Customer Case Study

Strict QC Mesh Supply for Japan Client

In 2020, we connected online with a mattress manufacturer from Japan. From the first discussion, it was clear this would not be a typical project—the client had very strict and specific requirements on fabric length, defect control, and even rolling quality, all of which needed to be consistently maintained.

Strict QC Mesh Supply for Japan Client

Mefiss Solution

Our Solution

Step 1

Understanding the Standards


The requirements were unusually detailed. Each roll had to be strictly between 50–55 meters, with no joining allowed. Defects were limited to no more than 2 per roll, with a total defect length under 1 meter. Even slight wrinkles caused by poor rolling were not acceptable.


Step 2

Building a Dedicated SOP


To meet these expectations, we didn’t rely on standard processes. A dedicated SOP was set up for this project, covering weight control at the greige stage, fixed-length rolling at the dyeing mill, and clear inspection standards for every production step to avoid variation.


Step 3

Full Inspection & Smart Utilization


After dyeing, every roll was checked one by one. Fabrics that didn’t meet the exact criteria—such as rolls shorter than 50 meters—were strictly removed from shipment. Instead of wasting them, these rolls were internally used by Mefiss Hometex for finished product production, ensuring efficient material utilization.


Step 4

Stable Delivery Control


By combining process control and strict inspection, we were able to maintain consistent quality without increasing cost pressure on the client. Over time, this stability became more important than anything else, especially for large-scale mattress production.


Outcome

Results

The project achieved stable 100% standard-compliant delivery. Over more than 6 years of cooperation, we have shipped around 30 containers, building strong trust and becoming a long-term, reliable partner.

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