Insider Tips for Product Development Managers on Facial Sheet Mask Production

Overview

Are you navigating the complexities of launching a new facial sheet mask pack brand or developing a new product as a product development manager? This post shares essential insights I've acquired in the field, aiming to provide a valuable guide for business owners and practitioners looking to introduce new facial sheet mask pack products.

Choosing a Factory

Selecting the right manufacturer is a pivotal step for a product development manager in the facial sheet mask pack manufacturing process. Here are some key criteria to consider, listed in order of importance:

1. State of Manufacturer Management

Do not base your judgment of a factory solely on phone or internet information. The images on websites typically showcase the best view of the factory, which means it's crucial to assess its actual management condition in person. If visiting is not feasible, check if the manufacturer holds either ISO22716 or KCGMP certification. Particularly, KCGMP refers to Korean CGMP (Cosmetic Good Manufacturing Practices) standards, applicable only within Korea. These are known for their stringent requirements, and not many manufacturers in Korea achieve this certification. Holding a KCGMP certification suggests that the manufacturer is a large-scale operation, potentially influencing order quantities and pricing. In contrast, ISO22716 is an international standard GMP, more commonly held among manufacturers.

2. Quality Team (QC) Capability and Position

Every factory has a quality team. It's crucial to understand how this team operates. Manufacturers stringent about quality maintain a dedicated quality team that doesn’t double up with other tasks.

Nowadays, many have categorized these under research labs or teams, which handle both sample manufacturing and quality tasks. For smaller-scale companies, the rank and authority of the head of research or the team leader can be crucial. The level of authority and power given to the quality team by the company or manufacturer can significantly dictate the overall quality of the manufacturer.

Additionally, it’s important to check the services provided by the quality team. Compatibility tests, stability tests, and microbial tests are standard offerings, and you should also inquire if they offer additional tests such as preservative efficacy tests or cycling tests.

3. Capability, Character, and Diligence of the Operational Manager

The significance of the person in charge at the manufacturing side should not be underestimated. Assess their response speed, understanding, and attitude. It is vital to gauge the kind of person you are dealing with as you proceed with the samples.

4. Additional Information

Facial sheet mask packs are still packed manually due to the absence of automatic folding machines. Even manufacturers with ISO22716 or CGMP certification manage their subcontractors and raw materials separately. It is essential to check this aspect, as some subcontractors might have poor management or inadequate hygiene standards.

Sample Development

Once your plan and product concept are finalized, the next step is to request sample development. The time frame for sample creation varies by manufacturer but typically ranges from 7 to 21 days.

1. Full Ingredient List

Upon completion of the sample, you will receive a full ingredient list. It's crucial to verify the accuracy of the sample number, prescription number, and the date the list was compiled. 

The quality of ingredients can differ depending on the supplier, so it's advisable to keep a record of each ingredient's supplier. Additionally, ensure the total percentage of ingredients accurately adds up to 100% – errors in calculation or spreadsheet glitches can sometimes lead to inaccuracies.

2. Sample Documentation

Documenting the details listed on the sample's label or taking photographs is recommended. It is essential to check whether the label clearly states the formula numbers and sample numbers. While this information is usually included for multiple samples, it might be overlooked in single sample requests.

Record comprehensive details of the sample upon receipt, including the date received, quantity, weight, color, scent, the size of the mask pack, and the feel or texture. If possible, using measuring tools to note the viscosity and pH level is also beneficial for future comparisons and evaluations.

3. Testing Requests

If you're satisfied with a sample, proceed to request compatibility and stability tests. These tests typically take anywhere from 8 to 16 weeks, depending on the agreement with the manufacturer. Generally, if no issues arise within the first four weeks, the product is likely to be stable. Personally, I favor a testing period of up to 12 weeks.

Microbial testing usually takes about 5 days. This involves observing the growth of microbes on a culture medium. If the results are ambiguous or raise concerns, conducting additional preservative efficacy tests can be a prudent step.

4. Acquisition of Product Specifications

Once the sample production and testing are successfully completed, it's crucial to secure a detailed product specification document. This document essentially serves as an instruction manual, enabling a third party to reproduce the desired product accurately.

The specification should include the fabric grade number, manufacturer's name, full ingredients list, supplier details for each ingredient, Material Safety Data Sheet (MSDS), the cutting number of the mask pack (shape), approved sample number, specifications of the pouch and its manufacturer, and if applicable, specifications of the DP(Display) box and the manufacturer, filling quantity, and contact information of the manufacturer's operational manager.

5. Additional Information for Export

If considering exporting the product, thorough research on the regulations and restricted ingredients of the target country is crucial. 

For instance, when planning to export to Japan, compliance with specific regulations is necessary. Japan requires a government-approved import-export permit for cosmetics, and the actual filling quantity must be higher than what is stated on the packaging. Failure to comply, even by a margin of 0.001g less, can result in penalties, although exceeding the stated quantity is usually acceptable.

Mass Production

When a product development manager takes the lead in mass production, there are several crucial aspects to consider.

1. Quantity and Price

The cost per unit typically decreases as the order quantity increases, though this can vary by manufacturer. For instance, if the Minimum Order Quantity (MOQ) is 50,000 units at a unit price of $1.00, ordering 100,000 units might reduce the price to $0.90 per unit.

The MOQ for pouches (sachets) is also important. Pouches are usually ordered in rolls or half-rolls. For example, if a half-roll equates to 70,000 pouches, orders must be placed in multiples of 140,000, 210,000, 280,000, etc. 

This is crucial to understand. For instance, if the production MOQ is 50,000 units, you would need to order at least 70,000 pouches. How the extra 20,000 pouches are managed varies by manufacturer. Some might charge extra for the surplus pouches, while others might store them until the next order and charge if they are not reused within a certain period.

For example, ordering 141,000 units would necessitate ordering 210,000 pouches, leaving an excess of 69,000 pouches. This could potentially lead to significant losses. Therefore, it's vital to understand how order quantity affects pricing and other related factors.

2. Setting Quality Limits for Variation

Unexpected issues can arise during mass production, particularly with color variations. The most common variations occur in the colors of pouches, individual boxes, or DP boxes. These variations can be due to differences in ink batches or the capabilities of the workers. 

Efforts to acknowledge and minimize these variations are necessary. For instance, when setting limits for color samples (as shown in the accompanying photo), it's important to coordinate with the manufacturer. 

** Due to rushing, I mistakenly swapped the position of 'Light' and 'Dark.' Thank you for your understanding.

Setting the limits too narrowly can lead to higher defect rates and increased costs, or the manufacturer might refuse production.

3. Quality and Textual Review Request

It's beneficial to be well-informed about the regulations governing cosmetic advertising. If you're not, consult with your company's responsible cosmetics sales agent or brand manager. Most facial sheet mask pack manufacturers provide a textual review service, and it's advisable to double or triple-check these details.

Use samples to predict potential defects and set quality focus points accordingly. For example, if a sample has a misaligned direction, the same issue is likely to occur during mass production. Coordinate with the manufacturer to randomly check product directions every 5 or 10 minutes during production, and instruct them to halt production immediately to address any issues found.

4. Production Planning and Management

Always plan production schedules with a margin for unforeseen circumstances. Even if a manufacturer promises a specific completion date, delays can occur due to raw material defects or external factors like political issues. For large orders, consider the worst-case scenario and plan for up to an additional month of buffer time.

Product Performance and Analysis

It's crucial to record as much data as possible to analyze the performance of your product. This includes not just the comparison of manufacturing quantity to sales volume but also detailed records of sales figures categorized by channel, store, customer demographics, season, and month. 

Over time, this data can be graphically represented to provide insights, aiding in the development of competitive products for future planning.

Customer feedback is equally important. Recording feedback segmented by age, gender, season, month, and sales channel can provide valuable insights for strategy development in your next product planning phase.

Conclusion

This blog has covered the basic framework and several key elements of product planning or product development. However, the world of product development is vast, requiring a wealth of knowledge and experience. There's a need for continuous learning and adaptation to new strategies and techniques, as well as the ability to handle unexpected situations.

Product planning is an ever-evolving field demanding constant innovation and learning. I hope this guide has been a useful starting point for those embarking on the journey of product development.

In future blog, I plan to share more in-depth content and solutions to a variety of scenarios. Your questions and requests for additional information are always welcome, as I aim to support your successful journey in product planning. 

Look forward to more insights in the upcoming posts. I eagerly anticipate your creative and innovative product developments and sincerely wish you success in your product launches!