Making Ikea stuffed animals and bringing joy to people

 We went to the Danu Vina factory in Ho Chi Minh City, which makes plush toys for IKEA. As a result, we participated in the Soft Toys for Education campaign and the effort to improve the quality of life for children. We were able to observe the entirety of the manufacturing process for stuffed toys, from the development of a 3D model of the eventual Ikea stuffed animal to its packaging.

The first thing that happened during the tour was a meeting with the business manager of the factory, as well as representatives from the IKEA Vietnam Trading Office and Save the Children. Ally, the manufacturing facility manager, gave a presentation on her business. For many years, this factory has been creating plush toys for IKEA, and right now, approximately sixty percent of the production facility is taken up by IKEA toys.

The plant has a workforce of 1,600 individuals, approximately 80 percent of them are women. We were taken aback by how much consideration the firm's management gives to environmental responsibility issues and providing their employees with favorable working circumstances. For instance, they offer their employees more paid time off than the law mandates, pay them approximately 40 percent more than the standard rate, and feed all their employees for free.

The manufacture of a plush toy begins with developing a three-dimensional design based on a sketch that IKEA supplies. After that, the research and development division creates a sample, puts it through its paces regarding safety testing, and conducts a production risk analysis. IKEA factory employees and designers work closely together to identify the most effective method of producing a toy that is of high quality, at an affordable price, and free from danger. Every outcome is recorded and utilized throughout the production process.

After these particulars have been settled, the plant will begin production by placing an order for the necessary fabric and other supplies. Cutting is the first step in the process. The manufacturing facility is outfitted with various cutters, including a laser cutter, which enables workers to cut intricate details with pinpoint accuracy.

Following the step of cutting, the next step is embroidery. Only embroidery is utilized for the noses and eyes of the toys sold by IKEA. This applies to all of their products. It is much less dangerous for children, who might rip the plastic into pieces and then consume them.

After that, the cuttings are sent to the sewing shop. The plant is home to 750 different types of sewing machines. They are set up in 24 separate lines, with each line creating a different kind of toy.

After being stitched, the toy shell is flipped, so the right side faces out and then is delivered to the filling business. The toys have already been sewn but do not yet have any filling; thus, they have an amusing appearance. Each hour, the coworkers put the shells of the toys through a series of tests to determine whether or not they are durable enough to withstand being pulled apart. The coworkers monitor the quantity of filling used to ensure that the toy is the appropriate weight and contains the relevant functions.

The toys are completed once they have been given their stuffing. The holes left open for the stuffing are stitched shut by the coworkers, and the toys are made to look attractive so that the children who will eventually play with them will like them immediately. When the process of completing the toys is complete, they are then wrapped up and delivered to the stores. The time required to manufacture a single plush toy ranges from one to two hours, depending on the level of detail required.

To begin production of a new plush toy, the factory needs approximately six months' worth of time. The factory places a high priority on ensuring that its goods are both safe and of the highest possible quality. On each sewing line, there is a quality control professional who works. Additionally, the plant conducts unannounced quality inspections on the finished goods. They exercise extreme caution when handling every needle during the sewing process to reduce the risk of injury. Before a coworker may receive a new needle, the broken ones must be recorded in a unique book. If the needle is misplaced, the other employees use a metal detector on all of the toys manufactured during this time to ensure that the needle is not concealed within any of the items.

Additionally, each toy is inspected with metal detectors three times: once after the sewing process, once after the stuffing process, and once before the packaging process. The firm maintains good working relationships with the companies supplying fabric and other products. They have stringent requirements for quality control and conduct tests on the material at least once yearly.

The factory is grateful to IKEA for the opportunity to work together. Because of our long-term cooperation with the factory, they can use their capacity more. For instance, they can make a seasonal variety for IKEA many months in advance during their low period, and they produce special toys for a UNICEF campaign in March. Both of these productions take place during their respective low periods.