You're now using third-generation machines?

Yes, the first models were completed three months after we contacted Nikon. However, they weren't really what we had expected... (here she laughs) The machines employed a suction mechanism. We were concerned that we might have asked them for the impossible. They were experts, but in different fields. Nevertheless, we could see that they were very enthusiastic. They had no real images to go on because they hadn't seen our actual production process. However, I explained as best I could. And, surprisingly, they surpassed our expectations and completed the machines. We were so surprised, and at the same time full of admiration.

The second-generation machines were simplified versions, and these eventually led to the current third-generation machines. Problems we had to overcome were machine settings and adjustments. It was quite difficult to make fine adjustments in the strength of grip springs, belt loop positions, tension, etc. Another problem we had to solve was yarn waste tangling up in the sewing machine. This was really troublesome. We had to somehow overcome these problems. We have tried to modify the machine mechanisms so that cleaning inside is easier. Of course, we use safety measures as well. At present, Toraichi now uses a total of nine belt loop inversion machines. For different material, we slightly adjust the settings. In particular, the 7th and 9th models in the third-generation series feature specifications for heavy cloth, which is actually impossible to do by hand.

By sewing together both sides of a piece of cloth to make it tubular, we can hide the outlet seam inside by turning it inside out. There are six or eight belt loops for each pair of trousers.

What were your impressions when you first saw the machine in operation in the factory?

I was really full of appreciation. I knew that we were no match for a machine. From my long experience, manpower has its limitations. You see how my own hands are in such bad shape. Machines must replace manpower if we are to survive in the market.

It's only because we clearly believed that machines were indispensable. When you want to develop an effective special-purpose machine you should go to an expert or a specialized company. The belt loop inversion machine is a good example.

To be honest, we've invested quite a lot of money in this. But, from a long-term management point of view, we believe we can recoup the investment. The answer is in using the machine. If it's poorly designed, it'll malfunction frequently. This only leads to poor results. I am quite willing to share the results of this machine with other people in the industry, and introduce it to other companies.

Has the machine improved efficiency?

If one machine works for one hour, for example, the volume of production will probably be equal to manual operations. However, the machine never tires and works all day long without resting. At first, I thought that one person could handle two machines at the most. However, one person can actually operate four or five machines at one time because it's very easy. Therefore, production volume increases as the number of machines does. If we introduce five machines, the production volume expands five times per one person. Even if an inexperienced person handles only two machines, the production volume doubles. As a result, the more machines we introduce, the more production costs fall. Although this might seem to be nothing special, it's really great for us!