Production

1. Introduction & Philosophy

At Shop By ABS, our production process blends traditional craftsmanship with modern precision. Every championship belt is not merely manufactured—it is engineered, crafted, and hallmarked as a symbol of achievement. This document outlines our end-to-end production workflow, from design to shipping.

2. Production Stages Overview

Our manufacturing follows a structured 6-stage process:

  1. Design & Conceptualization

  2. Material Procurement & Preparation

  3. Plate Fabrication & Detailing

  4. Assembly & Quality Control

  5. Finishing & Personalization

  6. Final Inspection & Packaging

3. Detailed Stage Breakdown

STAGE 1: Design & Conceptualization

  • Custom Orders:

    • Client consultation via our design portal

    • Creation of digital mockups (2-3 revisions included)

    • Final design approval with client sign-off

    • Technical blueprint generation for manufacturing

  • Standard Collection:

    • Seasonal design development by in-house artists

    • Market research and trend analysis

    • Prototype development and testing

Output: Approved technical blueprint with material specifications.

STAGE 2: Material Procurement & Preparation

  • Metal Components:

    • Sourcing of premium zinc alloy, brass, or steel (per design spec)

    • Sheet metal cutting to blueprint dimensions

    • Surface preparation (degreasing, cleaning)

  • Leather/Strap Components:

    • Selection of genuine leather (full-grain/corrected) or premium vegan alternative

    • Cutting to standard or custom sizes

    • Edge finishing and hole punching

  • Accent Materials:

    • Crystal/rhinestone selection (Swarovski or equivalent grade)

    • Enamel color mixing for recessed areas

    • Hardware preparation (buckles, snaps, d-rings)

Quality Checkpoint 1: Material verification against design specifications.

STAGE 3: Plate Fabrication & Detailing

  • Forming Process:

    • Hydraulic pressing for main plate curvature

    • CNC machining for intricate designs and text

    • Manual filing and smoothing of edges

  • Surface Treatment:

    • Polishing to specified finish (high-gloss, antique, brushed)

    • Electroplating (gold, silver, nickel, or black nickel)

    • Base coating for enamel areas

  • Detailing Application:

    • High-temperature baked enamel filling

    • Precision crystal setting using specialized adhesives

    • Hand-painting for multi-color details

Quality Checkpoint 2: Plate inspection under magnification for imperfections.

STAGE 4: Assembly & Quality Control

  • Strap Preparation:

    • Embossing/debossing of logos or text (if specified)

    • Edge painting/dyeing for finished look

    • Lining attachment (suede or padded backing)

  • Hardware Attachment:

    • Riveting of plates to leather strap

    • Buckle and tip attachment with reinforced stitching

    • Snap fastener installation (for adjustable sizes)

  • Initial Assembly Check:

    • Structural integrity testing

    • Functional testing of all moving parts

    • Weight verification (±5% tolerance)

Quality Checkpoint 3: Pre-finishing assembly review.

STAGE 5: Finishing & Personalization

  • Final Finishing:

    • Protective clear coating application (UV-resistant)

    • Final polish and buff

    • Micro-fiber cleaning for dust removal

  • Personalization (if ordered):

    • Side plate engraving (laser or rotary)

    • Championship record etching

    • Nameplate attachment

STAGE 6: Final Inspection & Packaging

  • 27-Point Final Inspection:

    • Aesthetic review (scratches, discoloration, alignment)

    • Functional review (buckle operation, strap adjustment)

    • Specification verification against order ticket

  • Certification & Documentation:

    • Generation of Certificate of Authenticity

    • Quality control checklist completion

    • Unique serial number assignment (premium lines)

  • Premium Packaging:

    • Acid-free tissue wrapping

    • Placement in custom velvet/flocked box

    • Outer shipping box with protective inserts

    • Inclusion of care instructions and warranty card

Quality Checkpoint 4: Final sign-off by QC supervisor before release to shipping.

4. Production Timelines

  • Standard Collection Belts: 7-10 business days

  • Semi-Custom Belts: 14-21 business days

  • Full Custom/Bespoke Belts: 21-45+ business days (depending on complexity)

  • Bulk Orders (10+ units): Quote upon request

Note: Timelines begin after design approval and full payment receipt.

5. Quality Standards & Tolerances

  • Dimensional Tolerance: ±2mm on plate dimensions

  • Weight Tolerance: ±5% of quoted weight

  • Color Match: 95% match to approved digital samples

  • Crystal Setting: Zero tolerance for loose stones

  • Stitching: 6-8 stitches per inch, uniform tension

6. Workshop Standards

  • Clean Room Environment: Dust-controlled finishing areas

  • Tool Maintenance: Daily calibration and weekly deep maintenance

  • Material Storage: Climate-controlled storage for leather and sensitive materials

  • Safety Protocols: Full PPE requirements, MSDS documentation for all chemicals

7. Sustainability Practices

  • Metal scrap recycling program

  • Water-based coatings and adhesives where possible

  • Biodegradable packaging materials

  • Energy-efficient equipment and lighting

8. Custom Order Modifications

  • Design changes after blueprint approval: 25% restocking fee + time reset

  • Material upgrades/downgrades: Price adjustment + possible timeline impact

  • Rush production (50% time reduction): 40% surcharge, subject to capacity

9. Capacity & Scale

  • Maximum Daily Output: 15-20 standard belts

  • Custom Order Slots: Limited to 5 concurrent major projects

  • Bulk Order Minimum: 10 units for dedicated production run

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