In just two months, YAYA's smart factory has sold 10 million pieces, making the rapid production of down jackets a new possibility

From October to November, over 10 million down jackets were sold on the Douyin platform alone. On Tmall's Double 12, it also topped the sales chart of down jackets, with a monthly sales volume of over 100,000 units for a single item. Through brand repositioning and digital optimization, YAYAYAYA has reduced the production cycle of a single down jacket from 7 days to 1 day, and increased the overall production efficiency of the factory by 30%.

In 1972, YAYA was founded and was once presented as a "state gift" to foreign heads of state, highlighting the brand's outstanding quality and extraordinary strength. In 2020, "YAYA" gradually transformed through multiple strategies such as category focus, channel focus, target audience focus, and price focus, and its brand sales continued to grow.

Meanwhile, at the beginning of 2023, the YAYA headquarters factory in Gongqingcheng, Jiangxi Province, in collaboration with SUNRISE, completed the upgrade and transformation of its intelligent down jacket factory, becoming a "digital and intelligent production fortress" that drives YAYA to conquer the market.

How can the cutting pieces and auxiliary materials required for the complex process be delivered to each workstation in one stop? Thus, reducing on-site transportation and efficiency costs is a core challenge for many garment manufacturing plants. However, in the YAYA smart factory, this issue has been perfectly resolved.

Unlike the regional production in the traditional clothing industry, the entire production line of YAYA's smart factory adopts a single-piece flow mode. Through the SUNRISE intelligent hanging system, it achieves efficient transportation across multiple regions, processes, and floors. The entire process is hung from piece to piece, covering the entire production process from cutting to finished down jackets.

The SUNRISE intelligent hanging system has solved the transportation problem of fabrics and auxiliary materials for YAYA, significantly improving the production efficiency of its own products and optimizing the production process. After the production workers handle the fabric and auxiliary materials before sewing, they are centrally hung from the first floor to the intelligent hanging and transportation line. There is no need for manual handling. They automatically pass through layers and go upstairs. According to the average SAM of different sewing processes and the labor efficiency of the day, they intelligently optimize the allocation of resources, implement decentralized processing, multi-warehouse storage for work-in-progress, and automatic hanging and sorting, which greatly improves the production efficiency. Reduce the labor intensity of operators and achieve rapid, precise and intelligent production.

With the help of IoT data collection devices, RFID chips, single-station operating systems and the entire factory's digital production and operation platform throughout the entire process line, the YAYA smart factory can automatically generate key data such as real-time output information and rework rate reports. In "Digital and Intelligent YAYA", the data from the sales end, production end and supply end are clear and accessible. Each piece of clothing can be traced throughout the entire production process, and the production quality is strictly controlled. Through digital means, not only is the quality rate of YAYA guaranteed, but also in the C-end sales environment of small orders and quick responses, the supply speed of products is increased and the return rate is reduced, ensuring that every consumer who receives YAYA down jackets gets satisfactory products.

To expand the utilization area of the factory building, further enhance the factory's production capacity, and meet YAYA's continuously rising production demands, a dual hanging storage area for semi-finished and finished products has been set up in the factory. The production rhythm is intelligently adjusted to achieve smart picking of ready-made goods. Color, size, and style sorting can be easily completed, effectively reducing labor costs while maximizing the inventory turnover rate. Further enhance the rapid response speed and delivery rate of YAYA production.

The factory director of YAYA Smart Factory once said in an interview with the media: "If a down jacket is made according to the traditional production process, it takes a week to complete. However, after introducing the intelligent hanging production line, the finished product can be produced in just one day." Overall, the intelligent hanging production line can help increase production efficiency by 30%. Previously, multiple employees were needed to manually receive, dispatch and deliver materials. Now, only one employee is required, who is responsible for placing the materials on the conveying equipment.

The YAYA smart factory has achieved full-chain unmanned material handling and automated operations, reducing operating costs and enhancing production efficiency, demonstrating a promising prospect of intelligent upgrading.

Empower manufacturing with technology and lead the future with intelligent manufacturing. SUNRISE will achieve win-win results and create the future together with its customers through innovative technological products and high-quality professional services!