Creativity, flexibility and quick response in marketing and manufacturing

During the last two decades this company has completely transformed itself. Originally a producer of upholstery fabrics for the lower to mid segments of the furniture industry, Valdese Weavers today is a leading supplier of decorative jacquard fabrics in mid- to highend speciality markets. During the 90's the transformation intensified, culminating in "Project 21st Century", now in the final phase of implementation. This project is described by Mr. Michael Shelton, president of Valdese Weavers, as "An Enterprise Resource Plan that will fulfill two main objectives: meet the challenges and seize the opportunities that lie ahead for our industry, and provide an operating platform that will propel our business for the next decade".

Valdese Weavers has been a member of the Shuford family group of companies since 1935. In 1996 the family organized three of its companies – Valdese Weavers Inc., Century Furniture Inc. (a furniture manufacturer) and Expressions Inc. (a furniture retailer) into one corporate structure, CV Industries Inc. Located in Valdese, North Carolina, Valdese Weavers operates totally independently within this corporate structure.

Since the mid 70's the manufacturing facility has been increased 11 times to a total of 500,000 ft2. This includes a second facility, commissioned in 1995 as a fabric finishing and distribution center. With a total of 580 employees, annual gross sales have reached $100 million and are projected to increase to $200 million by 2003. Manufacturing essentially includes yarn and beam dyeing, section warping, slashing, weaving and finishing. Since 1991 the company has invested $83.5 million in building construction, machinery and equipment, business and manufacturing control systems.

Fabric Collection of Messrs. Valdese Weavers The company is constantly developing new speciality markets, creating innovative products and expanding its customer base. A staff of 58 stylists and designers works in teams oriented with marketing personnel. CAD/CAM systems with pattern simulation capability significantly reduce the lead time from an idea to the final pattern and colorations. During 1998 the company produced 7,400 new designs, 90 % of which were custom made for individual customers, based on specific market needs. There are currently over 80,000 active patterns with by far the largest proportion being exclusive to specific customers.

Speciality markets currently being served include upholstery fabric jobbers. A wide variety of fabrics, styling and patterns are supplied to this market segment. The company is a leader in tapestry fabrics and engineered pillow/cushion designs and wall hangings. A strong presence has been developed in the contract upholstery and decorative fabric markets. In the mid 90's this dynamic organization developed a significant speciality market for top-of-the-bed products. The latest innovation – custom area rugs – provides the carpet industry with a totally new range of products which in no way emulates existing lines. Speciality markets demand innovative and aesthetically appealing fabrics, high quality and quick response.

The yarn inventory of 1.5 million lbs. consists of 2,500 filling yarns. Extensive use is made of fancy yarns including chenille, slub, bouclé, ratiné, etc. with new yarns and colors constantly being added to this vast assortment. The yarn inventory includes 200 different warp yarns, mostly 150 den textured polyester as well as Ne30/2 and Ne55/2 cotton yarns, all in a wide variety of constantly changing colors. In the weaveroom a pattern is changed on every weaving machine at least two times per day, with most weaving machines equipped with two warp beams.

DORNIER Rapier and air-jet waeving mashine installation at Messrs. Valdese Weavers The first DORNIER weaving machines – a group of double-width air-jet machines, type LWV8/J – were installed in 1995. The selection of the DORNIER air-jet weaving machine was based on flexibility, performance, reliability and userfriendliness. First and foremost these machines were for a new speciality market program, namely top-of-the-bed products. Valdese Weavers also planned to utilize these 8-color air jet weaving machines, each with 2x2370 hook electronic jacquard machines, to produce double-width upholstery fabrics.

The intention was to establish what existing and developing styling could be woven. To quote Mike Shelton, "DORNIER showed us the way with the air-jet, which we today feel will be capable of weaving an extensive range of our products". An initial small group of even wider 8-color air-jet machines has been subsequently installed for application in other market segments. Another group of narrower width air jet machines – 8-color with electronic jacquard machines – was commissioned in April this year. Application is focused on residential and contract upholstery fabrics, and also to support further air jet weaving development.

In 1996 Valdese Weavers installed a narrow DORNIER rapier weaving machine, type HTVS8/J to develop the custom area rug program. Right at the outset a decision was taken to develop this program based on one of the standard upholstery warp constructions to maximize manufacturing flexibility. Together, the weaving machine and jacquard machine with 10.240 hook capacity provided maximum patterning capability. And this not only for the custom area rug program, but also in the weaving of upholstery patterns requiring the same warp construction. True to its tradition and reputation, Valdese Weavers took its area rug program to the next level in 1997 when two double-width DORNIER rapier weaving machines, type HTV8/J, were installed. Each of these weaving machines utilizes two electronic jacquard machines, with a capacity of 2 x 10,240 hooks. This unique manufacturing platform, with single-end control of each end in the warp of almost 20,000 ends and the positive filling insertion system of the DORNIER rapier weaving machine provides flexibility and patterning capability without equal.

Since the mid 70's Valdese Weavers has been committed to an ongoing replacement of outdated business systems, design and all forms of manufacturing equipment throughout the entire company. The following are excerpts from a letter written by Mike Shelton to Valdese Weavers’ customers early this year:

"...Project 21st Century will result in the implementation of three basic elements:

· PDM: an enhanced product development system consisting of comprehensive market-directed
teams that will utilize new technology and streamlined processes...

· DASH: a shop floor manufacturing control system, custom developed, and beyond any textile
platform in existence today...

· SAP: a complete business systems solution that will enable us to communicate realtime
information throughout our business. We will also be able to interface with all customers and
vendors to whatever level required.

All of these systems will be fully integrated and will provide capabilities which, we feel, will be unmatched in our industry..."

This will not be the last word from Valdese Weavers!