The Canada Goose parka manufacturing process involves a complex, multi-stage production system where each jacket requires approximately 240 pieces, 680 minutes of work, and over 30 employees. The process begins with fabric cutting using automated machines with vacuum tables to hold layers of fabric, followed by down filling machines that inject specific amounts of white or gray down based on jacket specifications. Workers then distribute the down evenly using tools like badminton rackets and quilt the panels to maintain warmth distribution. The assembly occurs on dedicated sewing lines where workers perform sequential operations, with more experienced operators handling complex tasks at the end of the line. Final quality control involves inspecting jackets from both inside and outside, with any defects repaired before packaging. The entire process demonstrates how modern manufacturing combines automation with skilled labor to produce high-quality, complex products.
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How They Make Canada Goose Parkas | Explore CanadaAdded:
I'm cold.
Hey everyone. So, uh there's Mike Victor Uniform in the background. If you watched the last video, I flew from Oshawa to Sioux Lookout. Um I'm filming with Canada Goose uh in a couple of days.
So, I'm trying to get to Winnipeg.
And then this weather came in. Low cloud, there was freezing rain and snow.
So, I'm not going anywhere today. But, I walked uh about a half hour walk from town up to the airport cuz I wanted to get a warmer coat.
Um and that warmer coat just happens to be the Canada Goose jacket that I keep in Mike Victor Uniform um in the emergency pack at all times, just in case you get stranded somewhere and you're cold.
I'm cold. So, I'm going to get that jacket out and put it on. Not sponsored.
Couldn't plan this if I wanted to. Uh let's go get that Canada Goose jacket on.
This is so much better. It's uh it's a really lightweight jacket. It packs in that little pack, which is amazing.
But, once you shake it out and it gets all fluffy, it's good down to about minus 15. Um currently, it's like minus eight here.
So, uh this jacket's going to be perfect for the walk back into town and for my trips tonight to uh to get some food and other things. I'm also going to grab some mitts and a toque cuz I really need a toque. And we will reconvene here tomorrow um around noon when the weather should be a little bit warmer, a little bit clearer, and we'll get off on the rest of our leg to Winnipeg.
Mike Victor Uniform backtracking 34 from Alpha, Sioux Lookout.
Mike Victor Uniform, roger.
Sioux Lookout, Mike Victor Uniform rolling on 34.
Mike Victor Uniform Roger >> Airspeed's alive. Everything's in the green.
A little bit of gusty wind.
>> Mike Victor Uniform, you can check your flight plan is open.
Confirm your passing altitude.
>> Mike Victor Uniform passing 2,100. Thank you.
>> Roger, and what's your plan altitude?
>> 2,500 for now.
>> Roger.
Mike Victor Uniform, switch to local radio.
>> Traffic, taxiing for departure runway 30 westbound Canmore flight.
Uh I have filed an initially climbing up to actually the flight plan altitude 6,000.
>> Keep my eyes out for the traffic. I will be overhead Dryden in 3 and 1/2 minutes.
Foxtrot Mike Victor Uniform.
>> [music] >> Steinback North, this is Foxtrot Mike Victor Uniform, Cessna 172 currently 10 mi east of the field inbound for landing. Planning on joining the mid right downwind runway 33, full stop.
Steinback North wheels over the field in 6 minutes.
>> Zulu Kilo Charlie 1-mi final, Steinback North traffic at the state Foxtrot saying if you need us to overshoot, we will.
>> Hey Andre.
>> Good morning Glenn. How are you?
>> very well, very well. And yourself?
>> Great, great. Thank you so much.
>> Thank you for having me at Canada Goose.
>> You're very welcome.
>> Um we were supposed to do this a couple days ago.
I got stuck in Sioux Lookout at in a snowstorm and I keep a Canada Goose jacket, one of the little packable ones, in my plane and I pulled that out. I was so happy to have it because it was so cold and windy and snowy and freezing rain.
I want to know how these jackets are made.
Um can you show that to me?
>> Of course. You're in the better place.
Welcome to our factory.
>> So we're here in Winnipeg.
>> That's correct.
>> Uh how big is the plant?
>> It's around 2,500 sq ft.
>> And how many employees are there?
>> We have right now 520.
>> That's That's a lot of jackets.
>> Right.
>> Okay, let's go.
>> Okay.
>> Where are we now? Is this >> Glenn, John, right now we are in our cutting room.
>> Okay.
>> And John is going to walk us through the processes from >> nice to meet you.
>> Nice to meet you, Glenn.
>> So I assume this is the first step then.
>> That is correct.
>> Okay.
>> So please come in and see where the first process started.
>> So this is the start of the process. I see printers.
I see lots of computer screens. What is happening?
>> That is right. So basically this place is where everything is being planned.
>> Okay.
>> Where the markers are being printed.
Which the other people considered the blueprint.
>> So this is the cut list for the jackets.
That's the blueprint of how to cut the jacket down.
>> That is correct.
>> Okay.
And so I guess Mr. Taylor is someone who likes puzzles >> That's right.
>> and and tries to figure out how to fit all of the pieces.
>> That is true.
>> Okay.
>> To optimize the fabric usage.
>> Okay.
And then they then they print out the the patterns.
>> That's right.
And all these markers are being delivered to the cutting room.
>> To the cutting room.
Okay, let's go to the cutting room.
>> All righty.
>> Okay, John, what's happening here? I imagine this is all the paper that was just printed by Mr. Taylor in the other office.
>> correct.
>> So it comes out here and what happens now?
>> So now everything that they provide to us >> Yep.
>> is being separated.
>> Okay.
>> And each paper, as you see here, each roll is a different fabric.
>> Okay.
>> And as she [snorts] separates them this is what it looks like.
>> So this represents an order.
>> That is correct.
>> Okay. And what are the color codings?
>> So color codes means fabric.
>> Different fabric.
>> Different fabric. So when you see blue, that's the outside of the fabric.
>> So how many different fabrics are in an in an average jacket?
>> Oof.
I would say eight to nine different fabrics.
>> nine different fabrics.
>> In one jacket and they all have to have their own pattern.
>> That is correct.
>> And they're all And so it's represented here.
>> That is right.
>> So this is one order.
>> One order.
>> And multiple jackets, multiple sizes.
>> Multiple jackets for a thousand jackets.
>> A thousand jackets in different sizes.
>> That is correct.
>> Okay.
So now we've got this Now we've got this paper plan.
>> Mhm.
>> I imagine it goes over here to the cutting room.
>> That is right. That goes to the spreaders.
>> Let's go to the spreaders.
>> All right.
We call them the automatic spreading machine.
>> Okay.
>> So basically, like what the machine's name is, it spreads the fabric automatically.
>> Just lays the fabric out.
>> It lays out automatically for this >> Okay, so we just saw the material being spread out and then this is the You call it a marker?
>> That is right.
>> Call it a marker, which is basically a cut list that comes from Mr. Taylor.
>> That is correct.
>> So this gets laid on top?
>> Yep. So, everything that you see here is from Mr. Mr. Taylor's planning. We optimize the marker and now the spreader. After they spread the material, we put them on the top.
>> There's very little wasted here and there.
>> Oh, yes.
>> He's done a very good job of putting in little pieces and little >> That is true.
>> That is a skill >> that I just Oh, yes. And again, that piece is where everything is being planned and just handed it to us.
>> And so, each of these pieces has the style >> That's right.
>> what the part is. So, this is the body back and that is the size.
>> That is right.
>> Okay.
Everything's labeled.
Everything is where it's supposed to be.
Where does it go now?
>> Now, after we spread them, we push them towards the cutter.
And if you would notice, there's holes on the tables.
>> So, a little just of air? Like air hockey?
>> That is true.
>> Cuz I can imagine a lot of like 50 layers of fabric. So, fabric can be very heavy.
>> Oh, that's true. And again, with this air lift or air blower underneath the table, we we could move this with two fingers, with one person.
>> Down to the cutter?
>> Down to the cutter. And again, that is because we want We are very very strict when it when it comes to health and safety.
>> Let's go see the cutter.
>> All righty.
>> Okay, so this is the next step in the process.
>> That is right.
>> The cutter. Okay.
>> Automatic cutting machine.
>> Automatic cutting machine. So, it gets rolled out, comes down to this point.
>> That is right.
>> Plastic on top.
>> Yes. And there's a special reason why we have a plastic on top.
>> Okay.
>> And that is to make sure that we hold the fabric down using a very strong vacuum.
>> So, it's a vacuum table.
>> It is.
>> So, compresses it all so that when you're cutting through it, it's not moving around, not wiggling.
>> That's true.
>> Wow.
>> So, what does it look like, John?
>> So, look, it's a perfectly cut panel.
>> Wow.
>> Yep.
>> Amazing, isn't it?
Very little waste left, right?
But, these are the actual parts that you want.
>> That is right. So, these are the parts that the machine has cut.
>> Okay.
>> Yep.
And for the operator, she has to make sure that all the parts are picked up.
>> Okay.
>> parts are tied together so that we could pack them and put them in a box.
All together.
>> So, what does this bundle represent?
>> This represents one cut.
>> One cut?
>> One size of 50 layers.
>> And this represents all of the parts of one jacket in that fabric.
>> fabric.
>> That is right. In >> That is right.
>> So, 50 jackets worth of the one type of fabric that's in that jacket.
>> That is right.
>> That's what's here.
>> That is exactly what's here.
>> This sounds like a logistical nightmare to me.
A real logistical nightmare.
>> Yes.
>> Tracking and making sure that all of the parts are correctly labeled in the right place.
>> true. So, that's why we have this paperwork team. And you can see here, it says the size, the uh the style, and how many quantity, and this has to stay with it.
>> All travels together.
>> All travels together.
>> So, it'll be packaged into the boxes and these pieces that are cut go to your sewing across the street.
>> right.
>> Or in Toronto, or in Montreal, >> across Canada.
>> Across Canada, cut from this plant.
>> That is right.
>> Wow. Okay, so I think next Andre's going to take me in and show me how it's all sewn together.
>> Great, yeah. Oh, that place is amazing.
>> Thank you for your time.
>> Thank you for your time, as well.
>> So, this is the next step. So, we just saw all this being cut and bundled.
>> Correct. So, these are the cut goods that come from our cutting room across the street.
>> That is correct.
>> Okay.
>> Uh our uh operators, what they are doing is opening the boxes and uh staging all the cut goods accordingly before we deploy them into the production.
>> Okay. So, each of these bundles is is one panel.
>> That is correct. So, we have 50 layers of fronts here, 50 layers of backs, 50 layers of sleeves.
Each 50 layers are of the same size.
Before we bring them to the production floor, we're going to start making bundles of 10.
Taking the sleeves together, the fronts together, the backs together, so the employees can do their jobs.
>> To me, logistical nightmare.
>> Yes.
>> Okay.
>> We have pieces jackets that have 240 pieces.
>> 240 pieces.
>> That is correct.
>> And they've all got to make it to the right spot >> That is correct.
>> at the right time.
>> And with the same sequence.
The layering is important, the way how we manipulate the garment. You don't want to have buy a jacket where this sleeve is darker than this front and lighter than this front. We can have shading issues.
So, you need to maintain integrity of the product.
>> Okay.
>> So, let's carry on and see how it's made.
>> Of course.
Glenn, uh we have a lot of processes in our plants.
And one of our biggest challenges is to find sewing machine operators.
Therefore, we are working on the skilling operations. Where we are standing right now is called the bulk section.
>> Okay.
>> Here, we tend to do batches of operations. We don't have to work in bundles. We take our 50 units that we have from the cutting room, and just by pressing pedals and following templates, we can then sew a label into the garment.
>> So, this is a label for for a a garment.
>> correct. I don't know if you can see it but this is iconic in our garments.
>> So, if anybody has a Canada Goose, you know that this is on the back panel.
>> That is correct. panel.
>> And so by following the template >> That's it.
>> everything just happens smoothly.
>> sure that it's centered. She puts the label of the size label. Then by pressing pedals, the clamps hold them and the machine sews. You have continuity. Every label looks the same.
Perfect quality.
Glenn, the same as with our diamonds our iconic discs are being placed in the garments through our automatic machines.
As you can see, what she does is she takes the sleeve places the sleeve on the machine, a clamp holds it, then she puts the disc, press the pedal, the machine does the job.
And as I mentioned before, what you will have is a constant product. So you have consistency. All of them look the same.
Good quality. It's straight.
So yes, this is our down fill machine.
>> Okay.
>> Uh we have different types of down fill machines depending on the amount of down that we have to inject in our jackets.
>> Okay.
>> Okay.
Um this is our machine that is actually the medium size to small size. We use it for a small or medium size jackets.
>> Okay.
>> Uh right now we are using gray down. We have two types of down, white and gray.
>> And then within the white and the gray, are there different grades of down?
>> and duck.
>> Duck. Okay. That is correct.
>> Um the quality of the down is determined by the capacity of warming up your garment, right? So if we have a down that is good in quality, we require less amount than the one that has more. Uh the machines are very simple. We have three different canisters that are resting on a scales.
The employee enters the amount of down that the jacket specifies. We don't decide how much down we inject. That comes from design and the type of down as well.
The employee enters the settings. The machine just starts to deploy the down into the canisters. The scale registers the weight. Once she reaches what we want, the employee presses the pedal.
>> Down fills.
>> Fills it in. Fills it in. That's it.
>> So this is a bag.
>> That is correct. That is a bag full of down.
>> Okay.
>> Now that the bag has been down filled, we need to come and close this opening.
>> Yep.
>> After closing the opening, we need to quilt.
>> Okay. So, then the quilting just keeps the down distributed correctly.
>> If we don't quilt, it's going to receive in the bottom.
>> Just like it is.
>> That is correct. So, what we need to do now is distributed accordingly and then quilt so that stays in one place.
>> So, let's go to the quilting.
>> Let's do it.
Here our panels come from down filling as you can see.
>> Again, this is a back of a jacket. It's a box >> of down. You can see the down is not distributed accordingly. So, we have to do two things. First, the first one is distribute the down across our panel.
What we do, we use badminton rackets.
>> the badminton racket.
>> Sometimes we use rulers.
>> So, I I I find this amazing that this is, you know, so simple, yet it is the tool for the job, isn't it?
>> That is correct.
>> Cuz that just distributed it perfectly.
>> That is correct.
>> Yeah.
>> The down is now our cutting room create notches on our panels.
>> Okay.
>> You can see them here.
>> along here.
>> That is correct. Which is the a place where she's going to put the template and is going to quilt.
>> That's the guide for the quilting.
>> That is correct.
>> Okay. And so, the the machine has a a long It's actually a long ruler, isn't >> arm machine that allow us to pass the panels through it easily. If you notice the table has little rollers >> Yes.
>> that allows as well the movement of the material easily.
It has rollers in next to the foot that allows the ruler to move as she's sewing.
And the rollers allows us to maintain the seam straight and to make sure that the both notches are aligned.
>> And then you come out with a perfectly >> That is correct.
She's doing the side ones and then she does the ones >> perfectly lofted.
>> Perfectly lofted.
Our plant consists on different lines.
Currently, we have 14 sewing lines.
>> Okay.
>> Each line is going to be dedicated to an specific product.
>> To one one one jacket.
>> One jacket. Okay.
>> Correct.
The reason why we do that is because it allow us to have more repetitions. The more we produce the same style, the employees are going to be able to master the capabilities and skills. They will be more optimal, more efficient, the quality will be greater.
>> Yep.
>> Once we have a change of a style, definitely we will have to do a reinforcement and training, but the idea is to keep the style as much as possible in the same line.
>> So, they're making I I assume this jacket here.
>> In this line, we are making the Langford parka. It's one of our iconic jackets.
So, we have 30 employees that are doing the jacket in a sequential process flow.
>> So, it starts >> It just starts in the back.
>> And then it just keeps moving forward.
>> As in the back, we start making the small parts. We start making the linings, we start making the pockets.
And as you move through the line, you're going to see the jacket getting form and shape, and at the end you have the final product.
This is where we join the shell with the lining. She does the top stitching, which is basically the final stitching and inspection.
>> So, um does the process get more difficult as it moves along?
>> say that. The operators are more skilled as you progress through the line. That is correct. So, you will see the more experienced employees at the end and the new ones actually at the beginning.
>> Very interesting.
>> It's correct.
>> Very interesting.
>> I used to explain that to make our big parkas is like making two jackets.
You will see the outside, we call it a shell, which is made with our beautiful Arctic Tech fabric.
>> Okay.
>> And then we have the lining, which is the one that contains the down and makes you feel warm. So, what she's doing right now is she's taking that lining and joining it to the shell.
>> Joining it to the Okay.
>> Okay. What she does is she joins it from the inside. Then somebody over here is going to turn them in. Oh, sorry. And then we're going to close them, which is what happening over there at the end of the line.
>> With the lining. Okay. As you mentioned before, there is a sequential process flow, so the jackets are being finished over there. This is the second last operation, then we're going to turn and then over there that's going to be sewn together. Correct.
So, what I now we're doing is joining the outside with the inside together.
She's turning the jacket right now after being joined the shell and the lining. As you can see this is happening on the bottom through which we turn the jacket.
So, that that's what she's doing right now. Then she's going to close and hem.
Then we top stitch and the garment is finished.
>> So, this is the last stop on the line.
>> Correct, Glenn.
After our jacket inspection, as you mentioned, after our jackets passing through all the processes of bundling, down filling, quilting, closing, joining shell to lining, so on and so forth.
You can continue. What she does is she takes our garments, she puts the zipper pullers, she puts all the little additions, cord locks and stoppers. Then she's going to inspect the jacket first from the inside and then to the outside.
If she finds a defect, she's going to place it in the bin for it to be repaired and she's going to enter it in our records for us to understand there's a jacket that needs to be repaired so we don't lose track of it.
>> Yeah.
>> We can bring it back.
Once she finishes, she's going to fold them neatly and then we're going to go into moving to cleaning before we go and pack them.
>> So, they all get cleaned before they're packed.
>> That is correct.
>> I'm noticing your defect bin is empty.
>> That is correct, Glenn.
We don't pass, we don't make, we don't accept quality based on our blueprints.
>> Okay. That's a that's a very good mantra to have.
>> That's not make sense for us to make seconds knowing that we are the ones that produce the jackets.
Right?
>> Excellent.
>> repair them as we go, we can fix them as we go and then your product should be finished.
>> Thank you so much for the tour, right?
>> Glenn, it was a pleasure.
>> It was fantastic. I I have never I have you put the jacket on and you realize that there's a bunch of parts to it, but it until I actually saw how difficult it is to get all of the parts to come together correctly.
>> 240 pieces, 680 minutes, more than 30 employees. When you buy a new garment, you don't realize around 40 hands touch that jacket before you are.
>> before it came to me.
Amazing. Amazing and amazing quality. Um I absolutely love my my jacket. Thank you so much for having me.
>> a pleasure. Thank you so much.
>> Bye.
>> So I thoroughly enjoyed that uh that tour of Canada Goose. Absolutely amazing to see the parkas being made. How many operations, how many pieces, how many how many hands touch the jacket before it makes it to quality control, before it makes it to the hangar in your in your closet. I mean, I've been wearing Canada Goose since they started showing up on film sets, especially in Toronto and the and in the north, um where you're standing outside all day and it's cold, and uh and those jackets are perfect for that.
And so the first jacket that I ever got from them, I still have.
And I'll put up There I am wearing it in Mirabel, and the wind is howling and I'm warm and I've got a happy smile on my face. So, currently in Steinbach. Um Canada Goose is in Winnipeg, but I stopped in Steinbach because Steinbach has cheap gas, cheap tie-downs, a great hotel within walking distance, and fantastic restaurants.
A great place if you're a pilot uh flying cross Canada uh to stop and rest.
Uh right now we're get jumping in the plane and we're going to go to Saskatoon, Saskatchewan. There is a distillery there that makes a very unique whiskey. Um I'm not going to say much more about it.
Come on back for the next episode.
Steinbach North, Foxtrot Mike 561 from rolling on runway 33. Steinbach North.
Airspeed's alive.
There we go.
Yeah.
All about
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