midwest vs brother

Speed Comparison: HappyJapan vs Brother

When you have a superior product in the marketplace, it can be so frustrating when competitor brands miss-sell their product as equivalent to yours. Especially when there’s no evidence to support their claims. Business owners, marketers and salespeople reading this will understand all too well.

Many manufacturers sell commercial machines masquerading as industrial to customers who don’t know any better (which is fine, education is important). But then the end-user sets up their machine within an industrial production line and quickly realises that they’ve invested their budgets in commercial machinery that’s not fit for purpose.

So, here at Midwest, we’ve decided to combat this lack of education of the end-user (again, not your fault) by being straightforward and transparent with you all. With that in mind, this post and supporting video will compare HappyJapan machines with Brother – another brand on the market that specialises in commercial embroidery and sewing machines. 

 

The Experiment

Within the embroidery industry, businesses have worked hard to create industrial production lines that require quick turnaround times and uncompromised quality. So, the speed of your embroidery machine is vitally important. Strictly speaking, the more stitches per minute (SPM) – the better. 

HappyJapan values machine speed at its core. From single-heads to wide-area embroidery machines, you can see that speed is valued throughout their whole range. So, we’ve set up a speed comparison to see how they compare with other machines in the industry when performing. 

We gathered examples of all the Happy Japan ranges, from the multi-head range to the single-head range. We even threw in a variety of machines from each price band. 

We then put these machines in a room with a Brother ‘Embroidery Machine’, pulled up a standard ‘Bee’ design, and set them all running at the same time to see how long it would take to finish the whole job. There were no other variables introduced into play. 

We wanted to see how truly behind these commercial machines were in terms of speed and accuracy. 

What we found is pretty astounding. Take a look!

 

 

The Results

As you can see, with all variables the same, on the same design, here are the project time results:

1st: The Happy Japan HCU Series – 5:26:19 – That’s 5 minutes, 26 seconds.

2nd: The Happy Japan HCD3-1501 – 6:48:61 – That’s 6 minutes, 48 seconds.

3rd: The Happy Japan HCR3-1506 – 7:6:42 – That’s 7 minutes, 6 seconds.

4th: The Happy Japan HCS2-1201 – 8:5:16 – That’s 8 minutes, 5 seconds.

5th: The Happy Japan HCHP-701 – 8:7:18 – That’s 8 minutes, 7 seconds.

And a far off last place: The Brother PR60E – 11:4:08 – That’s 11 minutes, 4 seconds.

The results speak for themselves. All HappyJapan machines in the experiment were quicker than the Brother alternative. We like to base our statements and comments on cold, hard facts – that way, they can’t be argued with and are totally unbiased. 

If we compare the HCU Series, our premiere single-head machine, with the competitor Brother single head machine, that’s more than double the lead time per job. That’s a big saving for your business – this time can then be reinvested elsewhere within the business into areas that need it the most. 

Just think how this could affect your production line every month? You could see increased productivity, output capacity, profitability, quality – the list goes on! All that can be achieved by implementing the right equipment and finding the perfect embroidery machine that suits your business’ needs and requirements. 

We’re passionate that the HappyJapan range is the best in the industry for durability, quality and turnaround times – that’s why we’re prepared to put our necks on the line and put it to the test. We believe that our customers (both potential and existing) should be investing in machinery that provides unmatched value to their business – and that’s what you get with HappyJapan. 

 

Save Your Business Wasted Money

 

midwest embroidery machines

 

Now you’ve seen the real evidence, it’s time to make the right choice based on your business’ requirements. In order to reap the benefits of adding an industrial embroidery machine to your production line, you need to make sure that you choose the right one. You can’t pick any old machine and expect groundbreaking results – it doesn’t work like that. 

Don’t worry if you’re not sure about where to start – that’s where we come in. At Midwest, we help all of our customers find the machine that suits them the most. From output capacity to budgetary requirements, there’s a lot to consider. However, we allow FREE trial periods on all of our range, so that you can make smarter business decisions a lot easier. 

Now we’ve shown you why to choose our brand, you might be wondering which type of machine is right for you? Well, we even have a resource for that! Check out our handy guide to the right of this blog for a rundown of the HappyJapan machines we recommend for each stage of your business journey, along with helpful tips on when it’s best to upgrade from your current machinery!

Technologically Advanced Embroidery Machines: HappyJapan vs Tajima

Nothing is more frustrating than a piece of equipment that’s outdated. It’s behind the times. It’s not working as well as it should be. Older machines that are part of a modern production line only serve to slow down output, decrease efficiency and as a result, lose you revenue.

Not only that, your business could be losing out to competitors that have less downtime or more air-tight production lines. Customers in the modern business environment aren’t oblivious to these things. They notice when deadlines aren’t met or the quality of your products isn’t quite as good as before.  Not having the foresight to constantly be future-proofing yourself and your machinery will hit your business reputation and customer perception hard. 

So, what can you do to rectify this situation? Well, it’s pretty simple. Invest! More specifically, invest in technology. We cannot stress highly enough how crucial it is for businesses, especially embroidery businesses, to focus on looking to the future and budgeting for equipment that is cutting edge. 

But if you don’t know where to start, we’re here to help. In this blog we’ll compare the main features and technological capabilities of HappyJapan and Tajima embroidery machines. No prizes for guessing who’ll come out on top.

 

The Machines

 

embroidery technology

 

We see so many amazing embroiderers go under because they weren’t willing to invest in the area of their business that is most important; machinery

As with all our comparison series, let’s firstly analyse what makes an embroidery machine ‘technologically advanced’ – as we realise it’s an abstract term that’s difficult to define. 

When we talk about machines that are on the cutting edge of tech, we firstly have to discuss their features. Is the machine wireless? This is a must for modern production lines as the system has to be adaptable and moveable if necessary. And this is especially important in a growing business, as space has to be made for additions and subtractions to the manufacturing process based on capacity requirements. 

Another key feature of a tech-conscious machine is its accessibility options. The modern generation of embroidery machines are (mostly) equipped with LCD touchscreen panels and one-touch systems; all to aid operators, making training easier and daily operations a lot simpler.  

Thirdly, a key question you have to ask your embroidery machine supplier is “What operating system is the machine running on?” –  this is important when dealing with tight deadlines and more complex projects, as your machine has to seamlessly interface with third party software to realise unique product requirements. The only system worth mentioning for this purpose is Windows. Anything else is inferior software and will only lead to errors and conflicts with any third party products.

With that in mind, since you’re one of those forward-thinking businesses that invests (as you’re smart enough to read this blog) let’s look at the cream of the crop for technologically advanced machines you need to consider today.

 

HappyJapan – The HCR3-1512

 

hcr3 1512 machine

 

The HCR3-1512 is the top of the range for HappyJapan. It’s a machine that we would recommend only to businesses that have medium/large production lines and customers that have demanding lead time requirements. It’s a high-speed, 12-headed beast that has the highest level of production power available from the top embroidery machine brand in the industry. It’s completely wireless and can fit into a variety of environments and production lines – it’s compact, high-speed and designed to get the job done right, every time!

It has a maximum speed of 1000 SPM with all 12 heads active, and high-speed servo motors built in, to add that extra efficiency for jobs that need to be completed in rapid succession. This is all controlled via a 10.4 inch colour LCD touch screen control panel – one of the largest operational interfaces on the market. This easy accessibility is necessary for machines like the HCR3-1512, as operators have the responsibility for many embroidery jobs at once. So a panel that gives an overview of the process – including speed and design progress – is critical.

The machine’s memory can hold up to 40 million stitches. Again, this is something that makes the HCR3-1512 the best choice  for big projects. Couple that with automatic thread break protection, an automatic thread trimmer and a flat embroidery space size of 450 x 360mm, and you’re looking at a model that is at the forefront of embroidery technology.

Of course, all HappyJapan machine models come with Windows software built in and PC connection software through the use of Wilcom, which comes as standard. This means the operator can introduce third party software into production with no problems; but also save time by using barcode scanning on a PC to load designs automatically.

 

Tajima – The TMCP-VF Series

 

Image Credit: Tajima

 

The best comparison model from Tajima is the TMCP-VF Series. It’s a high speed, top of the range model, armed with servo motors and custom switches – a feature designed to aid operators when working with large and complex projects. This model, like the HappyJapan machine, can also go all the way up to 12 heads.

The TMCP-VF can expand to an embroidery space of 550 x 400mm. It comes with an LCD touch screen panel (which isn’t fully touch screen, we might add), which is a shame for the purposes of comparison. 

Tajima also states that this model has improved motor performance and is much more energy efficient. However, the machine doesn’t run on Windows software, which will create problems for embroiderers that rely on additional input software or barcoding to upload designs. 

 

Let’s Compare

To be brutally honest, the TMCP-VF Series doesn’t come close to HappyJapan’s HCR3 1512. Firstly, let’s take its size. The Tajima model is absolutely huge, meaning that it’s not flexible to fit into different working scenarios. The last thing you want when upgrading your embroidery machine is to have to look for a new premises too, isn’t it? Talk about rising costs! What you want is a compact, high-performance, reliable machine that packs a punch – if only we knew one? 

The HCR3 1512 is an energy-efficient machine too. When running your machine all day, you’re going to be using a lot of power. Which is why you need the most efficient machine possible to keep a cap on your spending, right? If you opted for the Tajima machine, you can expect much higher energy costs than the HappyJapan. Lower running costs and unparalleled quality, is that not your winer right there?

The HappyJapan machine will have no problem running faster over prolonged periods of time and is more consistent than the alternative. Also, it has a far superior colour change – meaning that you can have ultra-flexibility when it comes to embroidery design colours and overall quality. There’s only one winner for us and that’s the compact, durable and utterly impressive HappyJapan HCR3 1512.

 

Decide For Yourself

 

advanced technology embroidery

 

The ultimate deciding factor you need to consider is the operating system issue. The vast majority of third-party software requires integration with Windows systems, and only the HappyJapan model can deliver that. If you’re an enterprise business with a multi-layered production line, this is a crucial requirement.

For this reason, and the ones above, we can’t recommend the Tajima model over the HappyJapan. We simply can’t lumber you with all those software conflicts when there’s an alternative at a similar price point, that is faster and more accessible. 

Now that we’ve settled that, the question might occur to you “What size of machine do I need for my capacity and output requirements?” Well, we have just the piece of educational content for you. To the right of this blog, our Ebook will talk you through every level of our embroidery machine range and give you advice as to what is best for you. Whether you’re a startup or a national business!

Wide-Area Industrial Embroidery Machines: Happy Japan vs Tajima

Let’s set the scene. Your embroidery business currently has several single-head or multi-head machines in the production line. You’re running a fairly simple manufacturing process, producing embroidered garments en masse, all with similar or uniform designs. It’s a reasonably profitable system.

However, a new customer comes on board that wants much more detailed, custom designs on much larger surface areas. Items like banners, rugs, throws or duvets. You take a look at your machine setup and there’s just no way you’ll be able to facilitate the order because your machine embroidery areas are set to a particular size. But you don’t want to lose the custom either.

Enter wide-area embroidery machines. These models are specifically designed to handle the more complex, large surface projects that usually come with an increased budget and profitability for the embroiderer. The extra revenue that adding this new string to your bow can bring is not to be sniffed at. Having these models available to use for capacity will also separate you from the pack when a potential customer is choosing between you and the competition.

 

The Machines

Firstly, let’s debug some of the complexities of the term ‘wide area’ to describe these model types for anyone that isn’t knowledgeable in embroidery circles. 

Essentially, a standard single or multi-head machine becomes a wide area version when it’s specifically designed around a larger than normal embroidery area. The embroidery area will usually stretch from one side of the stitch heads to the other, giving the machine freedom to move the embroidered product around and accommodate larger designs with sometimes millions of stitches.

Why do you need one? Well, quite simply, if you wish to work on products with larger surface areas and expand your range to include items like the ones mentioned above (rugs, throws, duvets, etc) you need a wide-area embroidery machine. No other models can achieve the amount of adaptability and intricacy required.

A wide-area machine can generally come with one or two heads. This is one of the main factors that influence the price model to model. More often than not, the machine also comes with a removable work table to aid in embroidery, but again this varies from brand to brand.

So, let’s take a look at two prime examples of wide area machines. One from Happy Japan and the closest competitor brand, Tajima.

 

Happy Japan – The HCU-1501X-120

The Happy Japan HCU-1501X-120 is a big player within the wide-area industrial embroidery machine game. It’s one of our most modern machines and you can tell with the advanced features that users can benefit from with the machine. In fact, there’s no point feeding you empty words, we’ll let you see for yourself. Watch the demo of this ultra- impressive machine below.

 

 

 

Tajima – SUMO – TWMX-C1501

 

Sumo TWMX-C1501

Image Credit: Tajima

The Tajima SUMO – TWMX-C1501 has a body structure that secures a wide working space and emphasises workability and adaptability. It’s also a model for embroiderers that wish to utilise the additional part options that Tajima offers, like the sequin device and coding device. These extras are sold separately, however.

The SUMO – TWMX-C1501 also runs at 1,200 SPM at maximum speed and is available with stitch head numbers of 6, 9, 12, and 15 in total. All of these needle variations are based on a single stitch head.

This model can be used in a variety of situations, as the removable work table can be switched in and out depending on the requirements of the project. This wide bay stretches to 450×520mm. The frame exchange is very easy to perform, however, by just interchanging 2/4 screws and swapping surfaces.

The LCD touch screen panel on this model is 6.5 inches wide and designed specifically for ease of accessibility for the operator. 

 

For a Level Up… Happy Japan – The HFR-W1502-120

 

hfr wide area machine

 

It wouldn’t be fair to compare this machine straight with the Tajima model – it’s far more advanced and is specially designed for extreme production. Whereas, the Tajima machine is sub-standard and wouldn’t stand a chance. So, in light of keeping things fair, the HFR-W1502-120 should only be invested in if you’re ready to take the next step with your wide-area embroidery. Or, you’re a national business with a huge need for wide-area embroidery.

This machine represents the ABSOLUTE pinnacle in the wide area range for Happy Japan and is perfect for production projects that require a much larger embroidery area for the stitch heads to work on. Meaning it’s perfect for businesses that manufacture complex embroidery designs en-masse.

The touch screen panel (included in all Happy Japan machines) sits at the edge of the work area, which is unique to this model. This enhances ease of use for operators who don’t want to stretch across work tables to interact with the machine. We know from experience how frustrating it is for operators when the operation panel is just out of reach on competitor models.

The HFR-W1502-120 runs at a maximum speed of 1,200 SPM and can incorporate two stitch heads at the same time working on products, both with 15 needles each. The embroidery area can get as large as 600x1200mm. There won’t be any products too large or demanding for this machine to handle – it’s above and beyond any wide-area in the industry. And that’s not just our word for it, all of our statements can be backed up by trials, of course.

 

Let’s Compare

This is one of the easiest choices we’ve had to show on our series of comparison blogs so far. 

Mainly because we couldn’t find a Tajima model that was even in the same league as the Happy Japan model when it comes to wide area machines. We couldn’t even find a wide area specific model in the range that we could adequately compare.

In fact, the SUMO – TWMX-C1501 was introduced in 2003 – but what’s evolved within the product since then? Nothing! That’s a long time for “industry-leading” innovation to not change, isn’t it? Technology has come a long way since then. Think about it, Concorde was still flying until November 2003. While the aircraft was at the forefront of the industry then, if it was still flying today, it’d be far inferior to the latest innovation

Also, the Nokia 3310 was leading the way as one of the most innovative mobile phone products. 17 years later, that handset – which is now commonly known as “the original brick” – is absolutely no match for the iPhone 12 that’s being released in October 2020. Just look how far that industry has come – and the industrial embroidery machine game isn’t any different!

With that being said, Happy Japan wide area machines are constantly evolving. In fact, our current model is the product of FOUR evolutions of machines since 2003. Meaning that we’ve introduced the latest technology and performance factors four times into our machines within the same time period as Tajima. We don’t just give them a lick of paint and roll them out as a new model each time – not mentioning any names!

 

Make Your Decision

 

choosing your embroidery machine

 

For this comparison, it’s not fair to consumers for us to recommend anything but the Happy Japan model.

Wide-area machines are uniquely designed to accommodate niche products that would otherwise be very difficult to embroider onto with standard single head and multi head models. We couldn’t in good conscience suggest going for the SUMO – TWMX-C1501 for that reason; it’s a wide-area machine in name only. 

Some of you might still be thinking “What types of embroidery machines does my business need?”. It’s a completely understandable question. Maybe you don’t need a wide area machine just yet. Maybe it’s worth investing in a single-head or multi-head model first and then you can diversify later. 

Answers to all these questions can be found in our handy ebook to the right of this blog. It’ll give you a detailed rundown of what machines each level of organisation might need and gives recommendations of the best model for you, no matter what your requirements are. Grab your free copy today!

single head machine comparison

Single-Head Industrial Embroidery Machines: Happy Japan vs Tajima

Whether you’re looking to purchase your first ever embroidery machine, or already have a single-head machine and want to expand your capacity, it’s important to do your research before investing. There are so many brands out there, making it increasingly difficult to make an informed decision based on the real hard facts and figures. 

And so, it’s only fair that we lay out the full details by comparing and contrasting some of the best machines from the two biggest brands. That way, you can wade through all the marketing spiel and get down to the numbers – and make your investment decisions based on your business’ requirements.

With that in mind, who are the two biggest brands? Well, of course, Happy Japan is one of them. It wouldn’t make sense to omit our machines from the comparison, now would it? The second is Tajima, who are of course a staple of the embroidery machine industry, along with ourselves.

For this blog, in particular, we will focus on single-head embroidery machines. In future content, we’ll delve into multi-head, wide-area and then finally we’ll deep dive into the technology behind each brand’s machines.

So, let’s get started!

 

The Machines

First of all, for those of you who are beginners, let’s define what a single-head embroidery machine is, what it does and what it’s great for.

A single-head embroidery machine works as a great first step into producing and embroidering material on an industrial scale. It’s named as such because the machine has one single head.  A single-head machine is the ideal startup machine if you’ve just begun in business and are looking to enter into the industry. They’re often compact, portable, flexible and range from 7-15 stitching needles in total. 

Single-head machines are generally used by businesses that have a more simple production line, usually producing one product at a time with little variation in design from product to product. This is because the machine is incredible at doing one thing very efficiently at a time – so it’s perfect for jobs that require en-masse production with low lead times.

Right then, let’s kick on with the machines.

 

Happy Japan – The HCU Series

 

hcu series machine

 

The HCU series is a perfect example of a startup high-speed industrial embroidery machine to grow your business from. It has a great capacity for production due to the fact it’s speeds ramps are higher than any other machine.

It has a maximum speed of 1500 SPM and a Tubular Embroidery Area of 400 x 600mm – that can be expanded to 400mm x 1200 mm. Due to its high speed ramps and the ability to run consistently without constant thread break means this machine is world leader.

As with all Happy Japan machines, the HCU Series has a completely wireless connection, meaning no pesky wiring to deal with that causes potentially dangerous hazards within a busy workspace. Happy Japan machines are the only ones in the market who offer this. The wireless feature also makes the machine much easier to move around and simpler to accommodate into a variety of workplaces without the need for replacing cabling.

The HCU can also produce live reports of operation, showing management full details on how projects are coming along and how your staff are performing too.

Live reports of operations are a great way to ensure that the proper levels of work are being upheld; they also help your team manage their performance and the performance of the machine they are operating – minimising the need for loss of downtime.

 

Tajima – The TMBP-SC Series

 

tajima tmbpsc

Image Credit: AJS Embroidery

 

The TMBP-SC is the latest single-head machine in the Tajima range, and is the answer to the Happy Japan HCU series, as it performs similar tasks and services similar size projects. 

The TMBP-SC runs at a maximum speed of 1200 SPM with a Tubular Embroidery Area of 360 x 500mm – so it sits firmly in the industry standard for production speed and embroidery area. Similar to the HCU, this model can go all the way up to 15 stitching needles. 

In addition to that, a number of frames can be attached to give the machine the ability to stitch more efficiently to specific garments, like socks, wristbands, caps and shoes.

Asides from these similarities, there’s no comparison between the two machines – as the Happy machine outperforms the Tajima in every way. As proved in trials.

 

Let’s Compare

The key areas that the HCU series beats the TMBP-SC are in speed and area size. 

 

The HCU

  • 1500 SPM stitch speed.
  • Embroidery Area of 400x600mm.

The TMBP-SC

  • 1200 SPM stitch speed.
  • Embroidery Area of 360x500mm.

 

These are probably the most important statistics, especially at this level of machine, as your investment into a single-head model will likely be your first and only method of embroidery. It makes sense to choose the fastest and most adaptable.

The HCU Series runs on Windows software, whereas the TMSP-SC does not. This automatically puts the Happy Japan model into pole position, as Windows is the market leader; giving the HCU so much more capability to interact and interface with whatever third party software your business requires to manage its production line.

The ability of the HCU to wirelessly connect to apparatus is a big plus. Whereas, the Tajima model needs an Android tablet for connectivity. Plus, the Tajima machine isn’t easy to use at all. Employers often have to invest in training for their machine operators to get to grips with the models. As opposed to the HCU Series, which is a user-friendly machine that can be picked up incredibly quickly.

Most impressively, the HCU Series possesses the ability to run 3D embroidery on caps at 1200 SPM. And due to patented technology, it can determine the thickness of the material by itself – which gives the final product a far superior finish than any other machine in the market.

What tips the HCU series further over the line though is its ability to track and report live data. This additional feature, that the Tajima model does not possess, makes the HCU a machine your business can effectively scale on to – extending its lifecycle and future-proofing your manufacturing for the future – especially if you wish to add additional machines into the production process.

 

It’s Up to You!

 

single head machine decision

 

Naturally, there’s a clear winner in the race to be the most technologically advanced and efficient single-head machine in the market – the Happy Japan HCU Series. 

So, if you’re a business looking to enter into the industry as a startup, wanting to update your old Tajima model to something superior or looking to add new machines to your existing production line, what are you waiting for? At Midwest, we offer a free trial on all machines before you buy – that way, you can be sure that you’re making the right choice for your business. And trust us, with HCU Series, you’ll never look back. 

You can get in touch with our experts by simply going to our contact us page – or if you need more convincing, you can check out our handy EBook – which compares Tajima and Happy Japan machines in much more detail to the right of this page! Grab your free copy today!

midwest customer experience

What is the Customer Experience Like with Midwest?

Throughout the embroidery machine industry, Midwest is known as a leading brand. Why is that? Two reasons. Firstly, we are the sole UK stockists of Happy Japan machines; the highest quality embroidery machines in the world. Secondly, we provide industry leading customer service.

At Midwest, we look after all of our customers. It doesn’t matter whether you’re a returning client or a new customer, we treat everybody with the same professionalism and diligence. Our customers matter to us, and we love seeing their businesses’ grow from strength to strength with the help of our premium embroidery machines. So we make sure that our values are reflected in our customer support and service 24/7. 

In this blog, we’ll take a look at what those processes involve and how it helps create a great business relationship between us and our customers.

 

About Midwest

 

midwest logo

 

As the only stockists of Happy Japan in the UK, you won’t find another company that can provide the level of support we can for your Happy Japan machines. Whatever the query is, you can guarantee that we have come across it and know how to fix it. 

It’s this level of customer experience and service that has forged our strong reputation and formed long lasting relationships with our customers – some of these stretching over decades of us supplying embroidery machines as requirements and technology shifts.

That experience starts from the very beginning, with our machine demonstrations and continues with our customer care process.

 

Our Initial Conversations

 

midwest customer conversations

 

After your initial enquiry, our embroidery machine experts prefer to speak with you either on the phone or in person. Before we recommend any machine to you, we need to understand  your business requirements so we can find the perfect fit. This is from experience, as sometimes a business will come to us with an enquiry about a certain machine and we know there’s a better choice out there.

Perhaps you’re a startup embroiderer; you enquire about a high speed multi-head machine. Yes, we could sell you on the higher price machine, but there’s no way you’ll use it to full capacity any time soon – wasting a lot of budget in the short term.

We prefer to form lasting relationships with our customers that continues throughout multiple upgrades as your business grows. This is why we focus firstly on asking you about your business, where it’s at, what your output and products might be; especially if you’re a startup that doesn’t have a lot of wiggle room in the budget.

 

Our Machine Demonstrations

Once we’re both happy with the machine choices you’re interested in, it’s time to move on to demonstrations. 

Video Demonstration

At Midwest, we have two different types of demo we carry out. The first one is a video demonstration. These tend to suit businesses that are hundreds of miles away from us and can’t make it to our offices in person immediately. 

These video demonstrations are conducted via our sales representatives, who will walk you through every aspect of the machines you’re interested in. An example of this can be seen below, which represents a typical demonstration for our HCU Series machine:

 

 

These demonstrations focus on:

  • The look and feel of the machine.
  • The technical aspects – stitch speed, embroidery area, technological considerations
  • Features unique to your chosen machines.
  • Features that are unique to Happy Japan machines that aren’t included in competitor models.
  • And finally, a runthrough of a production project in real time.

This video is sent to you, along with any necessary brochures and price lists, in an online package so you can make a more informed decision to purchase or to arrange a further demonstration in person.

 

In-Person Demonstration

This type of demo is usually carried out by one of our engineers or our management team at our offices in Trafford. These tend to suit businesses who are larger or more experienced -who know exactly what type of machine they require to expand their capabilities or increase their output. 

The contents of the demo are similar to the video version; with the added value of being able to ask our representatives any questions that are outside the box or unrelated to your specific machine choice. It also makes a purchase decision much easier, as you have a direct line to our sales team, who can give you a much more accurate and detailed quote.

In person demonstrations tend to focus on:

  • Detailed quotes and investment discussions.
  • Questions about additional machines, as all our machines are viewable in the showroom.
  • Full technical readouts and in-person embroidery project run throughs. 

 

After Your First Purchase

 

midwest aftercare

 

After you’ve made your first purchase with us, don’t worry, we don’t suddenly lose interest like a lot of our competitors do. Firstly, we offer a try before you buy scheme – which comes with every Happy Japan machine.  All of our models are available for you to try for a limited time before you make a purchase, so you can be 100% certain you’re satisfied with the quality of work produced. That’s how sure we are that you’ll be happy!

Embroidery machines are a big investment, even for a larger company; so being sure that you’re getting a quality piece of equipment for your money is crucial – and our primary goal is to make sure you do.

Secondly, we arrange a time to get in touch and discuss how your machine is performing. Usually this is a few months after purchase. We’ll ask you if you’re happy with its speed and efficiency, plus we’ll check if anything has caused maintenance issues. 

 

Forming a Long Term Business Relationship

As we move forward after your first purchase and beyond, we’ll get in touch every now and then to check how you’re getting on; to see if we can help you with advice or suggestions as to how you can best scale your embroidery projects and business in the most cost effective way possible. 

Maybe you need to upgrade to a more technologically advanced machine to future proof your business. Or maybe you just need to invest in more machines to keep up with capacity and customer orders. Or perhaps you need advice on embroidery processes to make your production line more efficient. We’re here to help you achieve more with your Happy Japan machines.

 

Want to Hear More?

Want to do more research on our customer practices? Or just want to learn more about our machines in technical detail? Check out our ebook to the right hand side of this page. It’ll give you much more information on how we measure up against our direct competitor in the embroidery world: Tajima!

hfr series machine

Happy Japan HFR-W1502-120: A Closer Look

Some of the most profitable and impressive designs achievable in embroidery tend to be the larger, much more detailed products. This can include rugs, banners, ponchos, throws and duvets. These are specialised products that require a more complex production process and equipment that is designed specifically for embroidering onto them.

So, if you’re a manufacturing or embroidery business that already works with these types of products and wants to upgrade or expand your range, you’ll require the correct machine to do so.

And if you’re working with specialised products, the key to an industry leading and efficient solution for your projects is technology and machinery. This means constantly future-proofing yourself and your processes by investing in the latest tech and machines with the right capabilities for your output.

For those of you who are interested in this type of embroidery, we have the perfect solution for you. 

 

The Happy Japan HFR-W1502-120

 

HFR-W1502-120

 

This wide area embroidery machine is perfect for production projects that require a much larger embroidery area for the stitch heads to work on – and is perfect for businesses that manufacture more intricate products with complex embroidery designs. 

The HFR-W1502-120 also has a flat bed embroidery area which is much larger than standard multi-head machines. The embroidery area stretches from one side of the stitch heads to the other – giving the machine freedom to move the embroidered product around and accommodate large designs with millions of stitches.

 

The Key Features

1. LCD Touch Screen Panel

 

hfr touchscreen panel

 

The HFR-W1502-120 has a 10.4inch colour LCD touch screen control panel built into the embroidery area, conveniently placed so that operators have easy access to operations reports and live feeds of job progress. This includes current stitch speed, colourations of the design and status updates of any issues within the job or software.

 

How This Impacts Your Business:

The touch screen panel comes standard with all Happy Japan machines – something that competitor ranges can’t boast – and gives your staff the peace of mind to do their job safely and efficiently. It also provides useful reports of operations to managers of capacity levels, design details and information regarding maintenance requirements. These types of data are crucial for a production line that’s complex and specialised, as your operators can’t be at every machine all the time. So, having a quick method to analyse how things are running is invaluable.

 

2. Maximum Speed of 1000 RPM

Want speed and efficiency with your wide area embroidery process? The HFR-W1502-120 has got you covered. It’s speed of 1000 RPM is impressive compared to its competitor counterpart, the Tajima TFMX-C1501. As with all wide area machines, the expanded embroidery area forces you to sacrifice some speed – but for specialist jobs that require a unique amount of stitch space, there is really no other choice.

 

How This Impacts Your Business:

The quicker your stitch speed is, the lower the lead time on projects – plain and simple. No other wide-area machine with such a large flat bed area can achieve the speed this machine can. Is it a niche machine when compared to its other multi-head compatriots? Yes. But it’s ability to reach 1000 RPM while covering unmatched levels of embroidery area is a huge benefit to any business that produces embroidery on items like duvets, towels, rugs or banners.

 

3. Try Before You Buy

All Happy Japan machines, including the HFR-W1502-120 are available for you to try for a limited time before you make a purchase, so you can be 100% certain you’re satisfied with the quality of work produced. That’s how sure we are that you’ll be happy! 

This is something no other embroidery machine manufacturer offers. Need we say more?

 

How This Impacts Your Business:

This one is self-explanatory really – embroidery machines are a big investment, even for a larger company; so being sure that you’re getting a quality piece of equipment for your money is crucial. This is much easier to test if you choose to try a Happy Japan machine before you buy it.

This is especially true for businesses that require wide area machines specifically; as the products tend to be more specialised and expensive per unit, so getting a quality job every time is incredibly important.

 

4. One Touch Operations

 

one touch operations

 

Every feature of the machine is one touch of the screen away. This provides an unparalleled level of accessibility for your operators. Got a complex production line that needs to minimise machine complications? This is the machine for you.

 

How This Impacts Your Business:

One touch operations save time and money on training. The easier the machine is to use, the easier it is to pick up and create products. Resulting in decreased lead times with less time spent training new operators – especially on larger production runs that might require more staff. Plus, having machines that are easily picked up by new operators creates a frictionless onboard when increasing your machine capacity with newer models.

 

So, What Size of Business Should Buy It?

As the HFR-W1502-120 is a flat-bed wide-area embroidery machine, it’s perfect for businesses that require a more specialised type of embroidery. If you have a gap in your production line for projects that require a very large embroidery area, like duvets or banners, then we would recommend this type of machine over a similar standard multi-head machine.

The HFR-W1502-120 is a two head, 15-needle machine, so naturally it can complete 2 designs at a time. So if you’re looking to produce products en masse, you’ll be struggling to find a wide area machine that can perform the tasks you’re after. This machine is perfect at producing highly detailed, large projects, so the jobs tend to be unique or to order.

 

We Need a Wide Area Machine – How Do I Enquire?

 

happy japan embroidery machines

 

The best way to get in touch with Midwest regarding the HFR-W1502-120 is to contact us via the specific machine page. That way, we know exactly which machine you’re interested in. Our embroidery machine experts will then get back to you as soon as possible to set up a more technical demonstration.

If you’re desperate for more details on the larger range of Happy Japan embroidery machines, our Ebook will guide you through the process of determining which level of machine is right for your business – so have a look to the right of this page for more!

happy japan hcr3

Happy Japan HCR3-1508: A Comprehensive Review

What’s the biggest priority for manufacturers in the modern manufacturing industry? Efficiency. This is especially important for fast-growing businesses that want to stay ahead of the competition and push forward with bigger and more lucrative projects from more prestigious companies. 

Companies who are one step ahead of the game always focus on producing quality products in the most efficient timeframe. But to do this in embroidery manufacturing, you need the most technologically advanced equipment and machinery. Otherwise, you’ll be dragging your heels behind competitors that are willing to invest in future proofing their production lines.

Having a production system that’s built on a solid foundation of the latest tech, the most efficient machinery and air tight processes is crucial. That way, when those inevitable maintenance downtime periods do happen, you’ll have the correct measures in place to mitigate and minimise issues. So, it’ll have little to no effect on your lead times for those all-important customers.

And speaking of efficiency and technology, let’s take a look at a machine that’s become an industry measuring stick – one that we recommend to any manufacturing company looking to expand and grow quickly.

 

The Happy Japan HCR3-1508

 

HCR3 1508

 

This multi-head embroidery machine is perfect for a production line that’s expanding and looking to diversify in what it can embroider, without compromising on the quality of the products. It’s an 8-head machine, so it can work on 8 different products at the same time; a big jump, especially for a business that may be running with a single-head machine.

The HCR3 is a high-speed model designed for larger and more complex production jobs. It’s a powerhouse with servo motors, taking it a step above the standard multi-head machines you may see from competitors in the industry.

 

The Key Features

1. LCD Touch Screen Panel

 

lcd control panel

 

We start off with the Happy Japan touch screen panel, built into the machine as standard. This is a 10.4 inch Colour LCD screen, designed to interface with the operator to show job progress in real time and give updates on any potential hiccups with the equipment. It also has a live feed of stitch speed, ensuring uniform efficiency at all times during the production process.

 

How This Impacts Your Business:

It’s simple really; your operators’ lives are made easier and you can rest assured that every part of your production line is managed and maintained for optimum efficiency. It also keeps track of machine safety, as the machine will automatically flag up any setup mistakes or errors with stitching. This minimises the likelihood of faulty products by drawing attention to any non-uniformity, so that operators can fix it immediately. 

 

2. Maximum Speed of 1200 RPM

 

stitch speed 1200

 

The HCR3 has a maximum speed of 1200RPM – making it faster than similar models from competitors like Tajima and inferior commercial machines made by Brother. This high speed and efficiency make it a perfect fit for businesses with tight deadlines and a need for quick project turnaround. 

 

How This Impacts Your Business:

Happy Japan knows what the most desired trait of a multi-head machine is at this level of embroidery – speed. That’s why the HCR3 was designed with that in mind. Installation of servo motors to further increase job efficiency has really taken this machine into the elite tier when it comes to production power. This speed, coupled with the ability to embroider with all 8 heads at once, will super-charge your production line, giving you the ability to deliver bigger orders and vary capacity depending on project requirements. 

 

3. Live Management Reports 

Want to ensure maximum efficiency while your operator works with the machines? The HCR3 records all machine input in real time and commands entered into the dashboard can produce operational reports to measure work levels at all times. This can be managed via Windows software that is built into ALL Happy Japan machines.

 

How This Impacts Your Business:

Not only are live reports of operations a great way to ensure that the proper levels of work are being upheld; they also help your team manage their performance and the performance of the machine they’re operating. This gives your staff a level of control that competitor models just can’t measure up to.

 

4. Design Memory of 40 Million Stitches

That’s a lot of stitches. A stitch memory this large means your designs can be complex, detailed and of a size that you would expect from a top of the range multi-head embroidery machine. 

250 designs can also be saved – although this doesn’t take into account the huge variation that can be achieved using the Windows software the machine operates with. This allows designs to be uploaded on the fly using barcoding technology – making it really simple and easy to vary designs job to job.

 

How This Impacts Your Business:

You can create embroidery projects that are varied; incorporating a multitude of colours and patterns. Something that is expected when you’re dealing with high-prestige wholesalers, retailers and workwear specialists.

 

So, What Size of Business Should Buy It?

 

happy japan thread stitching

 

We’re glad you asked. The HCR3-1508 is built for established businesses that are ready to expand their production capabilities – so we wouldn’t recommend a startup embroiderer for this model. A great example of a candidate for this machine would be a manufacturer that already has several single-head machines, like the HCU Series or HCH-701P, but is looking to either grow beyond single-heads or add additional capacity.

Another example case for buying the HCR3-1508 is a business that is behind when it comes to technology. Perhaps they purchased a competitor’s machine and they’re now lagging behind their own competition when it comes to efficiency or speed – causing them to lose projects or spend money on extended maintenance and downtime periods.

Therefore, if you’re an established business that’s looking to grow or future proof your production line, the HCR3-1508 is a great choice to achieve your business objectives.

 

The HCR3-1508 is the Right for My Business – How Do I Enquire?

The best way to get in touch with Midwest regarding the HCR3-1508 is to contact us via the specific machine page. That way, we know exactly which machine you’re interested in. Our embroidery machine experts will then get back to you as soon as possible to set up a more technical demonstration.

If you’re desperate for more details on single head or multi-head embroidery machines, including the HCR3-1508, our Ebook will guide you through the process of determining which level of machine is right for your business – so have a look to the right of this page for more!

hcu series overview

Happy Japan HCU-1501: An In-Depth Overview

In the manufacturing sectors, perfecting your production line is key. It’s the lifeblood of your company; nothing works if your process and production aren’t on point. The question is, what is the key to keeping an airtight and streamlined manufacturing schedule?

Equipment. Equipment and machinery. If you don’t ensure your machines are in top notch shape, it’s only a matter of time until something breaks and downtime occurs. 

Downtime can cost your company a lot of money in wasted production time. Not only that, your reputation will take a hit with your customers. So, what can you do to minimise the chances of this happening to your business?  We’re glad you asked. 

Quite simply, you need to create a solid foundation of modern, market-leading equipment that is future proof and of a higher standard than your competitors. Having a production system built on machines that are modern, transportable and simple to scale is also a must, in order to avoid problems piling up if the worst case scenario does occur. 

With that in mind, let’s take a look at one of Midwest’s most technologically advanced machines – one we think would fit perfectly in your future-proofed manufacturing system.

 

Happy Japan HCU-1501

 

 

This single-head embroidery machine is the most technologically advanced high speed, single head machine on the planet. But it won’t break the bank, making it a great foundation machine for a forward-thinking startup to build upon. It’ll secure the future of your manufacturing process, while producing consistently high-quality products that’ll outperform competition machines at a similar head number.

 

The Key Features

1. Touch Screen Panel

 

happy japan hcu panel

 

Unlike standard Tajima machines, the HCU-1501 has a LCD colour touch screen control panel built into the dashboard giving visual cues to the operator in real time – making the machine safer and simpler to use. 

How This Impacts Your Business:

Increasing the safety of your work environment is paramount. It raises staff morale, creates a more comfortable environment and benefits work operations. If people feel safe doing their job, especially in the manufacturing sector, they work more efficiently.

 

2. Maximum Speed of 1500 RPM

 

hcu 1501 stitch speed

 

The HCU-1501 has a top speed of 1500 RPM – this is an industry leading standard of stitching numbers, making it a perfect choice for businesses that are fast paced and strict with production lead times. Despite the rapid job times, you’re also guaranteed to receive the same quality stitching from the first one to the very last.

How This Impacts Your Business:

The speed of design stitching is something that separates the men from the boys in the embroidery industry. Usually, to achieve this level of job production, especially with competitor brands, you’d have to upgrade to a multi-head machine. Not only does the HCU-1501 ensure your costs stay down by future proofing your equipment, it allows you to keep working with single-head machines longer while staying at a certain price level.

 

3. Windows Software

You’d be surprised to hear (we hear it all the time doing machine demos) that Happy Japan is the only brand of embroidery machines that use  Windows software to operate. That means instant recognition for operators who are starting to use your machines, as everyone knows how to navigate  Windows!

How This Impacts Your Business:

Having access to the latest  Windows software at all times reduces overheads by removing risk and saving money that otherwise would be spent on third party software.  Windows is the most trusted operating system in the world for a reason – nothing else measures up to it. 

Having  Windows software also ensures compatibility with the vast majority of third-party integration such as reporting software or CRM – which is crucial for the more complex production lines to function properly. 

 

4. A Wireless Connection

 

Ever had problems with your machinery being difficult to move around or reorganise? We can relate. We’ve seen so many warehouses with wire spider webs littering the floor, making it near impossible to provide the most efficient workspace for your staff and production.

That’s why we’re so glad to tell you that the HCU-1501 is completely wire free – just like every other Happy Japan embroidery machine. You’ll probably be surprised to know that no other brand in the marketplace can make that same claim. I know, we couldn’t believe it either!

How This Impacts Your Business:

For your workplace to run smoothly, it makes sense to ensure your business is running as free from wires as possible. It’s more flexible, safer and easier to manage. The less unnecessary mess you have, the easier it is to increase or decrease capacity too.

 

So, What Size of Business Should Buy It?

A great question. The short answer is that every business can benefit from the most technologically advanced machine in the market.

Of course, the long answer is that it depends on requirements. 

As the HCU-1501 is a single-head embroidery machine, by nature it can only stitch one design at a time. So, if you’re looking to produce products en masse, a multi-head machine might be more your style.

Single-head embroidery machines will work well for tubular embroidery, which allows a machine to work on garments such as sleeves, caps, bags or pre-assembled fabrics and garments. 

Therefore, if you’re an ambitious startup or established business looking to upscale, then a machine like the HCU-1501 is the perfect model to achieve your goals. 

 

You’ve Sold Me – How Do I Enquire?

The best way to get in touch with Midwest regarding the HCU-1501 is to contact us via the specific machine page. That way, we know exactly which machine you’re interested in. Our embroidery machine experts will then get back to you as soon as possible to set up a more technical demo.

If you’re desperate for more details on single head or multi-head embroidery machines, including the HCU-1501, our Ebook will guide you through the process of determining which level of machine is right for your business – so have a look to the right of this page for more!

sportswear manufacturers

Sportswear Manufacturers – Your Embroidery Machine Guide

For sportswear manufacturers, choosing the right equipment is pivotal to the level of growth and success you experience. But how? Well, think about it, if you’re trying to operate efficiently and productively but your equipment can’t keep up with demand, there’s going to be a breakdown in your framework, isn’t there?

It’s vitally important that your equipment can keep up with the wider business – otherwise, you may end up driving business away and towards your competitors. Not only should it be able to cope with demand, but it should also be scalable and account for periods of exponential growth.

In this short blog, we look at the equipment and machinery you’ll need to achieve your objectives at each stage of that business lifecycle – whether that’s managing capacity, scaling your business, controlling costs or innovating with state of the art technology.

 

We’ll cover:

 

The Key Stages of Business Development

Throughout your time as sportswear manufacturers, there are three distinct stages of development your business will go through:

Startup – you’re a new or emerging manufacturer. Perhaps you only produce one product to a select number of customers. Your production line isn’t as complicated because you don’t run multiple ranges and your capacity isn’t full. Yet. Don’t worry, it will be.

Established – you’re an established sportswear manufacturing business – you’ve carved out a healthy chunk of the marketplace for yourself, but you’re not quite a market leader. You have a good selection of clients buying your garments – and you’re producing from a lot of different designs. Maybe you have that one client that is asking to increase capacity, and it’s starting to become an issue.

Enterprise – As a market leader and an enterprise business, you’re working with lots of large retailers and merchandisers, who all demand state of the art products, at constantly shortening lead times. Not only that – they want to be highly cost-effective and efficient with the money they spend. You’ve got to stay ahead of the curve on technology, training and machinery to remain top dogs and outpace your competition.

 

Startup Businesses

sportswear startup business

 

Objectives: Work within a small budget, start on a solid foundation, start creating a simple production line.

Machines: As startup sportswear manufacturers, you need to start on a solid foundation of modern, market-leading equipment that is future proof and of a higher standard than competitors. Having a production system built on machines that are easily transportable and simple to scale is also a must. Especially as a startup – saving you money in the long run. 

A great start to that could be the Happy HCH-701P – it’s a solid, future proof and affordable starting machine. A great first rung on the ladder. It’s designed specifically for beginners who are just learning the ropes of industrial embroidery, so any new and emerging sportswear business would be wise to invest in one of these.

Another fantastic option would be the Happy HCU Series – this one is a little bit more expensive than the HCH, but you’re investing in the newest machine on the single-head block. It’s a heavy-duty, high speed industrial single-head machine that utilises artificial intelligence to produce garments at a maximum speed of 1500 RPM – that’s industry-leading speed at an affordable price with state of the art tech included. 

 

 

Established Businesses

Objectives: Scaling capacity, becoming more efficient, managing more complex production lines.

Machines: Now you’ve grown and started to establish yourself in the sportswear market, you might decide to start diversifying your garment ranges or pushing for more customers, so being able to efficiently scale the business and grow revenue is both a key objective and big challenge. You’ll have to keep in control of costs, but also know when to invest for growth. The difficulty of getting this balance right is why so many businesses get to this stage and never advance any further. 

 

established sports business

 

The main variable for expanding into machines with more output potential is how many needle heads does your business require. A good option for an entry into multi-head machines is the Happy HCR3-1504E – a 4 head machine with a 10.4-inch colour LCD touch screen control panel, allowing your operators to interface with the machine live during a job. Not only that – if your range is increasing, the 1504E can hold up to 40,000,000 Stitches in its memory; and up to 250 design can be saved and controlled via Windows software. Seems like a great piece of equipment for growing, established sportswear manufacturers.

For the bigger businesses that want to push forward and scale quickly, the Happy HCR3-1508E is a state of the art example of pure production power. This machine has all the features of the 1504E, but it doubles the needle heads to 8, which in effect doubles its capacity and output potential. The multi-head machine simplifies your production line and streamlines your manufacturing ability, while remaining affordable but still miles ahead of the competition models, like inferior Tajima multi-head machines.

 

Enterprise Businesses

enterprise business in sportswear

 

Objectives: Lots of deadlines, complex processes, large capacity for designs.

Machines: You’re a market leader now, so your customers have unprecedented buyer power – as they will only work with manufacturers that can prove themselves and constantly push standards higher and higher. Your work for these customers is critical to the success of their own business – so you’ll be working on strict deadlines and high output levels, along with serious consequences if things go awry. 

With those types of pressures, there are only a few machines in the market that can step up to the plate and hold their own. The one we would recommend is the Happy HCR3-1512.  This beast is a high-speed, 12-head with built-in servo motors to really maximise efficiency in pressure situations. This machine is the top of the range for Happy Japan and easily outworks the competition, with state of the art features that no other brand in the market possesses – like Windows software and a machine memory of up to 40,000,000 Stitches. That’s a lot of garments. 

 

Sportswear Manufacturers – Want to Research More?

So, there you have it! Now that you’ve seen the importance of having the right equipment at each stage of your business development, it’s time to take the next step and put the wheels in motion. This is a big decision – so, it’s not one that you should take lightly.

Get it wrong at this stage and it may prove very costly in the long run – whether that’s having to invest in further machinery, losing customers or gaining an unwanted opinion. Don’t worry if you’re still not sure on the right choice for your business – we’ve got you covered.

We’ve created a free guide full of detailed specifications of several machines that are perfect for sportswear manufacturers such as you – no matter if you’re a startup, established business or enterprise business! Grab your copy today!

manufacturing systems

Manufacturing Systems: Building An Efficient Process

In the world of manufacturing, there are a variety of systems to choose from, each with its perfect use case and set of advantages and disadvantages. Having the ideal manufacturing systems for your product range can yield a large list of benefits, such as maintaining the high quality of your goods, being more efficient in your production processes and saving money across the board.

The right system can also help you produce higher volumes and maximise capacity, thereby meeting your production volume targets and getting the most out of your current equipment.

For a sports business, the manufacturing systems resource is material; more specifically, garment material for your products. The efficiency and productivity of your supply chains depend on having products available on time at a cost that works for both you, as the manufacturer and your customers.

With that in mind, your business needs to assess all of the options when it comes to operational systems. You’re looking for a process that meshes well with your production line but also suits your staff of operators.

 

We’ll cover:

 

Custom Manufacturing Systems

Custom manufacturing is by far the oldest and most popular type of manufacturing system in the sector. It also happens to be associated with both the highest-quality products and the lowest-volume efficiency – so it makes sense that businesses would use it, right?

In custom manufacturing systems, each item is produced by a single operator, who works solely by hand or with the aid of a machine. When machines are used during the process, they tend to be highly specialised to each task; so they can’t produce more than one item at a time.

 

custom manufacturing

 

One drawback of this system is it will usually have the highest unit cost for the product manufactured. As a result, products that are custom manufactured are of the highest quality but they also tend to be on the pricier end of the market. 

In addition, scaling out of custom manufacturing systems into larger production lines is difficult to accomplish without significant investment from the business in new equipment, as the machines used are only good at producing one thing in a certain time frame.

 

Intermittent Manufacturing Systems

Employing intermittent manufacturing systems allows companies to make different types of goods while using the same production line. Therefore, the manufacturing warehouse is designed to handle different product sizes and requirements. Generally, the goods are processed in large scales to fulfil wholesale orders and varying (intermittent) output capacity.

This system is commonly referred to as a “job shop” due to its popularity in countries with cost-effective labour, making products for more developed countries across the world. The goods made using this manufacturing method are produced in batches to vary depending on the output required from the production line. In turn, this speeds up production and makes operations easier.

 

intermittent manufacturing systems

 

Product customisation isn’t usually done in the manufacturing stage with the intermittent system – what tends to occur is the product is made and then shipped to design studios, who will then customise it to their needs. 

This type of system is designed for production runs that happen intermittently (hence the name) or products that don’t require a high amount of custom labour. It uses general-purpose machines and requires highly skilled operators to run smoothly. 

 

Continuous Manufacturing Systems

The continuous manufacturing system is designed to enable the mass production of a single, uncomplicated product. The product goes through an assembly line with different stations, where parts are added or worked on in increments. This method first arose during the Industrial Revolution and was innovated by the Ford Company, which employed the system to produce Model Ts in the 1920s.

This type of production system is ideal when a business has to produce large quantities of the same product. It scales very well and is cost-effective, as the materials generally stay the same throughout. It does, however, require a massive investment at startup due to the budget required for equipment and the amount of staff needed to operate such a big operation.

 

Flexible Manufacturing Systems

Flexible manufacturing is the most modern manufacturing system covered here – and it has become very popular in the manufacturing sector recently. It involves a significant investment in machinery, although it reduces labour costs by implementing artificial intelligence, making the need for human operators redundant. These machines can easily be reprogrammed to manufacture a variety of products in different quantities, and the whole process is automatic, so there are no overheads for the business to cover in the forms of staff wages. 

 

flexible manufacturing systems

 

Flexible manufacturing relies on what’s called ‘group technology’ in order to achieve the manufacturing goals of the business. Dedicated machinery is often employed in manufacturing when cost savings are important, although these machines lack the flexibility that a more expensive, manually operated tool might have. By using this system, manufacturing can be done in smaller batches with the simplicity and efficiency of mass production.

This method is called flexible manufacturing due to the flexibility it has with capacity and varying output, plus the vast range of goods it can produce. Of course, due to the entire system being automated, the only time people need to step in is at the quality control stage to ensure that everything has worked as it should and the product is of satisfactory quality. 

 

Which System is Right For Your Sportswear Business?

You’ve now got the business case for each manufacturing system – so which one works for your business? Consider what your products look like, how they’re made and the degree of variability there is in output. The answers to these questions will determine your system choice.

The process you go with will also influence your equipment and machinery requirements – for our guidance as to the industrial machine you need, check out our free guide! It includes everything you need to know about single-head and multi-head embroidery machines. Grab your copy today!