Luggage firm sends Chinese packing – Engineering Capacity

Patrona Luggage had experienced a major quality issue with its Chinese factory partner in 2012, and subsequently could not get its tools out of the factory. The company approached the Manufacturing Advisory Service (MAS) for support and advice for repatriating the manufacture of the Shirt Shuttle to the UK and at the same time, improving the design, manufacturing quality, as well as lead times and availability.

With the help of a MAS design grant, Patrona validated much of its design before commencing tooling. By working in partnership with BEC Group in Hampshire, the MAS grant monies were used to prove the tooling design concept, reducing the risk of the project.

The result of the project was a significantly improved product in function and design. The move to using expanded polypropylene for the base of the case and folding board have resulted in a 32% weight saving which is key for those running or cycling to work. 16 parts and four manufacturing processes have been cut to just two processes and three parts, resulting in a 40% reduction in cost. This cost saving has been passed onto the customers by reducing the products RRP to £29.99, despite being made in Britain.

Not only did Patrona reduce its pre-production duration by a third, it also reduced the lead time from 12 weeks in China to ten days in the UK. Additionally, the minimum order quantity (MOQ) was reduced from 2,000 units in China to 500 units in the UK. This quick lead time and low MOQ has enabled the business to hold less stock and improve cash-flow, with standard orders produced “Just in Time”.

With the Shirt Shuttle back in stock after 12 months out of production, Patrona is set to dramatically increase its turnover to £450k in the next year, from £175k previously and expects to produce 10,000 units.

Andrew Brundan, managing director and founder of Patron Luggage says: “We had some real issues with communication and quality in the Far East. We have demonstrated that aside from the quality and speed of production, there can also be a significant cost advantage to manufacturing on your doorstep – if you can apply the right design approach.

“The support available from MAS is a real encouragement for companies to take the first step in re-shoring and will help UK manufacturers to have more confidence to compete in the global market. Anyone thinking of heading to the Far East by default should give MAS a call first.”