Planning

1

Propose from the factory site’s point of view

We manage the site, but also, we are happy to visit you to have a meeting regardless of whether it is in or out of Japan. We have a series of meetings to understand the identity and atmosphere of a brand as well as to improve its quality. We have also experienced many direct transactions with overseas companies, and by flying around in Japan and abroad, seeing a number of cases and absorbing information, we foster an unbiased perspective. We propose fabrics from the abundant lineup which our partner textile trading company is proud of. Sometimes we get involved in the step of spinning process in pursuit of quality. In addition to denim, we are always ready to respond to all kinds of needs from cotton to heavy weight wool. We propose a better production plan, assuming cost control and mass production from the time of planning. We also utilize online for face-to-face close communicate to share information and ideas.

→ Machines and equipment

Pattern making

2

Control the finished look with fine adjustments

In our system of cooperation, we can solve unexpected errors which could not be noticed if the company responsible changes at each process and are produced at the last or next processing. For instance, "shrinkage" after washing, which is unique to denim. The shrinkage rate varies depending on material, which is a concern for many designers. We precisely predict the shrinking percentage and reflect it in the pattern. What makes this prediction possible is the sense cultivated through experience and the system that commits to the entire process and allows us to grasp the details. This experience is utilized for a wide range of materials besides denim. Especially for peculiar processing and new challenges, you can rely on our experience.

→ Machines and equipment

• ・Computer aided design(CAD)

  x2

Cutting

3

From machine cutting to hand cutting

We are capable of handling sample cutting, small lot manufacturing and pattern matching. We adapt according to each product with auto cutting making full use of CAD and CAM or traditional delicate hand cutting. By adjoining cutting and sewing spaces, we achieve closer cooperation so that we can correctly mark the sewing and pocket positions, avoiding misalignment and realizing higher quality.

→ Machines and equipment

• ・Rewinding machine

  x1

• ・Hand cutting machine

  x5

• ・Perforating machine

  x1

• ・Automatic fabric cutting machine(CAM)

  x1

• ・Band knife

  x3

Sewing

4

Techniques to respond to detailed specifications

Through projects with numerous brands including high-end brands, we have nurtured a broad range of techniques. We can handle detailed specifications for sewing and combining various materials from cotton to special fabrics and thick fabrics. Details such as thread tension and stitch width. In fact, we believe that those details greatly affect the impressions of each brand. The strength of our sewing is that the person responsible for each brand understands the nuance of the brand and is present at the sewing process, so we can consciously control the details. We are proud of the techniques of machinist who thoroughly grasp the strength and perform delicate sewing while achieving the finish as imagined. Also, our own sewing machine studio is set up in the company. We are sewing professionals and experts in the sewing machines who can even repair them inside and outside of the company.

→ Machines and equipment

• ・Stitch machine for denim

  x20

• ・Stitch machine for ultra balky yarn

  x7

• ・2-needle flat stitch machine

  x9

• ・3-needle safety stitch machine

  x6

• ・2-needle safety stitch machine

  x5

• ・Rolled seam machine(UNION SPECIAL)

  x2

• ・Rolled seam machine

  x10

• ・1-needle chain stitch machine(JUKI)

  x1

• ・Chain stitch machine for hem(UNION SPECIAL)

  x2

• ・Chain stitch machine for hem(SINGER)

  x1

• ・Chain stitch machine for waist belt(UNION SPECIAL)

  x1

• ・Chain stitch machine for waist belt

  x3

• ・42-needle bar tacking machine

  x1

• ・36-needle bar tacking machine

  x2

• ・Electronic bar tacking machine

  x3

• ・Button holing machine for jeans

  x4

• ・Button holing machine for shirt

  x4

• ・Button sewing machine

  x4

• ・Machine for belt loop

  x3

• ・Zigzag stitch machine

  x4

Special sewing machine

• ・1-needle overlock machine

  x1

• ・Babylock machine

  x2

• ・Tacking machine

  x1

• ・Binding stitch machine

  x2

• ・Stitch machine for leather patch

  x3

• ・Blind stitch machine

  x2

• ・Belt loop sewing machine

  x2

• ・Decoration stitch machine

  x3

• ・Sewing machine for elastic band

  x1

• ・Post-bed sewing machine

  x1

• ・Yarn winding machine

  x1

• ・Embroidery machine（BARUDAN）

  x2

• ・Needle detector（HASHIMA HN-610C）

  x1

• ・Fusing press machine

  x3

Washing / Processing

5

Pursuit of technique and expression by a long-established factory

Nissen Factory is a long-established factory which developed stone wash and chemical wash around 40 years ago. By washing and processing, various expressions are created on denim, expressing a realistic used feeling. They keep studying and improving their unique expression. It is one of a few washing factories which can flexibly handle coating processing and dyeing. In the factory development lab, jeans processing techniques is diverted to other items. They progress with development every day.

→ Machines and equipment

• ・Stone washing machine

  x3

• ・Barrel stone washing machine

  x2

• ・100kg washing machine

  x2

• ・50kg washing machine

  x4

• ・30kg washing machine

  x4

• ・Small washing machine for sample

  x6

• ・Dyeing test machine

  x3

• ・Shaving machine for jeans

  x6

• ・Machine for giving effects with chemicals

  x4

Printing

6

Print processing to bring out textures

A printing factory unique to Kojima that specializes in special processing of ready-to-wear. We receive requests from various high-end brands and pursue a wide variety of printing techniques from a realistic used feeling to expressions made by new materials or techniques. Including printing with indigo dye which was considered to be chemically difficult, we are capable of many kinds of special printing.

→ Machines and equipment

• ・Printing table

  x30

• ・Rotary printing machine table

  x2

• ・High-frequency printing machine

  x1

• ・Small ink-jet printer for fabric

  x1

• ・Exposure machine for screen

  x1

Finishing / Inspection /
Shipping

7

Giving unique expression to each brand

We manage the quality confirmation, inspection, and shipping of the finished product in the presence of our company. Even for the same material, iron work at finishing can largely change the impression and texture. Our role is to give a different look suitable for each brand even when handling similar products and to ship them. We have plenty of experiences and achievements not only with denim but also other materials such as wool and nylon. We can also handle finishing of various items including jacket products.

→ Machines and equipment

• ・Needle detector（HASHIMA HN-670C-100)

  x1

• ・Ironing board with vacuum

  x10

• ・Ironing board

  x5

• ・Garment finisher for pants

  x4

• ・Packaging machine

  x3

• ・Binding machine

  x1

• ・Spot removing machine

  x2