1 inescop footwear technological institute use of advanced tools for multilocalized design and...
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INESCOPFootwear Technological Institute
Use of advanced tools for multilocalized designand manufacturing in the footwear industry
Dr. Enrique Montiel
Industry of Design-Based Products: Creating Value through Customization
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What is INESCOP?
Independent service organisation.Founded in 1971. Non-profit making institution.More than 500 associated companies.
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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 1986.
Technology Centre
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Testing services, quality control.Technology development.Applied research.Industrial and fashion design.Environment.Training.Information.
INESCOP’s services
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Close to the factories
Network of laboratories: 6 technical units and 1 affiliated centre
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The world footwear sector
Value of the world footwear market:
1All data obtained from World Footwear Yearbook 2011
246 Billion Euros1
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The world footwear sector
In 2010 for the first time ever World footwear production exceeded: 20 Billion Pairs
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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
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The European footwear sector
Europe: 20% of world shoe consumption
destination of 45% of world imports
Europe exports only 11% of world total footwear
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The European footwear sector
9 European countries
are in the top15 world footwear exporters
Spain
Italy
Portugal
23%Share of allfootwearexported in the world
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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.
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The Spanish footwear sector
In 2011, Spain exported to China footwear with an
average value of 46.43€
Footwear average value
Exported
40.2€
Imported
5.9€
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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.
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The Spanish footwear sector
Imports grew rapidly, both from China and from European markets
such as Italy and France.
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The Spanish footwear sector
Footwear exports concentrate in leather shoes, while imports concentrate in cheap
rubber & plastic ones.
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The product problem
Price
Life-cycle
10 y.
0.5 y.
80€ 12,000€
Short life cycle + low price( + extremely short series: customisation)
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The time-to-market problem
Typical design, manufacture and commercialisation cycle
…but there are other cycles
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The time-to-market problem
One season/year design, manufacture and commercialisation cycle
e.g. Kelme (sports footwear)
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The time-to-market problem
Continuous design, manufacture and commercialisation cycle
e.g. Tempe (Zara)
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The communication problem
Headquarters
Lasts
Heels
Soles
Manufacturing
Prototypes
DesignPrototypes
LastsHeelsSoles
ManufacturingDistribution
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Possible solutions
Flexibility
Speed
Accuracy
Integration:
Marketing support: new means
at the design stageat the manufacturing stage
seamless communication of teams
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Proven experience
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Case 1: Kelme
Problem: to develop a high performance FUTSAL shoe, in collaboration with Michelin, reducing the development/manufacturing time.
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Case 1: Kelme
Solution: to integrate new biomechanical paradigms,
All shoe images in this presentation are Virtual Models
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Case 1: Kelme
Solution: to integrate new biomechanical paradigms, new materials
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Case 1: Kelme
Solution: to integrate new biomechanical paradigms, new materials and new sole design in a digital model,
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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.
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Case 2: Sacha London
Problem: to add value to the point-of-sale, and to increase mass media impact of the brand.
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Case 2: Sacha London
Solution: to offer the chance to customise
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Case 2: Sacha London
Solution: to offer the chance to customise all the footwear collection,
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Case 2: Sacha London
Solution: to offer the chance to customise all the footwear collection, using a tablet
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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),
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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).
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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.
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Case 3: Tempe (Inditex)
Footwear accounts for 10% of INDITEX’s total sales.
Footwear is INDITEX’s most profitable product.
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Case 3: Tempe (Inditex)
60 million shoes/year (1 billion €).
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Case 3: Tempe (Inditex)
TEMPE’s Design Center employs 110 designers, working on the two-season collections and the out-of-season designs.
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Case 3: Tempe (Inditex)
Footwear is worldwide manufactured in 200 factories.
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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).
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Case 3: Tempe (Inditex)
Every year 25,000 prototypes are designed and manufactured…
…only 8,000 of them are selected for final production.
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Case 3: Tempe (Inditex)
Solution: To use INESCOP’s integrated CAD/CAM solutions, starting from the shoe design phase.
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Case 3: Tempe (Inditex)
Solution: To use INESCOP’s 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.
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Solution: To use INESCOP’s 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)
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Case 4: CallagHan
Problem: to add value to their shoes to differentiate them from their competitors.
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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. 507378“CEC-made-shoe. Custom, environment and comfort made shoe”
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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.
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Case 5: Duna
Problem: to allow the integration of customised footwear manufacture in an industrial line of serial production.
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New Products LinesNew Products Lines
New communication systemsNew communication systems
Specific solutions to integrate different technologies in the production processes
Specific solutions to integrate different technologies in the production processes
All products must be developed according to the European laws for medical devicesAll 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.
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.
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.229261DUNA is official partner of “SSHOES - Special Shoes Movement” European Project Grant agreement no.: NMP-2008-SME-2-R.229261Special R&D ProgramsSpecial R&D Programs
Case 5: Duna
The technology innovation in DUNA
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Case 5: Duna
Solution: by means of the research project SSHOES3 (Special Shoes Movement), to develop a completely digital process to manufacture a customised diabetic shoe:
3 NMP2-SE-2009-229261, Seventh Framework Programme.
Biomechanical analysis (MiniLab).
Foot scanning (3D scanner).
Activity pattern analysis.
Knowledge-based CAD/CAM design.
Robotic cell production.
Testing devices.
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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.
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You are invited…
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INESCOPFootwear Technological Institute
POLIGONO INDUSTRIAL CAMPO ALTO C/ Alemania, 102
03600 ELDA ·ALICANTE· SPAINTel. +34 965 39 52 13 - Fax +34 965 38 10 45
E-mail: [email protected]://www.inescop.es
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