These ribbons, upon closer inspection, appear to be two layers of machine-made fabric sewn together to form a single piece with one side puffed out like an arch in bridges, the “Alpine Loop” band that symbolizes the Apple Watch Ultra, which was just announced in the fall of 2022. The band is made of lightweight yet sturdy polyester fiber, the band is designed for outdoor activities by threading a metal hook through a hole in the fabric that expands in arch pattern, which prevents it from being pulled out in any direction. The fact that this intricate and delicate band is woven is astonishing.

The “Alpine Loop” uses 520 warp threads, which is far more than the number of threads used in ordinary fabrics, and this first process alone takes about six full days even for experienced employees.

After inspecting the heat treatment process on the first floor of the factory, I asked Tim Cook about his impressions of the company. “I love the the ability to scale something that is so intricate, something that is so detailed. And you know they’re making a lot of these as you can, tell but they’re doing it in such a high quality way. And the yields are very high.”

“They were very flexible, and willing to try new processes, new ways of doing things. This was the first time that this particular process was ever used. And so they have to be very nimble but that nimbleness has to be underpinned by great expertise. And they have that great expertise here. And I can’t stress enough the attention to detail and quality. These are the things that make the products look so great right out of the box.”

Apple prefers to use the term “supplier” over alternatives such as “subcontractor” because they believe in equal business partnership.

“What sets Apple apart [from other companies] is that they let us work as a team. If we have a problem, we spend time together to come up with a solution.” Seiji Inoue, managing director of Inoue Ribbon Industry, spoke from the opposite side of Cook’s statement.

In addition to bands for the Apple Watch, the company also produces handles made from woven paper for “Mac Pro” product packaging. Normally, nylon or other materials would be mixed into paper to give sturdiness, but Apple places importance on recyclability, so they need to make them from 100% paper. The team worked together with the Apple staff to find a way to meet these requirements, and when we introduced a manufacturer that could produce paper, they said, “Great,” and accompanied us to the manufacturer.

The first product they worked on was a band for the Apple Watch called “Woven Nylon.” It took four years to develop. At first, Mr. Inoue was fed up with the high quality requirements. Compared to other industries, the textile industry is not very strict about size control.

at some point the front-line workers became accustomed to Apple’s standards, and are now saying, “We have to do this much, don’t we?” and aiming for higher quality manufacturing. He added, “Apple taught me from scratch about quantification and other things. They taught me how to manage, how to make a table like this, how to do standard deviation like this, how to take data like this, and so on. You can’t learn so much even if you paid someone. But Apple shared all those knowledges sayin we are on the same team.”

Mr. Nobunari Sawanobori, the president of Teikoku Ink, which supplies white ink for the iPhone, once said, “The loss of learning through working with Apple is a bigger loss than the loss of orders from Apple.”

After working for so long with Apple, recently Inoue Ribbon Industry began to make proposal or provide supplement data when they work with other clients, Most of those clients are surprised and delighted.