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Business

SAE-A is committed to efficient,
innovative manufacturing techniques at all stages of the supply chain.

location

Overview

Overview

SAE-A’s manufacturing capabilities extend beyond just the production of garments. Over the years, we have worked to bring together research, design, manufacturing and retail. This allows us to provide our clients with a fully complete experience from concept to product. The production of a cotton T-shirt can be summarized in 10 processes:



Vertical Integration

Product Development & Design

From our establishment, we have worked to provide customers with the highest quality products and production services. In 2001, we added design and research and development capabilities helping us best understand and integrate the customer’s vision from concept to creation. Several of the components of these efforts include:

Fabric Research & Design (R&D)

  • Conduct research, analyze market trends based on customer's needs.
  • Establish fabric library capacity in New York, Los Angeles and Seoul offices.
  • Maintain and consistently update fabric library.
  • Presentation Tool Making Presentation Tool
  • Fabric Conducted Fabric Show and Seminars
  • Fabric Library Fabric Library

Design

Wash Innovation Testing

  • Conduct seasonal, graphic, wash and fabric trend research in US, Europe and Japan.
  • Develop garments based on global trends and customers’ concepts.
  • Customize services based on customers’ needs.

Wash Innovation

Wash Innovation Testing

  • Provide customers with full up-to-date washing trends and techniques.
  • Ensure garment washes meet clients’ expectations and needs.

Technical Design

Technical Design

  • Review sample pattern & fit for best quality garments.
  • Employ dedicated technical design specialists to meet the specification of customers.

International Branch Offices Conduct Trend Research

International Branch Offices Conduct Trend Research

  • Set up a fabric library & showrooms in New York and Los Angeles.
  • Customize trend and market research for our customers.
  • Deliver results to product development & design department at SAE-A's head office.

Manufacturing

The apparel manufacturing process covers order placement from customers to the shipment of the finished garments to our customers.

There are three main components of the manufacturing process:

  • Pre-Production : sampling, sourcing of raw materials, approval of details, pre-production meetings.
  • Production: production processes from receiving all materials including fabric, and producing garments through cut & sew process.
  • Post production : finishing processes, quality checks, packing, shipment inspection etc.

Generally speaking, in order to complete the manufacturing process, there are several 3rd party suppliers and manufacturers involved. However, to increase efficiency and ensuring the highest quality, Sae-A has established complete vertical integration by bringing the entire process under one umbrella. To do this, we have applied a Lean Management system.

Realizing Vertical Integration

Seeking to reduce costs, improve quality and streamline our supply chain, SAE-A has worked to realize full vertical integration. For example, the addition of our Spinning Mill in Costa Rica will supplement fabric production, reducing overall production lead time.

Vertical Integration

What is "Lean Management"?

Lean Management makes it possible to reduce, or even eliminate, waste at each phase in the production process.

SAE-A strives to produce the highest quality product as efficiently as possible. Lean Management is the process through which we focus on value and safety to achieve our goals. The company has established its own tenets of Lean Management that promote best practices, process, eliminate waste, and ultimately standardize best practices. As with the majority of our initiatives, training is critical to the implementation of these practices and we provide courses and training to all employees across the company.

We also encourage all of our facilities to provide suggestions for improving work-flow, efficiency, work experience, and quality of the end product. We have already seen suggestions from our facilities been adopted as best practices.

Quality Assurance

SAE-A’s quality assurance protocols ensure SAE-A facilities to maintain the highest product standards, and customer satisfaction. SAE-A carries out proactive quality assurance activities across the company.

The Five Key Elements of Quality Assurance

5 key tasks
5 key tasks
Automation System
Tooling System
Standardized Testing
Supplier Management
Employee Education
Leveraging Technology
Ensure employees know how to utilize the latest technology to maintain the highest levels of quality.
Common Production Systems
Train employees on standardized tools that help improve efficiency and consistency.
Uniform Quality Inspections
Leverage technology and employee knowledge to ensure every product meets our high standards.
Partnering with Suppliers
Work with each supplier to comply with quality assurance certification systems.
Continuous Internal Improvements
SAE-A continually works to review, refine and improve our quality assurance processes.

Performance Material

Warm

AdvancedHeat Technology

Aeroheat

  • Absorbs the thermal energy from the body and re-emits
  • Light and very soft handle
  • Wicking and breathable

Heat Technology

Carbono

  • Special fabric coated with carbon nano tubes absorbs the solar energy and re-radiate it into far infrared rays to keep warm
Breeze warm

  • The layers of air by special yarn keep the body warm
  • Lighter than conventional materials

Cool

AdvancedCooling Technology

Springer

  • Inorganic particles in the yarn prevent UV rays from penetration
  • Facilitates the release of heat to keep the body cool & dry
  • Sweat activated cooling technology gives much more comfort

Cooling Technology

Ice-ever

  • Flat yarn increases the surface area of contact with bare skin, which helps to release body heat out of the clothes
  • Special minerals in the yarn keep body cool and prevent transmission of UV-rays
  • Non-see through for light colors
  • Wicking and quick dry
Xylicool

  • Feels fresh, cool to the touch
  • Durable after repeated washes

Stretch

AdvancedStretch Material

Omni-Span

  • Soft and natural touch
  • Lightness
  • Stretch & better recovery
  • Better wet fastness and chlorine resistance

Seamless

Seamless knit
for Active wear

We can supply a wide range of seamless wears for all activities.

  • We can supply a wide range of seamless wears for all activities
  • Body mapping for Moisture management
  • 3D-knit technique by computerized knitting machine