Tabio Network System
The Factory Gets Closer to the Shop
We have established a network system that brings the factory closer to the shops so that we can immediately provide our customers with a full selection of products to meet their needs. This epoch making system, which brings “the factory closer to the shops,” is the Tabio Networking System.
Like any other fashion item, trends in socks change quickly. People used to expect a lag of a month or two from planning to delivery. But that meant that even well-planned, well-designed products were likely to be out of fashion by the time they reached the shop shelves, so shops could not satisfy the needs of their customers. Furthermore, shops had to order in lots of ten assorted-color pairs, and store managers were left to figure out what to do with those odd colors of otherwise popular products that didn’t move.
The question, therefore, was how to provide the customers with the products they really wanted without burdening the shops with unneeded inventory. The ideal solution would be for the planning stage to be able to forecast the exact quantity that would sell. Unfortunately, though, that would be tougher than predicting the weather. Through a long process of trial and error, we have succeeded in devising a system that gives us a full grasp of every item sold in the stores so that we can immediately replenish the socks they need, down to a single pair.
Essentially, this requires a combination of detailed product tracking and accurate timing. To overcome these hurdles, we have developed our own network system that shares the sales information at every store with our dye factories, knitting factories (knitters), distribution centers, shops, and dan, thus linking all stages of dan's operations. This open system allows us to forecast the specific production quantities and raw materials required for every product, and make deliveries to the stores within a day or two. Even when a product is out of stock at our distribution centers, we can supply it to the stores within a week.
The Computer-Less System
Many hurdles had to be overcome to develop the Tabio Network System. Initially, we introduced a "Unit Control" system, wherein we asked store clerks to call in their store inventories after hours. This data was compiled at headquarters, where the reported inventory was deducted from delivery quantities to calculate each store’s sales volume. This gave us an accurate grasp of sales, but placed an excessive burden on the store clerks.
We decided to try something new, called the "Card System." Every pair of socks contained a card, and when a pair was sold, the card was pulled at the register. These were sent in batches to our headquarters, where the sales were calculated. The card system allowed us to reduce the workload on our store clerks and still have an accurate grasp of sales volume. Nevertheless, as the number of stores quickly grew to 1,374, so did the workload at headquarters, and our salespeople ended up being too busy to go out and collect payments. To solve these problems, we introduced a computer system.
The Samurai System
We took a risk on a new computer system at time when computers were generally beyond the budgets of most companies like ours. It is important to introduce a system that is suited to the company’s needs and its organization; otherwise it won’t work. The “Samurai” warriors of our associate companies are the ones who make this system work. They are the ones who strive day and night to satisfy our customers’ needs by synchronizing with the storefront. The present Tabio Network system is based on trust between the associate members of the group that has formed over many years. We have invested a great deal of time and resources to build a system that today allows us to improve our delivery time, reduce inventories, improve management at all levels, and sharply reduce risk for our associates.
