At the beginning of the assembly process, large sheets of raw materials are converted into smaller "component parts" which make up the pieces of a shoe.
Workers cut out excess material from component parts that will eventually make up the design portion on the shoe.
In "high frequency welding", an image is welded into synthetic leather. For this shoe, the image will go on the heel.
What proves to be a very difficult process, workers cuts natural leather for the shoe. The worker shown has to make sure that she only cuts the best parts of the leather, and ensure that the leather does not stretch too much as to disrupt the size.
Foam for the tongue of the shoe must be cleaned out manually to make it more breathable.
Over the past ten years, Nike has implemented automated stitching into its factories. This type of computer stitching creates cleaner lines and fewer inconsistencies.
This process, called "skiving," takes a piece of natural leather and makes it thinner in the areas where it will be stitched.
Component parts for the side panel of the shoe are already embroidered with the Nike logo. These strips have been sent over for further skiving in preparation for being stitched onto the side of the shoe.
This crowded area is the stitching center at the factory. Ten years ago you would see all of these seats, back to back, in one line. Now workers sit in a cell side to side, so that pieces can flow one by one. This has helped streamline the stitching process.
In the stitching center, various components are put together to form the base of a shoe.
Thermal plastic cement is sprayed onto the lining in areas that will be stitched and require a bond.
Workers do what's known as the "stitch and turn," stitching products inside out, flipping it over, and finally creating a base that resembling the finished product.
Lace holes are punched into the shoe. Years ago, this task was accomplished using a single hole punch. Now, it's replicated with one device.
A woman hand-laces a shoe prior to sending it to the assembly lines.
At the beginning of the assembly process, a worker sets the heel height to minimize variations from shoe to shoe.
A difficult process, a woman stitches the bottom of a shoe.
Shoes go through a metal detector to make sure there are no broken needle remnants left behind.
When heat is added to the thermal plastic, it becomes moldable. Here, shoes are molded to fit the consumer's foot.
Workers apply cement to the upper and lower part of the shoe.
Toe guards are inserted onto the shoe. They are then molded to allow for a better shape on the toe of the shoe.
Considered the "heart of the assembly" workers are priming and cementing the bottom portion of the shoe to the upper portion. Workers face challenges, such as ensuring that the alignment is perfect and making sure that they secure the pieces before the cement hardens.
After going through alignment, pressure is applied for 12 seconds. The shoes are then moved into a chilling tunnel to cool down the assembled product.
After assembled shoes come out of the cooling tunnel, they are cleaned in preparation for packaging.
An inspector makes sure there are no defects in the shoe.
The inspected shoe is then put in a box where random hourly inspection takes place. Once the hourly check passes, the boxed shoe is sent to the warehouse.
Workers prepare for shipment.