Since its inception in 1992, Unionwear has been committed to preserving the art of American craftsmanship by manufacturing high-quality and durable baseball caps and sewn bags. Known for its unwavering dedication to authenticity and reliability, Unionwear is the trusted choice for businesses, athletes, and the promotional products industry. In today’s competitive global landscape, Unionwear stands out by leveraging innovative processes and advanced technology to create premium products while embracing the unique value of products made in the USA.   Needle’s Eye has written a great piece on Unionwear, summarized here:

The Journey of Unionwear:

Unionwear faced challenges when the fashion industry moved production offshore. Initially, the company focused on producing caps and hats for popular fashion brands like Polo Ralph Lauren, Izod, Gant, Barneys, and several skateboard and hip-hop lines. As the fashion industry shifted production towards countries with lower labor costs, Unionwear adapted by targeting B2B clients who value the “Made in USA” label and offering custom products with a competitive edge.

Automation and Lean Processes:

Unionwear recognized the need to evolve in order to survive in the challenging and competitive market. The company invested in automation, advanced technology, and lean manufacturing to streamline production processes while maintaining high-quality standards. Automation has allowed Unionwear to reduce overhead costs, enabling the company to manufacture locally at competitive prices.

For example, Unionwear now utilizes Pathfinder’s M5-180 multi-ply cutting system in its production processes. This has resulted in a 30% increase in fabric utilization compared to traditional die-cutting methods. With only two people manning the Pathfinder system, Unionwear now produces 3,000 hats and 2,000 bags per day, whereas seven people were needed for the same output previously.

Embracing Lean Manufacturing:

Lean manufacturing is another key component of Unionwear’s strategy for success. Amid significant global competition, the company has adopted lean manufacturing principles to eliminate waste, reduce lead times, and ensure maximum efficiency. This approach focuses on creating value for clients by streamlining processes, reducing inefficiencies, and optimizing resources. This has enabled Unionwear to expand its product offerings, respond quickly to market demands, and ensure consistent, high-quality products.

Continuous Improvement and Growth:

Unionwear’s commitment to continuous improvement has led to the company’s growth and expansion over the years. In 2017, Unionwear successfully restructured its operations, raising funds to add new product lines, expand web offerings, and automate labor-intensive processes. The company has also ventured into new niches like medical packaging, travel gear, safety products, and workwear to cater to emerging market demands.

The Future of Unionwear:

With a strong foundation in automation and lean manufacturing principles, Unionwear is taking confident strides towards a promising future. As the era of cheap imports comes to an end, the company is well-positioned to continue its upward trajectory and further establish itself as a leader in American manufacturing.

The success of Unionwear is a testament to the power of innovation, dedication, and the unwavering commitment to domestic manufacturing. By investing in advanced technology, streamlining processes, and prioritizing customer satisfaction, Unionwear has managed to survive and thrive in an ever-evolving market.

Conclusion:

Unionwear is a shining example of how American businesses can revolutionize their operations and remain competitive in the global market through automation and lean processes. The company’s unwavering commitment to quality, innovation, and American craftsmanship has set them apart from others and ensured lasting success. As a customer of Unionwear, you can trust that you’re supporting a truly American brand that values its communities, workers, and the future of the American dream. Together, we can continue to uplift and support domestic manufacturing and promoting genuine, high-quality products made in the USA.