What would the toy manufacturing site that tempts childhood look like? When small, even dust can form, so removing things like that is the fastest way to adapt to rapidly changing trends. Busy toy production lines are in line with the peak season of the stationery industry, the new semester, where precise processing technology is concentrated in the production process of Sharp pencils. That's the level of expertise. From component production to final product assembly, workers continue the tradition of domestic production. The notebook binding factory, also known for its meticulous work, carefully protects the pride of domestic products with the hands of workers, entering the hot scene. When the new semester begins, students and parents who head to the stationery store fulfill their duty. Among them, the most purchased item by students of various types is stationery, right? Anyone in a pencil case.

How is a Sharp pencil produced with just one point? After asking around, I found the Sharp pencil factory located in Gimpo, Gyeonggi Province. From component production to finished product assembly, everything is done in one place, making it virtually the only place of its kind. Despite the onslaught of low-priced imported products, they persist in production. At first glance, the process seems quite complex. There are about 15 to 20 processing steps involved. For example, to create just one lead, a pathway that allows the lead to move is made. Even in a common Sharp pencil we encounter in daily life, there are hidden complex technologies. With as many as ten parts needed for assembly, when considering the processing of each component, making a single finished product requires more than 40 different processes.

Fairness is necessary. Especially in the front part that pushes out the sharp core, precise technology is concentrated. It is because all the ultra-precision parts need to be assembled into a space of about a centimeter in the sharp core. First, the parts that fix and spread the connecting pipe that the sharp core passes through, each part is so delicate and sophisticated that it wouldn't be caught in a regular camera lens. Each part must perform its role properly for the mechanical pencil to be completed. Early in the morning, workers who start the process of changing the brass first bring a sturdy wire and place it on the machine. This is a brass material. Brass wire with copper and iron added is not only a material with good workability and flexibility but also stable with the right weight.

Because it can provide a good writing feel, it is said to be mainly used as a primary material for making mechanical pencil parts. Compared to low-cost imported products made of plastic, it boasts a much superior writing feel. In the first cutting process for making connecting pipes, the wire is first cut to a length of 1.93 cm. Next to it, the worker double-checks if it has been cut to the correct specifications. The outer diameter is 2.2. We cut all the outer diameters, drill through the inner diameters, and process them so that they can penetrate deeply and be movable. It is a process of making it possible to sharpen through a wire gap of 2.2mm in diameter. It seems not easy to create. With the cut brass material, a worker moves somewhere and feeds the prepared material into a large machine. This machine, called a line machine, is used to process mechanical pencil parts.

It plays the most significant role, meticulously cutting and refining parts smaller than fingernails multiple times. Initially, after the material is input, the outer diameter is processed first. It is flattened to make it straight, then the inner diameter, which can be moved very delicately with a drill, needs to be created. Because it is so small, it is an ongoing process that never ends, dividing it each time. Comparing the appearance before and after processing one by one reveals the beauty. Working on thin brass, even a slight hole could ruin it, so the process is carried out gradually over 16 stages. First, gently shave the outer surface, then use a drill to gradually carve out the inner space over four steps. Then, repeat the process, refining the surface, creating patterns, and going through the process until the blunt end is smoothed flat and transforms sleekly once again.

So much care and effort is put into this. After completing the task, the parts are first visually inspected and then the dimensions are rechecked with a measuring instrument. Adjusting to 1.94 during processing. It's best to have almost no variation, about one one-hundredth. Bring the oil. Shortly after, a worker from the external warehouse brings the oil and goes straight to the back of the cutting machine to pour the oil. We are running out of cables, so we need to get more. When cutting, heat it up again and protect the tool. In precision metal processing, it is essential to use a high-quality lubricant to prevent corrosion, which is a type of synthetic oil with added additives. However, even after supplementing the cutting oil, why can't the worker leave? What seems to be the problem? Oh, the drill broke, so it needs to be replaced quickly while cutting the brass.

Preparing to switch to a new day, the drill used for a long time is worn out. It is a sharp pencil drill, as thin and sharp as a needle, with a diameter of 1mm. We will switch from a 1.2mm drill to a 1mm drill. Yes, yes, we will cut 300,000 pieces. 300,000 pieces, yes, yes. Oh, the diameter of the drill changes depending on the type of sharpener. There are even 0.5mm ones. Since there are several drills on one line, we have to sharpen them like this every 2-3 days. Compared to the old days when parts were manually shaved by hand, it has become much easier, but tasks that require labor are still abundant. They say there is another task that needs to be done while the machine is stopped. If it accumulates, the space where oil comes out gets blocked, so the task is to clean the bronze chips by drilling.

The workers who clean the gaps between the machine parts thoroughly will restart the season shortly to boost the production of parts. After the line completes a full rotation, the products are taken out for another round of inspection. To examine them properly, they even use microscopes because the parts are only 0.6mm thick, making it hard to see with the naked eye. It's not easy to confirm visually the ultra-precision mechanical pencil parts that need to be monitored daily. The workers' struggles are not limited to this. The length is only 2mm, and they have to check if there is a groove of about 0.5mm. Therefore, they need to look closely, which strains their eyes a lot. Mechanical pencil parts are like the weak point of a mechanism where precision parts come together. Every time you press the knob once, it can evenly discharge the lead.

To achieve this, all devices need to operate organically. After the parts processing is completed in the late afternoon, we now continue with the assembly process. This machine is responsible for fastening the parts. It is practically difficult to do it manually like in the past, so it is more efficient to do it mechanically both in terms of efficiency and effectiveness. That's why assembly is mainly done mechanically here. Although the parts produced here are mainly supplied to large stationery companies, depending on the order, we also assemble them into finished products. Today, we are scheduled to assemble the quantity ordered for pencil products. First, when each part is loaded into the machine, the assembly machine with a circular shape starts moving one by one, fastening the parts. Placing the spring and lead pipe on the main part that holds the pencil lead, the shape of the pencil starts to take form.

Starting with placing an eraser at the end of the pipe, covering it with a cap-like knob completes the first assembly process. Every day, making pencils like this, the representative business owner who has been doing this consistently for 40 years. In the past, even though raw materials and labor costs were high, good products were made domestically. But now, almost 90% comes from China, and we survive by moving the remaining 10%. The hopeful reason I do this is that if you make a good product, people will come. Now, the next generation, my son, is continuing this belief. Decorating the sharp manufacturing process is, of course, the hands of the workers. After completing the first assembly by inserting the finished body into the case and assembling the pencil tip, the work is completed. However, it is said that there are still some imperfections, which is the inspection.

This is the process of verifying if the hearts are coming out now, right? Doing about 3,000 to 4,000 of these. So many processes are needed for one Sharp to reach the hands of consumers. Finally, only the products that have passed the inspection through the workers' hands are eligible for shipment. Following that, we visited a factory in Goyang, Gyeonggi-do. This place is where they bind Sharp's close-fitting notebooks. In the binding process of bundling paper into books, from regular notebooks to sketchbooks, it is said that they still heavily rely on manual work. Notebooks are considered mature from January to early March, which is the peak season. Since they need to buy notebooks before the contract, don't we make them in advance? That's why it's the busiest time now. Around 5,000 to 6,000 are produced to catch up with the pattern of orders. To keep up with various patterns, they have to work all day without a break. Moreover, they produce in small quantities with various types.

As the method becomes mainstream, we have to constantly change the paper to work and cut it, so we can't help but be busier. It's a stitching note. The stitching method used in binding notes, where the center of the note is sewn with a thread, is popular because it is good for folding and sturdy. First, the worker brings the paper with the printed pictures, then they start combining the notebook cover with the inside pages one by one. They insert a cover sheet between each set of notebook pages. However, the work desk looks a bit unique. There is a machine that aligns in one direction, facilitating precise cutting during the next step. Thanks to this, the neatly aligned notebook paper is immediately moved to the side cutter, ensuring a smooth and efficient cutting process without delay.

The skilled representative worker is aligning the work accurately, but just watching makes me feel a shiver. The blade looks very sharp, so when your hand goes in, the sensor activates to prevent the blade from coming down. But still, you need to be careful. The note cutting process, which ends with just that word, continues with the sewing process where two people work together to match the count without any gaps. One worker continuously inserts notes according to the speed of the sewing machine, while another worker trims the notes coming in like a flood one by one with scissors. Shortly after, another worker applies something to the notes that have finished the stitching. What kind of task is this? Since the paper doesn't fold well just by folding it, you need to moisten it slightly; otherwise, it won't fold properly. This is why, in the middle, there is a solid line.

When you wet it before folding, it is much easier to fold in half. Now the process continues to the next stage. Several workers are simultaneously involved in the folding process. Literally, each one must be folded by hand, one by one. It's said that it hurts a lot when folding 3,000 to 4,000 pieces. Next, after the folding is done, they are hit with a wooden hammer to fix any slight bending that may occur during folding. The neatly finished notes are stacked on one side of the workspace. Then, heavy metal weights are placed on top of them to prevent them from curling up. To prevent them from curling up, they are pressed for a day or two, and the process does not end here. Lastly, they need to go through another cutting process. If you look at the notes here, you can see how they stick out like this.

To create a notebook with rounded edges, even the smallest parts that consumers can hurt their hands on must go through perfect finishing. The notes that will engrave the dreams of children in the new school year have been completed. Until a few years ago, we struggled a lot in the Chinese market, but now with the rise in labor costs in China, many companies are turning back to domestic production. We are now filled with hope, striving to live hopefully for the future. On the other hand, for children, there is a neighborhood like a different planet, the Dongdaemun Toy Alley, where there are no missing toys. Among the colorful toys tempting the innocence, even in the bustling crowd, they enjoy without any hesitation.

Children who are deeply immersed in toys, even though their favorite toys may vary, it is difficult to choose just one, which is unchanging. It's killing me, I want to go, I couldn't sleep well last night. The dinosaur is amazing, it's huge. The domestic toy market has reached a scale of 15 trillion won annually, but imports account for 60% of it. As time goes by, it is not easy to find domestic toys. Made in Korea is different from Made in China, so less than about 10% of our products come from factories that actually make them in Korea. Many toy manufacturers in Korea are facing these difficulties. The reality is not easy, but despite that, they are protecting the domestic toy market. This goes back to the 1980s when toy molds were made.

Starting from a small company, it has been carrying on its reputation to this day. From classic hits like robot toys that have marked decades of history to today's trending baby shark dolls and various interactive toys, they are preserving over thousands of toys. Even among imported toys, this toy factory proudly maintains the pride of domestic toys. Shall we take a look into a day at the toy factory? The production process begins right here, [MUSIC] starting with the basics of making toys. The first step is to use a crane to move the mold that will produce toys. When you put the mold into the cylinder and push it out, if a pirate doll pops out, the operator who made the mistake will be selected as a penalty in the roulette game. Among them, they are planning to start with this cylinder part first, [MUSIC] which is the mold's top plate.

It's a plywood. It's a structure where two molds, one on top and one on the bottom, fit together as a set. The raw material flows into the narrow gap between the molds, creating toys in the shape of the molds. There seem to be quite a lot of molds here. There are about 50 types of molds here, and in this factory alone, there are around 3,000 types of molds. Some products take 2 to 3 years to produce, but many take 6 months to 1 year. In other words, recently, this place has gathered various molds that are the best sellers. However, before the actual production of the products, changing the molds is not an easy task. The biggest challenge is that each set can weigh up to 500kg, so special attention is required. Okay, in order to securely place the heavy molds inside the machine, more than anything, the know-how of the workers is needed. If the bolts are tightened too much...

When the bolt is injected, if it is too weak, there is a possibility of gold plating, which is truly a careful work injection machine. When you look at the material, it goes in like this, and here it goes like this with a screw type, and it goes out like this, going in with gold to inject and mold the product. The injection molding method heats the plastic raw material, then injects it into the mold at high pressure, and cools it in the high-pressure state before discharging it. Shortly after, the injection molding machine starts operating in earnest. As the front screw part of the machine and the mold's inlet are connected, the product is immediately imprinted and revealed. Strangely enough, defective products continue to pour out. They are broken. Oh, not broken, but because the gold is cold, it takes some time for the process to be completed, and the gold temperature and product composition must be correct.

It becomes a tendency at 230 degrees, so we need to continue to produce prototypes like this until it reaches the point of plating. Meanwhile, in one corner of the workshop, two people are preparing a raw material mixture for the next process, pouring a handful of white plastic chips and starting to stick them together. This is the material for making handles, it's called HIPS, and it's a plastic material. Since 2016, following the enactment of the Special Act on Safety of Children's Products in Korea, strict compliance with safety standards for harmful substances is required. They mix another type of granules with the basic raw materials to prepare the mixture. These brown granules are called Masterbatch, and when 2.5% is added, the entire product turns brown. The solid pigment Masterbatch must also be used with certified products. The worker mixes the materials well to ensure they melt properly. Well-blended raw materials are immediately ready for use.

It is poured into the mold. Now, once it is melted into a high temperature, the preparation is all done, and shortly after, the plastic resin in a viscous form starts to come out of the machine. First, when ABS is injected and mixed, the product may break if the injection ratio is wrong. It is said that this process needs to be repeated every time the product being produced changes. After observing for a while, the product finally starts to come out as if making fish-shaped bread, with the mold shape and pattern replicated exactly on the roulette body. However, this is just the beginning. To produce all the parts, there is still a long way to go. If the roulette body has 500 parts, there are as many as 2 parts that come out accordingly. It's a precise job. Even spending the whole day, time is short. In the meantime, in the design office, the touch of design seems busy.

I am currently in the middle of producing samples. To make jewelry, when you need to create a mold by looking at an image, you need a model. It costs around 70 to 100 million won to develop and produce a set of molds. Therefore, it is essential to create samples and confirm the performance and marketability of the product before actually making the jewelry. Thanks to 3D printers these days, sample production is possible. It is said that for small figure toy types, it is possible to respond to trends more quickly. Compared to decades ago when making robot products, it is like heaven and earth. This is a product called Mechander Boo, which was extremely popular in 1986. Back then, we developed the product by watching TV and taking pictures, and only based on those photos. Nowadays, we develop products by drawing in 2D and 3D, but at that time, such systems were not available, so we mainly relied on photos and imagination.

We developed the product just by looking at the form. In 1993, there was a hit work, and the robot was also directly drawn in won and then turned into a product after starting the mold. They say that this is like the lion's share of the work. That robot, which wouldn't even hurt your eyes if you put it in, had its arms sold separately back then, going up to 40,000 won. Oh, in 1993, if you come now, it's like 400,000 won, 500,000 won. People even lined up in front of the factory from early morning to buy it, causing a buying frenzy. In the afternoon of that day, as the injection-molded products started to come in, the workers at the painting party began to get busy. Since you can't extract multiple colors at once through injection molding, various colors are applied through painting. It's a spray painting process. You wear a mask and spray. You spray it like this to paint it. You make it like this, spray it like this, and hold it like this.

It seems that only the black parts that need to be painted on the buoy are shown. To accurately paint multiple parts at once, a mask jig is used. It is said that four colors are needed to paint the pirate doll. First, the worker starts by painting the white base. After painting the white base, they prepare the second jig and switch to black. This time, they paint the eye patch, eyes, and beard all at once. By using jigs like this, the work can be completed neatly at once. Thanks to this, the paint job progresses smoothly without delays. About 1500 paint jobs are done here according to the CASE certification standards, using only designated paints. Since it is for children and infants, non-toxic paints are mostly used. Once the painting is done, the pirate doll is assembled by joining the front and back pieces to become one. It seems like the clothes are wings, and the paint

After extermination, the character changes. The toy parts that finished the paint job now head to the final destination, the assembly part. First, starting the assembly of the core part of the roulette, which is the central axis launch body. It is said that even this small part has a lot to go through. Six assemblies are carried, and now they go into the shaft. Filling the spring into the slender launch body, connecting the launch button. This assembled launch body central axis will take its place in the middle of the roulette. Once pressed, there is a groove here. Inside the doll, there is also a groove, so when the doll goes in here and gets caught in the groove, it rotates. So, as you keep inserting it here, it only pops out here, so turning it with the doll changes the knife position. Randomly, it catches in a certain position.

The term only humans are leaders may sound emotional, but in reality, as the dolls are given, the seats change every time, so only up to a certain point, the black number roulette, every 24 minutes, insert a new doll, and when the wheel turns, the penalty seat resets. However, if you keep losing, you may need to reconsider whether it's not the game but your own fault. Toys go through meticulous inspections to ensure they function well. After completing the inspection thoroughly, even if one component is missing, we check with the eyes of a hawk and package it. Besides the roulette, there are several other items. By assembling them like this, about a hundred different things are done in a day, about two here. This is also a small-scale production system. Oh, what's the most challenging thing? Oh, the automatic one. Up to 40, it's really hard. It's complicated, and in fact, if you start with dominoes, people

Many people may feel stressed even before playing the game properly because they have not set it up correctly. Dominoes are so difficult like this, and that's why automatic domino toys have emerged to solve such problems. As the age of playing with these toys gets lower, they are made to allow children to have fun without stress. For those who have never properly passed on a domino, it is truly an innovative toy. However, the more convenient a product is for users, the more complex it is behind the scenes. The reality is that there are many reasons why workers find it difficult to assemble. With about 40 parts to assemble, there is no room for error. After completing the electrical wiring work to drive the motor on the car body, they start aligning dozens of gears in place. This time, the alignment is complete.

The worker who applies something between the gears, oh, the oil, works meticulously to ensure that the gears connected to the motor operate smoothly without any issues. Just by looking at it, it seems quite intricate. When you open this window and insert it, if it gets stuck, the domino won't fall properly. The props push this, and it pushes out like this. Yes, when it falls all the way down, it aligns with this and pushes it back. When it comes out, like this, like this. Yes, so once the assembly of the internal machinery is completed, the front and back of the car body are covered to create a complete automated form. Tight wheels are also attached here, and when that's done, the assembly of the automated domino is complete. Aligning the 5 and 10, waiting for the packaging process, the cars must also go through something before that, which is ensuring that the dominoes are properly.

It is an inspection job to confirm that it is well set up, and applause is sent to the workers who sweat for the joy of someone. Meanwhile, these days, when playing indoors has increased a lot, a toy that is indispensable for children is large ride-on toys. It is a product that must be even safer because it needs to support the weight of children. Located in Busan Metropolitan City, a toy factory can be called a witness of the toy industry that started making toys in the 1960s. The factory that produces large ride-on toys is truly enormous. Among them, the machine that boasts the largest size is the extrusion molding machine. In an instant, a large slide mold reveals itself to the world. It is a place that produces and manufactures large products that belong to the category of giants. Melting plastic and molding products may look similar to the injection method, but it is a ride-on toy that you can directly board.

Due to the superior strength of the raw materials, a slide operation is being performed. Like pulling out taffy, a yellow plastic cylinder descends through the gap of the molding machine. At the same time, a machine device rises from below. As the mold is filled, the entrance of the yellow cylinder closes. This is a different method compared to the injection production method of small operating toys we saw earlier, yet somewhat similar. Shortly after, the worker takes out the finished product for inspection. This is the slide part of the slippery slide, where air is injected to put it into the mold and shape it. This process involves blowing air into the empty space to shape the plastic material. Unlike assembling the front and back parts in injection molding, extrusion blowing molding is a one-shot process, making the material.

By being more involved, we can see that it is more robust. It can be pulled out in a cylindrical shape without distinguishing between the front and back, so it can be removed more safely. In an instant, another slide is created. However, the expression of the observing worker is uneasy. If the zero supply is not smooth, a space is created, and then bubbles form, causing this black tea to be created. Consumers tend to want to eliminate things that seem slightly strange, making it difficult. Perhaps parents cannot overlook any mistakes. Workers, more than anyone else, understand this feeling well, so they put their full effort into the work. Meanwhile, on the other side of the workspace, the process continues, this time related to automobile parts. It seems to be the spring of the suspension that supports the car.

It serves as a baby walker and also as the first car for children around three years old. As it is a long-lasting product, the work is more meticulous. After the first cut, removing a large piece, the second cut is done very detailed so that there are no sharp edges. The work is done in two stages like this. Since it needs to be cut quickly before the material hardens, you have to endure the heat and work. Not only that, but the surface is smoothly shaved multiple times to ensure that children do not get hurt. How much effort must have been put into these repeated cutting processes to make it smooth like this after several sharpenings. Now, it's the final assembly stage of the Bbung Bbung-i production. The final assembly is done by the consumers themselves, but to enable this assembly, each part is individually assembled in perfect condition.

It's a share. Through the hands of many people, one precious toy for children is created. Ah, it's burning like that. Yes, it's burning like that. Thinking of the children who will enjoy it, the workers are making parts that will make them happy. Even though the birth rate is low and we are a bit lacking in strength, we will now show our craftsmanship spirit and do our best to create meticulous and high-quality products.

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