As part of a consulting project that I am currently working on for Nike Vision, I had the opportunity to visit both Marchon (on 5/10/06) and SOLA (on 4/20/06) factories. The processs of production for Nike Max Rx sunglass frames is detailed below.

General Background: Nike contracts with Marchon and Sola for the production of its Nike Max Rx sunglasses (i.e. prescription sunglasses). Specifically, Marchon is currently responsible for sales and distribution to selected optician's accounts. In addition, Marchon manages the sunglass order from optical accounts, holds the frame inventory, and ships the frame to SOLA for lens production. The order receipt and frame shipping takes ~1 day. After receiving the frame, SOLA Technologies then processes the selected sunglass lens according to the designated prescription. SOLA holds all lens inventory for the Rx process. Finally, the SOLA multi-access machine shapes the outside of the lens to fit in the selected frame. The SOLA process averages ~6-10 days. More detail follows below....

Sunil, a good friend and fellow Kellogg student working on the Nike Max Rx project, accompanied me to Marchon in Long Island, NY on 5/10/06.

A view of the Marchon facilities. The boxes in the background hold the near-term Marchon inventory for all opthalmic and sunglass frames.  

Inventory for Marchon advertising.  

The Nike Max Rx order process begins here....

After the Nike Sun Rx order is received by either fax or phone, this is where the production process begins, with our friend Bill Taylor. Bill verifies the order, which often consists of calling the optician for verification, and then enters the order information into the computer. The order is assigned a Marchon tracking number which follows the order throughout the production process.

Delivery point for Nike frames from China

Here we see the delivery point for various frames at the Marchon factory. The Nike sunglass frames specifically are shipped from a plant in China.

Frame selection from Marchon Inventory

After entering the Tarj order in the computer system, Bill then handpicks the Tarj classic from the Tarj inventory stock. (Note: the Tarj is one of the few frames that is hand selected, as there have been recent problems with this frame in the production process). For the Tarj especially, Bill verifies the Tarj frame in the box is consistent with the order.

Marchon Packing Area

The frame moves to Nora in the packing department.

Shipping Area -- Part I

Carlos then packages the frame box into a small cardboard shipping box.

Shipping Area -- Part II

The frame then moves to the next part of the shipping process. Here we see Josh scanning the Tarj frame, acknowledging receipt in the shipping department.

Josh then places the Tarj Classic frame inside the SOLA box. 

On this day, there were ~10 Sun Rx Nike Frames (as you can see in the box) being sent to SOLA