months) and controlling the quality up to customer’s demand. So customer added two cases based on this, 1,200,000 pcs and 3,000,000 pcs. Because of our more and more skilled experience, it only took 25 days to finish the last 3 million one.
SOE
At the beginning of December in 2014, we received an enquiry for 4 million backpacks with 2 locations printed logos, and the ETD must be the end of March in 2015.
Our team made an analysis for this requirement in the first time. As customer said he shall release formal order in the early January, which means the available time for us is only 3 months. We should have the daily output of 60,000 pcs, and 2,500 workers keep on working without any interruption from the raw material purchasing to shipping out the finished goods.
And the serious problems also existed.
Above all, Chinese New Year was coming in February, traditionally, workers should be on vocation for this festival about 20 days. How can we guarantee the orderly production?
Secondly, it is really a big challenge to control the quality and timely supply of raw materials for each batch. After all, it is a huge quantity.
Thirdly, considering the effective capacity, we have to give orders to more than one factory to produce at the same time. But how can we guarantee the same quality for each plant?
Big deal brings big challenge, but big challenge also brings big success.
To move this case, we spent 3 days to make the exact sample to deliver to customer for approval, and selected suitable and reliable suppliers in nationwide, mainly inspected their output capacity and ability of controlling and resource allocation. In comprehensive conclusion, we preferred two factories that excellent from the team. We planned to get the level for 100,000 pcs output each day, so that is no problem to promise to catch the required time.
At the late of December, customer informed us the order was confirmed, and several days later in early January, he arranged the deposit to us to push this big case.
So we discussed an exhaustive schedule and made strict rules right now.
1. About the whole layout
We broke the order in two parts to the selected two big factories, and convene them together with all suppliers that responsible for raw materials, accessories, components, packing, and transportation to have a meeting, required exact quantity and clear delivery time for each part. In order to unify the same standard for quality and service, we play a trial in first period, adjusting the manufacture practice and efficiency to be the best state.
2. About the labor division
In the process of practical production, these two professional factories released the orders to 20 workshops to divide the labor for each link. It involved 6 provinces in China. With the purpose of same quality demand, they selected outstanding workers of their own appointed to be QC of each workshop.
Another significant point, the coming CNY has serious influence on our output capacity. So we selected the workshops as close to workers’ hometown as possible, and inspired them to have an extra work during this festival. Additionally, we provided the round-tickets for outsiders to ensure they can be back to work on time.
3. About the time of material supply
As we scheduled, each MC center distributed materials to workshops according to practical budget, due to the large regional span, we set up a special transfer truck team to ensure timely supply in 24 hours whenever appears shortage. On the other hand, each QC of workshop should check the stock for 3 days in advance. It can avoid the emergency of material shortage, saving effective time. And 10 days before the finished time we required, all workshops must begin to prepare balance material and kinds of accessories to ensure no interruption at the period of ending.
4. About the quality controlling
President Manager of each workshop should have a meeting after production every day, and QC will make a conclusion to report day output amount, quality situation, and available workers the next day. All finished goods should be transited to the big factory for inspection, cleaning and packing, and will form a certification of analysis for each patch. They will inform relative QC to take measures once finding disqualified part. This is the inspecting system of supplier themselves. For us, we appointed our inner inspector to check packaged bulk in standard way, if checking out any unsatisfied part, we strictly required to return for reproduces. In the last step, we invited professional QC company to do inspection, and arranged to ship out the mass commodities when all approved.
5. About the time of production
At the beginning of quotation, we calculated the price with the logo in 6 colors by silkscreen. Now we decide to change it by heat transfer, it greatly increased the cost for us, but really speeds up the efficiency, and the imprint effect is pretty good.
Otherwise, each workshop made reports every day, considering potential problems in order to find problems and solving problems immediately. In this way, we can avoid wasting the valuable time.
Based on the 5 points above, we moved faster and faster. Although it was an intense case for our team at the beginning, problems and challenges were keeping on appearing, we spent much time to coordinate the speed and quality, but we are good at summarizing the experience, also for our workers. In the final case, our output capacity raised 3 times than before. What amazing it is!
Successfully, we completed this case and really satisfied our customer, so brings two additional orders following.
Confidently to say, we have the ability to handle with huge or huger case, no matter what you want to try, please trust that we can create legend!