Specialized in Hunting Decoys Development & Production
At Tian Yi, we wanted to provide good services. When our customers need certain work to be done, if we can provide that service, we will follow through till completion. We can help in design, develop prototypes and produce tooling for a product. Our specialty of course is in blow-mold plastic and painting.
Instead of express the kind of services we provide, we are describing the kind of jobs we perform from begin to end.
Prototyping
Idea always comes first before turning into a product. Prototyping is the first step of creating
the model closely resembling the actual product itself. Prototypes allow customer to evaluate the design
and concept, test the fitting between pieces, and make adjustment and/or improvement before the
expensive tooling process.
Prototyping for blow-mold decoys however, starts by carving a piece of wood/clay with reference to a picture or a model in which it resembles a duck, goose or turkey. The style, the expression and the feather detail will all be carved into this clay model. The finished clay model will go through the adjustment and approval process by our customer before we move to the tooling phase.
Blow-mold Tooling
The tooling process begins after a cast is created. It takes about 3-4 weeks to complete
the alloy mold. Once the mold is done, the factory will have to perform mold testing to produce
some plastic samples. There could be some fine tuning on the mold if required.
When plastic samples are produced during the test run, the factory will record the time it takes to mold one decoy, they also put a decoy on scale to check the weight to make sure it complies to the specified weight by our client.
At this stage, molded samples will be painted according to customer's specification, and they will be sent to the customer for approval. When customer sign-off on the paint scheme and color, paint samples became the paint master for production.
Plastic Production
At Tian Yi, we have plenty of blow-mold machines that can produce decoys in various sizes. We have small machines that
can produce items as small as decoy heads, medium size machines for producing duck decoys and large
machines that can produce over-size goose decoys which they are as large as 26 inches in length.
Plastic decoys that came out of the machine will be checked for shape or scratch marks to make sure they comply to specification. Good decoys will also be put on scale to check for weight, then check for thickness all around to ensure durability.
Painting
We have dedicated the third level of our building for painting and flocking decoys. There are
two painting booth to apply base/premier coat for the decoys. Two painting assembly lines for
spray paint decoys, each worker is assigned to apply one to two color to a decoy, and the decoy is
being passed to the next person to apply the next color. Our QC managers will inspect the paint job
while the decoys are being put on the shelves for drying.
These 2 painting assembly lines give us the flexibility to paint 2 kind of decoys at the same time.
We also have two rooms specifically designed to perform flocking and drying, goose heads and bodies are some of the most commonly application for flocking. To shorten the drying time during production, we put the flocked heads and bodies in the heating booth.
Quality Check
Our QC staff are being trained to inspect paint job and durability before they are assigned to the task.
We know how important it is to provide quality products for our customers, and that is
why we check the decoys at least three times before it goes in a box. Decoys are being checked for
defects when it first came out of the blow-mold machine, we check for shape and scratches, if
a decoy did not form right or got deep scratches, it will be rejected.
Painted decoys are being inspected by QCs for color and paint scheme, if there is a color missing or the color do not match the paint master, it will be rejected and send back to the painting line to get it corrected.
Decoys that passed our QC inspection will go to packaging, and QCs will perform a final inspection while the decoys are being packed in a box.
Packaging
Our management team will make sure all packaging materials are ready by the time painted decoys passed their inspection. In most cases, floating decoys are ready to be packed in a box without assembly work.
Field decoys and motion decoys however, may require some assembling works, they will be sent to the assembling area for hardware installation. Other accessories such as decoy stands, poles, batteries, charger, etc. will be put inside each package by the packaging team.
Shipping
When merchandize are ready for shipping, our Shipping Department will arrange the booking of
containers, file the appropriate paperwork, and deliver the container to a designated port.
The port that closest to our factory is Shenzhen Yiantan.
Our Shipping Department do perform the 7-point inspection for each container before loading, we do exercise C-TPAT security at the factory because most of our containers are going to US.
With the size of our facility, we have room to hold two 40 foot container worth of merchandize, and we can ship two 40ft at the same time as well. Our courtyard allows us to load merchandize onto the container without much effort. Pictures and shipping documents will be sent to our customer for viewing.