YDS Boots

YDS began in 1927 when Mr Yakupoglu began trading leather in a town called Isparta in Turkey.  Trading in leather and raw components began to increase and a move to an industrial business centre, Ankara in 1971 led to the development of a footwear business YDS.  Having supplied the domestic Turkish Military and security forces with quality made boots, YDS continued to progress into a product design and development capability from 1990.

Dual Density Rubber Injected Soling Systems

DDR - Dual Density Rubber Injected Soling System - Diagram  DDR - Dual Density Rubber Injected Soling Systems

Durable and Reliable Footwear

Selling Points
YDS is the leading producer of Dual Density Rubber (DDR) injected soles in the world.  This is a special formula of rubber compound which is injected in two densities to the uppers; a tough rubber outer skin and a lower density midsole where air is injected into the rubber to create a lightweight shock absorbing cushioned bed for the foot.  This technology is important for those working and existing in harsh conditions where a highly durable but comfortable solution is required, so is an enormous advantage in military footwear.

YDS has a license to produce GORE-TEX® footwear.  This is not only a product and performance benefit but an assurance of product quality as the stipulated lab testing of footwear by WL GORE as part of the agreement is so highly rigorous.

Both of these selling points combined make YDS products unique in this market.

YDS Military Boots

Dual Density Rubber (DDR) Military Tan Boots YDS Brown Boot Military Tan Boots

Dual Density Rubber Injected Soling Systems

Selling Points
YDS is the leading producer of Dual Density Rubber (DDR) injected soles in the world.  This is a special formula of rubber compound which is injected in two densities to the uppers; a tough rubber outer skin and a lower density midsole where air is injected into the rubber to create a lightweight shock absorbing cushioned bed for the foot.  This technology is important for those working and existing in harsh conditions where a highly durable but comfortable solution is required, so is an enormous advantage in military footwear.

Best Performing Military Boots

Goliath Military Footwear and YDS Boots Goliath Military Footwear and YDS Boots Goliath Military Footwear and YDS Boots

Since then YDS has become the biggest boot supplier of the Turkish Armed Forces and General Directorate of Security and have gained a solid reputation for maintaining quality standards.

Today the success of YDS, financially at £51 million turnover per annum, spans beyond the borders of Turkey and leaves footprints all over the world.

YDS Rugged Military Footwear Rugged YDS Military Footwear Rugged YDS Military Boots

Company Information

1.  Introduction  Yakupoglu (hereafter referred to as YDS) is a Turkish ‘Top 500’ company’ which has invested over $20 million in the last 4 years in industrial capability.  It has five components; Footwear and Outerwear manufacturing components both under the ‘YDS’ brand name, a  construction component, a retail component for selling direct to trade or public and a wholly-owned UK subsidiary; Goliath Footwear Ltd. This broad base provides strength and financial stability.  YDS also has its own in-house Design Facility with state-of-the-art CAD/CAM tools and its own SATRA-accredited ISO 17025 Test Laboratory, TEKNOTEKS.  YDS manufactures and supplies Footwear and Technical Textiles products to military, emergency services and industrial customers in the UK, Europe, the Middle East and Asia.  The company specialises in all types of footwear (Goodyear Welted, Injection Moulded), gloves, uniforms, sleeping systems, load carriage equipment, outerwear and tentage.  The ISO EN 9001:2008 certified company has 60,000 sq ms of manufacturing capability on a 90,000 sq ms site together with 15,000 sq ms of warehousing.

2.  Production Capacity  YDS is vertically-integrated in that it buys in raw materials and then undertakes and controls all production in-house to the finished goods.  Raw/Base materials, such as rubber, polyurethane, Cordura@ and other fabrics are brought in to be manufactured by the company into finished goods.  Piece parts such as zips, laces and buttons will be purchased from YDS’ approved supplier list. YDS’ manufacturing division makes Footwear and Outerwear (including accessories such as rucksacks and bags) for the military, emergency services and industrial markets (principally safety wear).  The workforce of 926 is multi-skilled and is able to undertake the production of footwear, gloving, clothing and accessories, such as bags and rucksacks.   The Outerwear production capacity is 2,500 rucksacks per day or 3,500 ammunition vests per day.  Other daily production rates are 1000 Gore-Tex Garments, or 3000 uniforms, or 500 ballistic vests, or 1,500 gloves, or 1000 goggles, or 2000 belts/holsters, or 200 insulated tents, or 1,500 sleeping bags.  In terms of footwear, YDS now has the capability to manufacture over 4 million pairs of footwear per year and sub-contractor support can increase these production rates if required.  Therefore YDS has the capacity in-house to easily satisfy the volumes required by customers, both military, emergency services or commercial. In terms of resources for Outerwear, the factory has:

a.  Staff.  8  Designers, 14 Engineers (Textile, Chemical, Mechanical), 4 Textile Cutters, 449 staff with stitching skills.  These can be supplemented by a further 300 skilled stitching staff employed in the YDS sub-contractor supply chain.

b.  Design.  A Lectra Textile Design CAD System.

c.  Cutting.  A Lectra Automatic Cutting System and 145 Cutting Presses.

d.  Stitching.  1300 Stitching Machines of varying types including 600 PFAFF Stitching Machines and 23 fully computerised ORISOL stitching machines, 110 Heavy Duty stitching Machines, 41 Glove Stitching Machines.

e.  Taped Seam.  35 Tape Seam Sealing Machines and 3 Lamination Machines.

For Footwear, YDS has, in addition to the resources detailed above, the following plant and machinery:

a.  Nine DESMA moulding robots with over 240 stations offering 5 types of sole moulding process.  

b.  24 Schonn Lasting Machines and 40 machines for Goodyear Welted production.

c.  2 Stations for the production of rubber.

3.  Production Volumes  During the period 2006-2009, YDS delivered, as an example, 22,275 sleeping bags, 125,686 Rucksacks and 170,050 Ammunition Vests.  It had the resources and the planning tools that enabled all these orders to be delivered on time and to specification.  At the same time, YDS was manufacturing about 1 million pairs of safety footwear for the commercial market for distribution globally and had delivered over 4 million pairs of military footwear.  Because YDS has a multi-skilled workforce adept in working in either leather or textiles, spare capacity within its two factories and with approved sub-contractors, it can rapidly increase production or switch from one type to another to meet unforeseen circumstances. Because YDS has to adhere to a very strict delivery and quality regime imposed by one of its principal customers, the Turkish MoD, it has thorough experience in creating a system that ensures delivery in volume and to requirement.

4.  Production Planning  YDS has a policy of establishing long term relationships with key suppliers of materials to ensure regular supplies. The YDS MIS enables it to create a production plan for each contract and to monitor progress and quality.  Barcodes on each product in manufacture enables production progress to be monitored in detail and reported to the Planning and Sales Departments to ensure orders are being processed correctly and to time.  YDS, as a matter of policy, always undertakes a supply chain risk assessment to ensure that it will have the requisite component stocks in place to ensure continuity of production.  The Approved Supplier List ensures, in the event of a problem, that there is a readily identifiable alternative supplier of component parts.   For components and piece parts, YDS requires all its suppliers to demonstrate resilience in their supply chains.  Regular meetings are held with suppliers during the duration of a contract to ensure that there is early warning of any likely supply problems.

5.  Management Information System  YDS  also has a sophisticated Management Information System (MIS) which uses a SQL sequel database, which is held on a Main Server with a Back Up Server in a different location to minimise loss in an event of a catastrophic event.  The MIS is capable of producing individual reports in whatever configuration is required. The YDS MIS can interface with other systems provided that they use the Sequel Language (SQL).  YDS is unique amongst manufacturers in that each item on the production line carries a Bar Code which is scanned on completion of each manufacturing stage.  This enables a constant record of production rates for each style in each batch and quality levels or faults arising.  This enables Quality staff to quickly pinpoint if there is an issue and to rectify it, enables Production staff to have real time information on production flows and considerably reduces reject rates which currently run at an average of 0.5%.

6.  Fluctuating and Surge Demands  Because YDS has a multi-skilled workforce adept in working in either leather or textiles, constantly active production lines manufacturing a range of products and spare capacity within its two factories it can rapidly increase production or switch from one type to another to meet urgent requirements or sudden surges in demand.  Typical response time for rescheduling production would be 24 hours.  YDS’ Approved Supplier List includes a number of stitching sub-contractors and so, if the factory is at full capacity, it can quickly sub-contract elements of production to these local suppliers.  Because it is company policy to create long term relationships with key materials suppliers, it is able to call on these as a priority customer.

7.  Stock  As part of YDS Risk Management, the company’s strategy is to hold up to 4 months stock of all strategic raw materials.  Analysis is undertaken of the difficulty in sourcing items and stock levels adjusted to compensate for this.  The policy default is to always ensure that there are sufficient components and raw materials to support one month’s worth of production.  Because YDS maintains a pool of Approved Suppliers for all components and materials, there are always alternative sources available.

8.  Quality Assurance - PROVEN QUALITY  YDS’ Quality Assurance (QA) system and Quality Management System (QMS) is based on ISO 9001:2008 and these QA requirements are also applied to all sub-contractors and suppliers. The CEO ensures commitment to quality as he believes that quality defines the company and its products. The QMS covers all actions to be taken from the receipt of raw materials, through the manufacturing process, final inspections and batch and random testing.  It also includes details of how interrelated activities are managed (such as the parallel management of components before final assembly, or adjustments to machinery) on a systems basis.  YDS QA is based on checks at each stage of production to ensure that no faulty item passes to the next stage. Suppliers will also receive, as part of the Supplier Approvals process, the YDS Quality Manual which lays down what is expected in terms of QA within the supply chain together with a formal inspection by the YDS Quality Manager and his staff.

9.  Innovation and Collaboration - TECHNICALLY INNOVATIVE  As a vertically-integrated manufacturer, with its own Design Department and its own ISO 17025 accredited laboratory/test facility, YDS is able to undertake continuous product development and innovation with the flexibility to react rapidly to customer requirements or changes in the market place. Internally, the Design Department will work with the strategic suppliers to develop products they have brought forward or will institute new products as a result of ideas generated within the company or as a result of market surveys. Because YDS has long term relationships with materials suppliers, there is a flow of product innovation from these such as Gore for membrane and insulation materials, Invista for technical textiles and YKK for fasteners.

10.  Design Facilities  The Design Department is equipped with the latest CAD/CAM tools including state of the art LECTRA ROMANSCAD 2D and 3D Design linked to a CAD/CAM ZUND Cutting Machine, ADOBE ILLUSTRATOR and INDESIGN, COREL DRAW X4 and PHOTOSHOP CS3. The Design Department has a team of 5 designers (including Graphics Design), a Stylist and 2 Footwear Technicians supported by production staff.  TEKNOTEKS can undertake tests on raw materials, semi-finished products and finished products, and has the ability to undertake nearly 90% of all British Standard and ISO tests for leather and textile products.

Achievements
ACHIEVED SO FAR AND BULDING FOR THE FUTURE

  • By providing consistently high quality standards, YDS has become the largest manufacturer of Police and Military Footwear in Europe.
  • We are one of 4 firms shortlisted among 47 firms all over the world in the biggest military boot purchase tender of the world in terms of turnover.  This is the UK MOD and covers a 4 year agreement.  The tender shall be concluded through a long evaluation process and is expected to be finalised at the end of 2011.
  • YDS is the first and only firm in the sector that has been accepted to ‘Brand/Turquality Support Program’ in order to be a world brand.
  • YDS is the leading exporter of police and military footwear by exporting to over 35 countries and primarily to the UK.
  • YDS were the first firm to provide injection sole military boots to Turkish soldiers who had up to that point worn solid sealed soles.
  • YDS are the first and only firm that has all International EN ISO 20345-47, ISO 9001 and OHSAS 18001 standards to manufacture work safety shoes.
  • YDS is the only firm that has a laboratory having ISO 17025 standard accredited by SATRA & TURKAK in the sector.
  • YDS are the first and only firm that is included in Fortune 500 and ISO 500 lists from Turkey in its sector.

YDS GORE-TEX® Footwear

YDS has a license to produce GORE-TEX® footwear.  This is not only a product and performance benefit but an assurance of product quality as the stipulated lab testing of footwear by WL GORE as part of the agreement is so highly rigorous.

Both of these selling points combined make YDS products unique in this market.

Step Forward with YDS

Objective
As YDS takes firm steps to becoming a world brand by exporting to more than 25 countries.  YDS aims to be the most preferred technical boot brand in the world.

Values
Continuous Improvement – YDS is committed to reinvesting profits into research and development to ensure YDS continues to be a forward thinking.

Customer Orientated:  Whilst producing footwear on a massive scale, YDS, are different from other manufacturers.  Since the environmental conditions in each marketplace we serve are different, we adjust and shape our products according to those needs and provide full after sales support to ensure complete satisfaction.

Credibility:  In addition to a fully automated barcoding system, YDS continually test and retest the entire product range regularly in the SATRA accredited laboratory.  YDS is keen to ensure that the wearer of YDS boots is confident and assured of the quality standard.

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