Production and quality
management system


Production system of TOYO ORIMONO

Instead of owning factories, we engage in the development and
manufacturing of textiles through fabless production overseas.
Regarding our main product of woven fabric, by not only concentrating
on weaving process but also paying attention to production techniques and quality control of dyeing,
yarn texturizing, we are able to develop and mass produce highly functional and high quality textiles.

Yarn Yarn texturizing Weaving Dyeing Sawing Selling Development of textiles Production and quality control system Development of differentiated products and securing stable supply Yarn Yarn texturizing Weaving Dyeing Sawing Selling Development of textiles Production and quality control system Development of differentiated products and securing stable supply

Our production bases

Our production bases are located mainly in Vietnam, but also in Japan, China, and Indonesia.
We use different equipment and material backgrounds in each country according to customer demand.
In our main center of production, Vietnam, Japanese engineers and management staff are stationed long-term at each facility.
We ensure stable supply of our products through quality control, production management, and product development.

Japan Japan

(flat, dobby, jacquard)
Dyeing at domestic dyeing plants, various functional treatments

China China

Yarn Texturizing
Twister machine, false-twisting texturizer, Air texturizer
(flat, cam, dobby)
Jet dyeing machine, printer (Transfer, Digital)
Sewing of ready-made curtains

Indonesia Indonesia

Cotton-spinning, Twister machine, False- twist texturizing machine
(flat, cam, dobby)
Jet dyeing machine, Printer (flat screen, rotary)

Vietnam Vietnam


[Local management system]
5 Japanese technicians (yarn, weaving, dyeing) stationed,
30 Japanese-speaking Vietnamese staff.
POY polymerization
Yarn processing
Twister machine, False-twisting texturizer, Air texturizer machine
WJL, AJL (flat, cam, dobby)
Loop knitting, Warp knitting
Polyester dyeing equipment (Jet dyeing machine, heat-setter, etc.),Calendaring machine, Coating machine (dry type), Sanding machine, Transfer printer, Flammability testing machine
Sewing of ready-made curtains


About our production system in Vietnam

In Vietnam, our Japanese technicians and local Vietnamese staff work together to oversee production and quality control.
Prototyping and mass production process at our Vietnam base:

  • 1Strict quality control by Japanese technicians in yarn, weaving and dyeing
  • 2Smooth communication with contractor factories by Vietnamese staff who can speak Japanese
  • 3Quick response through online meetings between Japan and Vietnam These factors help us achieving speedy delivery while satisfying Japanese strict standards
We are able to provide rapid and accurate prototyping and development in Vietnam,
which is difficult to do only in a local factory in Vietnam.
Quality and delivery management, and visualization of production status
in accordance with Japanese standards.


Introduction of Japanese engineers
and Vietnamese employees

In charge of yarn texturizing and weaving

Seiichi Hiramatsu

Joined the company in 2007

I am in charge of quality control of weaving and yarn texturizing at the contract factory in Dong Nai Province, Vietnam.
I have been stationed at the current factory since 2007, and it has been 15 years since then. From the time of my arrival to the present, Vietnam has achieved rapid economic development. I feel that our 30 Vietnamese staff members are growing day by day, just like the Vietnamese economy. They are diligent and good with their hands. Making full use of the fact that we present on-site with them, we can conduct thorough quality control with an emphasis on the three ""real"": real place, real things, real time.

Working in quality control in Vietnam, I have come to realize that "common sense in Japan may not be common sense elsewhere in the world". There are people overseas who think that what is common practice in quality control in Japan is sometimes excessive, or even insane.
In my opinion, the key to quality control overseas is how to get the local leaders and workers of the factories to understand and implement this excessiveness. For this reason, I try to communicate with them not only at work but also in more informal times, such as over meals, so that they can understand how we (Japanese) think and work.

In charge of dyeing and functional treatment

Toyomasa Nishida

Joined the company in 2013

I have been stationed at a local dyeing factory in Vietnam since 2013, and I am working hard together with the local staff to improve the quality every day.
Mainly by investigating the causes of manufacturing rework and losses and coming up with countermeasures, we are trying to reduce the defective rate that occurs in dyeing, reduce losses, and meet delivery deadlines. In order to bring the quality level of the products produced at the outsourced factories up to the Japanese level, cooperation from the factories is essential. To this end, we disclose as much information as possible, and in meetings with the factories, we always take their opinions into consideration (and show them that we do), so that we could gain their trust and confidence.
For secondary manufacturing at contract factories, we send special dyeing chemicals from Japan or order them from Japanese manufacturers in Vietnam for trial production, development, and mass production. Since many of the chemicals ordered are expensive, we also manage the actual products.

In charge of overseas sales


Joined the company in 2013
Japanese level equivalent to JLPT examination N2

There are many dyeing factories in Vietnam, but in order for TOYO ORIMONO to compete against them, we must not only develop more and more value-added products, but also manage the quality and delivery time in accordance with Japanese standards; and do so at a higher level than our local competitors.
For example, it is important to cooperate with the sewing factories to which the products are shipped. If a problem occurs after the fabric has been shipped, we will try to understand the current status of the problem and deal with it as soon as possible by receiving the actual product from the sewing factory or, in some cases, visiting the sewing factory.
We also work together with shipping companies to manage shipments so that we do not have to stop the sewing line due to late delivery.
I believe that the accumulation of each of these efforts will lead to customers' trust in Toyo's products.

In terms of human resource management, since production in Vietnam accounts for 60% of our total output, there are many tasks that need to be done locally. Most of the Vietnamese staff at Toyo Textile are technical trainees who have returned from Japan, so they are well accustomed to the Japanese work culture. In order to produce results as a team, we are conscious of enhancing teamwork, assigning roles to improve the level of staff, providing guidance on the work, and communicating our own experiences.
In 2019, we established a local subsidiary in Vietnam to sell curtains and clothing fabrics to local Vietnamese customers.
There are differences in the way products are used in Vietnam and Japan, and we are facing some difficulties, but we are expanding our sales with the help of local partners. In the future, we would like to expand this business to countries other than Vietnam.

In charge of Dyeing


Joined the company in 2013
Japanese level equivalent to JLPT examination N2

I started working at TOYO ORIMONO in 2013, and have been for nine years now.
I am in charge of product quality control and overall quality control at the dyeing factory in Dong Nai Province, Vietnam.
Since there are differences in how people work and think between Japan and Vietnam, I have realized that it is difficult to manage products in Vietnam according to Japanese quality standards.
As a Vietnamese, I have to make sure that fellow leaders and workers at the factories I am in charge of understand and implement Japanese standards for quality control and delivery management.
In order to improve quality, I have to study technical knowledge, quality improvement methods, and management techniques.
I believe it is important to study and improve my abilities in order to improve quality.

In charge of weaving


Joined the company in 2014
Japanese level equivalent to JLPT examination N2

Since I joined the company in 2014, I have been in charge of greige fabrics production and quality control at a weaving factory in Ho Chi Minh City, while learning about textiles and yarns from Japanese engineers.
My role in production management includes placing orders to the partner factories based on orders from Japan, organizing yarns needed for production from third parties, and shipping them to the dyeing factories. To avoid delays in delivery, we communicate the delivery date requests from Japan to the consignment factories and make arrangements for production. The production status is also communicated to Japan every day.

If the price of yarn or greige fabric is not acceptable, we negotiate with the consignment factory so that the price of yarn and raw materials can be adjusted to meet the order.
As for quality control, when a problem occurs, I go to the site to see the actual product, check the current situation, and work with the person in charge at the partner factory to make improvements in order to reduce the amount of losses. The partner factory originally specializes in cotton, but most of Toyo's fabrics use polyester filament yarn. At first, it was difficult to produce with filament at the consignment factory, but after guidance from Toyo and others on how to do it, we were able to achieve success.