Increasing Production Efficiency at Flexi de Mexico

Increasing Production Efficiency with START’s zcM2000-NS-E Tape Dispenser 

Flexi de Mexico, a leading shoe manufacturer in Mexico and a significant presence in the U.S. market, encountered substantial hurdles in their production process due to the manual dispensing of adhesive tape. This tape, essential for reinforcing stitched bonds in their shoes, was cut by hand—a labor-intensive task that caused significant delays, material waste, and inefficiencies. The manual process also created a bottleneck, requiring additional operators to assist in preparing tape pieces, which slowed down the entire production line.

 

The Challenge:

Their primary objectives were clear: streamline the tape dispensing process, minimize both time and material waste, and eliminate the production bottleneck. With sales on the rise, Flexi de Mexico sought a solution that would enhance efficiency and enable them to meet growing demand while maintaining their high-quality standards.

 The Solution:

The turning point came through Adhecintas, Flexi de Mexico’s trusted tape supplier and a key distributor for START International in the Guanajuato region. Adhecintas identified the productivity challenges and recommended the zcM2000-NS-E, a machine from START International tailored to Flexi de Mexico’s unique requirements. Its ability to dispense small pieces of high-adhesive textile tape in varying lengths and its compact design made it a perfect fit for their limited workspace.

The implementation began with Adhecintas providing a sample unit for a demonstration. Flexi de Mexico tested the machine in their factory for several weeks, during which Adhecintas collaborated with START International to train the operators, ensuring seamless integration into the production line. The trial proved successful, prompting Flexi de Mexico to order 125 units to equip all their factory operators. The rollout was smooth, with no significant difficulties, thanks to the comprehensive training and the machine’s user-friendly design.

Flexi’s workers applying specialized tape to reinforce the stitching bond.

Impact and Benefits:

Since adopting the zcM2000-NS-E machines, Flexi de Mexico has experienced transformative improvements:

• Time Savings: The time required to dispense adhesive tape has been drastically reduced.
• Waste Reduction: Material waste from manual cutting has been completely eliminated.
• Bottleneck Elimination: The production bottleneck has been resolved, boosting productivity across all five of their factories.

Although exact figures are unavailable, their success shines through with the deployment of 125 machines, significantly boosting production flow. The bottleneck that once hindered their ability to meet demand is now history, reinforcing their leadership in the shoe industry. The cutting mechanisms—referred to as “knives”—have proven exceptionally durable, requiring no replacements despite heavy daily use.

Overall, the machines have revolutionized Flexi de Mexico’s operations, enhancing production efficiency and enabling them to meet rising sales demands without delays. This has strengthened their bottom line and solidified their reputation as a top shoe manufacturer in Mexico and a key U.S. market player.

Customer Experience:

Flexi de Mexico describes their experience with START International and Adhecintas as excellent. The team’s responsiveness, support, and commitment shone through from the initial demo to the full deployment of the machines. Standout features of the zcM2000-NS-E include:

• Memory Feature: Allows programming of different tape lengths, streamlining the process.
• Double Sensor System: Effortlessly handles two rolls of even the stickiest tapes, meeting their specific needs.

Operators have also praised the machines, noting their user-friendliness and the significant reduction in physical effort compared to manual cutting, making their jobs easier and more efficient.

A testimonial from Flexi de Mexico captures the impact:

“The zcM2000-NS-E has revolutionized our production process, making it faster and more efficient than we ever thought possible.”

Operators have also praised the machines, noting their user-friendliness and the significant reduction in physical effort compared to manual cutting, making their jobs easier and more efficient.

 

Future & Final Thoughts

Looking ahead, Flexi de Mexico plans to make the zcM2000-NS-E a cornerstone of their production process, incorporating it into future expansions to support their growing business. They emphasize the outstanding partnership with Adhecintas and START International, whose collaboration and dedication were pivotal to this success. The  zcM2000-NS-E has exceeded expectations, positioning Flexi de Mexico for continued growth and operational excellence.