Key Points
- Flamingo Co., Ltd., a specialized beret factory in Uki City, Kumamoto, faces significant production hurdles following earthquake damage to its facility and equipment.
- Critical infrastructure, including the groundwater pump used for dyeing and industrial boilers, was severely damaged, halting the company’s integrated production line.
- Despite damage to their own homes, employees have been instrumental in the recovery effort, manually moving heavy machinery and performing basic repairs.
- The company is shifting focus toward its private brand to offset the loss of OEM orders and is appealing to customers for continued support during the rebuilding process.
Full Transcript (English)
Host: It is incredibly hot today. Thank you for your hard work.
Guest (Teruaki Yoshida): Not at all, thank you for coming. I’m Yoshida from Flamingo Co., Ltd.
Host: We are here in Matsubase-machi, Uki City. (To Kaori Yoshida) Thank you for having us today.
Guest (Kaori Yoshida): Thank you for coming all this way to visit us.
Teruaki: This time, we were truly supported by our employees. They stood up and helped move these heavy machines when the professional contractors couldn’t make it. They worked together to minimize the damage.
Kaori: Even though their own homes are partially destroyed, they come to the factory in the morning to help us. Their support is everything.
Host: It must be difficult to replace or repair everything quickly.
Teruaki: Yes. About 10% to 20% of our machinery requires professional repair. We’ve managed to get some running through our own adjustments, but the ones that need specialists are still waiting.
Host: Since you handle the entire process from start to finish, that 20% of broken machinery must significantly impact the production line.
Kaori: Exactly. Our factory’s strength is that we do our own dyeing. But the pump that draws our groundwater—our lifeline—broke completely. When we heard that in Osaka, we thought it was over for our dyeing process. The boiler also tilted and broke. We felt like we couldn’t produce the hats we wanted to deliver.
Teruaki: But the factory manager and the person in charge of the facility worked tirelessly. When the water finally started flowing again, everyone cheered. We aren’t using it for full production yet, but having water for daily life and to share with neighbors was a huge first step.
Host: What is your biggest concern regarding full operations?
Teruaki: Canceled orders. Because we manufacture goods, missing deadlines is a major issue. Even if clients understand we are disaster victims, they have their own schedules to keep. Losing that business is our biggest fear right now.
Host: What is the ratio between your private brand and OEM (Original Equipment Manufacturing) work?
Teruaki: OEM is overwhelmingly larger, about 80%. The remaining 20% is our private brand, “Flamingo,” and student caps.
Host: Is there anything the general public can do to support your recovery?
Teruaki: If people could buy our existing stock or our private brand products, that would be the most helpful thing right now. We are working hard to meet our deadlines despite the cancellations.
Host: Tell us about the appeal of your berets.
Teruaki: It’s the shape. Berets originally came from overseas, and they don’t always fit the head shapes of people in the East. We’ve spent years perfecting a shape that is fuller and more flattering for us. We use 100% wool for winter, and for summer, we use materials like Japanese paper (washi) blends that are breathable and hold their shape even after washing.
Host: You are one of the few specialized beret factories left in Japan.
Teruaki: Yes, we are quite rare. A beret doesn’t have a brim, so it shows the face clearly. I believe berets are hats that deliver smiles. They make people look bright and cheerful.
Kaori: Once we get the boiler fixed, we can deliver more products. We’ve received so many kind words from everyone, and we want to return that kindness by getting back to full production and bringing smiles to our customers again.
