Salomon built a new shoe factory in France. Now it must also build a footwear supply chain in a country without one.
For decades, Western companies have made everything from clothes to toys in Asia, Eastern Europe or Latin America, taking advantage of cheaper labor and highly developed supply chains. But the business case for that practice has eroded in recent years amid repeated shocks to the global economy, prompting many companies into a rethink. Air Blowing Slipper Injection Moudling Machine
After 15 years of manufacturing entirely in Asia, French sportswear firm Salomon SAS, eager to cut emissions and reduce bottlenecks, decided it was time to start making its signature sports shoes at home.
The first phase was to build an automated sneaker factory in Ardoix, France, near the Alps. It also redesigned its shoes, drastically shrinking its supply chain by slashing the number of components in each sneaker by nearly two-thirds.
Salomon’s Advanced Shoe Factory opened last year and is initially making two types of trail-running and hiking shoes due to hit stores later this year after several delays.
The France-made shoes will be as profitable as those made in Asia, said Guillaume Meyzenq, vice president for footwear at the company, thanks to savings from lower transportation costs and the elimination of customs duties.
At full tilt, the plant is slated to make one million pairs a year; Salomon will take half of that capacity, and two other French footwear brands, Babolat and Millet, which are also partners in the factory, will take the rest.
The plant requires 15 human workers a shift; a typical shoe factory in Asia would require five times as many to match its output.
One machine uses heat and pressure to stick the sneaker’s upper parts together. Others spray glue onto soles which are then bonded with the rest of the shoe, or use lasers to cut sections of sneaker from colorful plastic sheets.
Salomon’s redesigned shoe has 26 parts, down from over 70 in its other models.
Mr. Meyzenq said getting the shoe plant up and running will be key to convincing European suppliers to work with them. Developing a local chain for all these components will likely take years, Mr. Meyzenq said.
Sports Shoes Making Machine If the French project is successful, Salomon wants to build a similar automated plant in the U.S. to meet demand there. The aim is for the new plants to meet around a quarter of local demand in the U.S. and Europe, Mr. Meyzenq said.