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1 INESCOP Footwear Technological Institute Use of advanced tools for multilocalized design and manufacturing in the footwear industry Dr. Enrique Montiel.

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Presentation on theme: "1 INESCOP Footwear Technological Institute Use of advanced tools for multilocalized design and manufacturing in the footwear industry Dr. Enrique Montiel."— Presentation transcript:

1 1 INESCOP Footwear Technological Institute Use of advanced tools for multilocalized design and manufacturing in the footwear industry Dr. Enrique Montiel Industry of Design-Based Products: Creating Value through Customization

2 2 What is INESCOP? Independent service organisation. Founded in Non-profit making institution. More than 500 associated companies.

3 3 INESCOP works as a Technology Centre that supports footwear industries to develop scientific and technical activities that cannot be undertaken by themselves. INESCOP owns 20 patents on different systems, most of them transferred to the industry for exploitation. INESCOP has participated in over 90 EU projects since Technology Centre

4 4 Testing services, quality control. Technology development. Applied research. Industrial and fashion design. Environment. Training. Information. INESCOPs services

5 5 Close to the factories Network of laboratories: 6 technical units and 1 affiliated centre

6 6 The world footwear sector Value of the world footwear market: 1 All data obtained from World Footwear Yearbook Billion Euros 1

7 7 The world footwear sector In 2010 for the first time ever World footwear production exceeded: 20 Billion Pairs

8 8 The world footwear sector Manufacture is heavily concentrated in Asia: they produce 87% of all the pairs of shoes produced worldwide European Countries produce only 4% of world footwear pairs

9 9 The European footwear sector Europe : 20% of world shoe consumption destination of 45% of world imports Europe exports only 11% of world total footwear

10 10 The European footwear sector 9 European countries are in the top15 world footwear exporters Spain Italy Portugal 23% Share of all footwear exported in the world

11 11 The Spanish footwear sector The Valencian Region is the hub of the Spanish footwear industry, although it is also present in areas such as Castilla La Mancha and La Rioja.

12 12 The Spanish footwear sector In 2011, Spain exported to China footwear with an average value of Footwear average value Exported 40.2 Imported 5.9

13 13 The Spanish footwear sector The Spanish industry has been able to increase its exports to the most important European markets, but lost some share in USA.

14 14 The Spanish footwear sector Imports grew rapidly, both from China and from European markets such as Italy and France.

15 15 The Spanish footwear sector Footwear exports concentrate in leather shoes, while imports concentrate in cheap rubber & plastic ones.

16 16 The product problem Price Life-cycle 10 y. 0.5 y. 8012,000 Short life cycle + low price ( + extremely short series: customisation)

17 17 The time-to-market problem Typical design, manufacture and commercialisation cycle …but there are other cycles

18 18 The time-to-market problem One season/year design, manufacture and commercialisation cycle e.g. Kelme (sports footwear)

19 19 The time-to-market problem Continuous design, manufacture and commercialisation cycle e.g. Tempe (Zara)

20 20 The communication problem Headquarters Lasts Heels Soles Manufacturing Prototypes Design Prototypes Lasts Heels Soles Manufacturing Distribution

21 21 Possible solutions Flexibility Speed Accuracy Integration: Marketing support: new means at the design stage at the manufacturing stage seamless communication of teams

22 22 Proven experience

23 23 Case 1: Kelme Problem: to develop a high performance FUTSAL shoe, in collaboration with Michelin, reducing the development/manufacturing time.

24 24 Case 1: Kelme Solution: to integrate new biomechanical paradigms, All shoe images in this presentation are Virtual Models

25 25 Case 1: Kelme Solution: to integrate new biomechanical paradigms, new materials

26 26 Case 1: Kelme Solution: to integrate new biomechanical paradigms, new materials and new sole design in a digital model,

27 27 Case 1: Kelme Solution: to integrate new biomechanical paradigms, new materials and new sole design in a digital model, using an integrated knowledge- based CAD/CAM solution.

28 28 Case 2: Sacha London Problem: to add value to the point-of-sale, and to increase mass media impact of the brand.

29 29 Case 2: Sacha London Solution: to offer the chance to customise

30 30 Case 2: Sacha London Solution: to offer the chance to customise all the footwear collection,

31 31 Case 2: Sacha London Solution: to offer the chance to customise all the footwear collection, using a tablet

32 32 Case 2: Sacha London Solution: to offer the chance to customise all the footwear collection, using a tablet and an web-based online customisation system (iShoe),

33 33 Case 2: Sacha London Solution: to offer the chance to customise all the footwear collection, using a tablet and web-based online customisation system (iShoe), and offering the possibility to test the model in an Virtual Mirror (iMirror).

34 34 Case 3: Tempe (Inditex) Problem: complex and multifactorial operational environment, with multiple conditional factors. …some data: 2 April 2012 published data, INDITEX group INDITEX has 5,618 shops, opening at least 1 new shop/day. TEMPE designs, manufactures and distributes footwear for all INDITEX brands. 2

35 35 Case 3: Tempe (Inditex) Footwear accounts for 10% of INDITEXs total sales. Footwear is INDITEXs most profitable product.

36 36 Case 3: Tempe (Inditex) 60 million shoes/year ( 1 billion ).

37 37 Case 3: Tempe (Inditex) TEMPEs Design Center employs 110 designers, working on the two-season collections and the out-of-season designs.

38 38 Case 3: Tempe (Inditex) Footwear is worldwide manufactured in 200 factories.

39 39 Case 3: Tempe (Inditex) Footwear design and production has 2 main seasons, but they also maintain a continuous design/manufacturing cycle for the whole year (to cope with emerging trends & oversales).

40 40 Case 3: Tempe (Inditex) Every year 25,000 prototypes are designed and manufactured… …only 8,000 of them are selected for final production.

41 41 Case 3: Tempe (Inditex) Solution: To use INESCOPs integrated CAD/CAM solutions, starting from the shoe design phase.

42 42 Case 3: Tempe (Inditex) Solution: To use INESCOPs integrated CAD/CAM solutions, starting from the shoe design phase. To exchange information using compatible data files between design and production centres: components (lasts, heels, soles) and whole footwear.

43 43 Solution: To use INESCOPs integrated CAD/CAM solutions, starting from the shoe design phase. To exchange information using compatible data files between design and production centres: components (lasts, heels, soles) and whole footwear. To create hyper-realistic virtual prototypes. Case 3: Tempe (Inditex)

44

45 45 Case 4: CallagHan Problem: to add value to their shoes to differentiate them from their competitors.

46 46 Case 4: CallagHan Solution: to design and develop a casual shoe with an integrated electronic device that records physical activity Result from the FP6 EU Project No CEC-made-shoe. Custom, environment and comfort made shoe

47 47 Case 4: CallagHan Solution: to design and develop a casual shoe with an integrated electronic device that records physical activity and is connected to a web-based personal trainer.

48 48 Case 5: Duna Problem: to allow the integration of customised footwear manufacture in an industrial line of serial production.

49 49 New Products Lines New communication systems Specific solutions to integrate different technologies in the production processes All products must be developed according to the European laws for medical devices Small production lot till the single pair or shoe with specific technical solution against production industrial machines generally studied for simply workout and lots with high volume. The large range of technical info on the products to be transferred to end-users, customers and medical world require appropriate communication systems. DUNA is official partner of SSHOES - Special Shoes Movement European Project Grant agreement no.: NMP-2008-SME-2-R Special R&D Programs Case 5: Duna The technology innovation in DUNA

50 50 Case 5: Duna Solution: by means of the research project SSHOES 3 (Special Shoes Movement), to develop a completely digital process to manufacture a customised diabetic shoe: 3 NMP2-SE , Seventh Framework Programme. Biomechanical analysis (MiniLab). Foot scanning (3D scanner). Activity pattern analysis. Knowledge-based CAD/CAM design. Robotic cell production. Testing devices.

51 51 Future trends: Seamless integration of functional analysis/biomechanics, material science and comfort issues in CAD/CAM software. Low-cost robotic cells for short series production as well as massive introduction of robotics. Better simulation tools, both for product and processes: VR, AR. Better use of ICT tools: interoperability, embedding Knowledge in products.

52 52 You are invited…

53 53 INESCOP Footwear Technological Institute POLIGONO INDUSTRIAL CAMPO ALTO C/ Alemania, ELDA ·ALICANTE· SPAIN Tel Fax

54 54


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