3. Case Study
This paper refers to a felt hats production line with a throughput time of about 50 days for every batch. Each batch is composed of about 10 hats. The production process is described in what follows. Fur is the raw material for the felt production, especially rabbit and hare fur. The first processing phase is “blowing”, in which hair is mixed and blown in a particular machine called, properly, a “blower”. Next, with the “basting and pre‐fulling” phase, the hair is compacted around a cone with a jet of hot water. This operation creates a bell‐shaped product, called a “cloche”, that is carefully checked for any defect. After the cloche
inspection, it undergoes “steeping” treatment, which gradually shrinks its size. The next phases are “drying” and “dying”, following which the bell is shrunk further until it reaches the desired size. The hood is then treated with certain natural substances (lac) in the “stiffening”
phase: the lac makes the cloche bright and resistant. Next, there is the first “blocking” step, which gives the right shape and size required by compression on specific aluminium moulds. The final form and size are completed after the second and last blocking step, occurred after the “pumicing” phase which sands the felt outside. The production process ends with the “finishing”
phase, which includes the application of final standard accessories (lining, leather bands, etc.) and those required by customers. The hat is then ready for further packaging activities.