When Brad and I opened the store up to the world last June, we wanted to put out a new product. The Fodderstack was that product. It wasn't that much longer that we started toying with the idea of a Fodderstack to fit a 3.5"x5.5" notebook. We leaked a photo to see what people thought. It was followed with a physical threats and people throwing money at computer screens.
Now that we are closing in on offering this product, we wanted to share what it is like to work a new product into our product line. First it starts with an idea, then a sketch, a hand-cut prototype, digital pattern, and then we get hundreds of pieces cut. Recently, we posted pictures of us counting all of the items that we had cut.
The short sentence above takes months. I have covered this before on the blog that you can read here. After we do our full inventory and we are ready to start production, the battle begins. When putting out a new product we have to make room in our daily sewing for something new. That means time aside for training our employees, lots of QC checks along the way, and doing them in relatively small batches to make sure they are consistent.
With the Fodderstack XL, even though it is the "same" as our standard note card Fodderstack, it is a brand new case that is sewn differently than all others. Taking into consideration seam allowances and tolerances requires setting the machines up in a unique way.
After we have trained and set up the machine we sew the first step, at least 100 times.