A Look Behind the Scenes
From the Sewing Workshop
How does our repair service work?
The inner pocket of my jacket has come loose. While this is only a minor defect, I take it as an opportunity to take a closer look at our repair service at the Köngen site.
Together with my jacket, I make my way to the colleagues in the returns department. Here, my jacket is received and labelled with a tag. This tag includes the customer’s name, the date, and details of the damaged area of the garment. Several items are collected on a clothing rack and then taken to the sewing workshop.
The sewing workshop is where Ibadete works. She stands next to shelves filled with small components and fabrics, surrounded by a variety of sewing machines and other equipment. A steam iron hisses somewhere in the background. We quickly start talking about her work, and it becomes clear that my jacket has been brought to the right person. Ibadete began her training in the sewing workshop of Maier Sports GmbH in 1998. After spending several years working outside the company, she returned more than ten years ago. At the time of her training, the sewing workshop employed around 30 seamstresses and trainees. All prototypes were created there, and jackets consisting of up to 60 individual pieces were assembled.
„I still remember how, during my training, I was able to sew a complete jacket. That really meant a lot to me.“
Ibadete, seamstress in the sewing workshop in Köngen
Today, she coordinates the sewing workshop together with two colleagues. All returns received by Maier Sports GmbH pass through her desk. Often, zippers need to be replaced or buttons renewed. Her stockroom always holds a suitable spare part. If the original zipper is not available in the required length and colour, a suitable alternative is used. In many cases, seams also need to be repaired.
Ibadete shows me a special feature of the sewing workshop in Köngen: the taping machine. Not every workshop has such a machine, but for her work it is essential. For waterproof jackets, seams need to be taped to ensure they remain fully sealed. A smaller device can also be used to test whether taped seams or materials are waterproof.
In the case of my jacket, the detached bonding is replaced with a small seam. As this is not the first jacket of its kind where the tape has come loose, Ibadete also reports this back to the design and technical departments. This feedback makes it possible to address the issue already during production and implement product improvements. Even before items go into production, the design department consults Ibadete. She creates sewing samples to check whether the design ideas can be implemented. This allows an on-site assessment of whether new ideas or materials can be used before production begins.
„It never gets boring - there is always variety, as different repairs need to be carried out every day.“
Before I leave, she shares one final piece of advice. To extend the lifespan of garments, I should always follow the care instructions on the label. For example, items with taped seams must never be washed with fabric softener. And if something does need repairing, the available repair services should be used. Maier Sports GmbH offers a five-year warranty on products from both brands.
I say goodbye to Ibadete and follow my jacket to the quality management department. After a final inspection, the repaired items can be returned to their owners via the returns department.
I am happy – in less than a week, I have my jacket back, repaired, and have also contributed to product improvements. With that, I can get back on my bike after work.
