Production secrets: 7 steps to create a licensed merch

Every day 6 designers, 30 seamstresses, 20 decorators, 6 cutters, and dozens of other specialized specialists work on the production of merchandise, which is sold in the USA, Europe, and the CIS countries. We check the quality of EVERY copy we create in order to ensure that our clients get the same wow effect.

From the very beginning to the moment when the product falls in the hands of every fan, the toy goes through 7 difficult stages. You can find out how the whole process goes from the deputy production manager Valeria Vykhristyuk, who works in WP Merchandise! since its foundation.

Step 1. An application is sent to R&D that describes all the wishes for the future toy: size, type, whether embroidery or printing should be there, as well as the requirements of the customer-licensor and the estimated price. Every detail can make a toy either more expensive or cheaper.

Step 2. The artist develops sketches of the approved concept. If we are talking about a character in a game or comic book, we learn all the important details in advance in order to take them into account in the toy.

A sketch is the first thing that the licensor sees and approves. Therefore, the Head of R&D takes part in the creation of the sketch and confirms that all elements can be implemented in plush. After confirmation, the sketch is sent to the licensor, who can correct the color and details of the product.

Step 3. The finished sketch goes to the designers. Together with the chief designer, they develop a toy. It takes from 5 days to 3 months - depending on the complexity and detail. Something simple will take less time, for example, a plush ball is developed for 5 days. During this period, a layout and patterns are created, embroidery is drawn.

The head of R&D, relying on his many years of experience, understands how much time is needed for each toy to be made, therefore he calculates the terms of work in detail. Designers always have rational deadlines to safely design and model a toy.

We learned that the layout turns out to be close to what is needed for the 8th version. At this stage, the character is transferred to the technology department. The work is taken over by the Head of the Technical Department. Together with the technologist, designer, cutter, pattern designer, Chief Designer, and Head of the Development Department, they make edits without external changes and adapt the toy for the production of future batches. After that, the designers finalize the layout in a couple of iterations.

The finished model goes to the technical department for sewing 2 master models. One of them remains in the development department. The second goes to the copyright holder. The customer can immediately approve our version or can suggest changes. We modify the toy until the customer is completely satisfied. Sometimes, after the licensor's edits, the toy can go through all the stages again, some requests require significant changes.

Step 4. After the approval by all parties, the technical department evaluates the time of all operations to calculate the cost and prepares a technological map. It contains all processes, a list of all fabrics, accessories, fillers, packaging, etc. Layouts for laser machines and embroidery machines are also being prepared.

Thanks to the flow charts, you can quickly and easily define the required amount of material and time for the production of large batches. We also understand exactly when the toy will hit store shelves.

For each department, 8 master models are sewn in parallel. This is a reference for craftsmen so that all copies are made the same way. Two master models are given to sewing - in clothes and without. Also in the design department - one for cutting, the other for embroidery. Back to the quality control and packaging department. After that, an order for a specific quantity comes.

Step 5. The Сhief Production Technologist creates and controls the work schedule so that each next production stage starts and ends on time without overlaps and downtime. The production of each toy is scheduled literally in minutes for each department. Thanks to this, the chief technologist can supply up to 10 models at the same time, in batches of 1000 pieces.

The first ones in the cycle are the cutting and embroidery shops. The cutter prepares canvases of fabric for embroidery, on which faces, details of clothing, armor, and weapons will appear. While they are being embroidered, laser machines do their magic. After that, the details of the cutting are completed by knots. For example, a character's hat has 10 parts. They are sorted separately, as are the entire body, armor, weapons, or other accessories. For convenience, they are laid out separately.

All the parts in packages arrive at the sewing workshop. Seamstresses assemble toy components from cutting and embroidery parts. This is where the appearance of our products is already beginning to take shape. Then the registration department works. They put everything together, stuff the "skins" of toys with synthetic fluff, put on clothes, add external details like buckles and buttons, shape hairstyles, and put the finishing touches before packaging.

We check the quality after each department. The cutting, the fabric itself, and how the parts were cut. The accuracy of the embroidery. The integrity of the seams. The craftsmen check each toy after the decorators. After that, the quality control department carries out a stress test for each batch of products.

Step 6. Finished toys are transferred to the packaging department. There they are placed in boxes that were designed simultaneously with the sewing, they put the necessary materials in order to give the product an additional charm.

Step 7. Finished products go to customers.

We do everything we can to ensure that the toy remains in its best shape for as long as possible.

Sellers sometimes share some insights about customers with us. How the mood changes at the first meeting with a favorite character, how a person reacts at the moment of picking up a toy, how the customer examines it. This is the last and most important quality control - the emotional one. And if this one is passed, then all the rest were done properly and for the reason.