LensCrafters 2012 Annual Report Download - page 32

30 ANNUAL REVIEW 2012
its manufacturing capacity in China. During 2010, Tristar started producing plastic sun
lenses which are paired with frames manufactured in the same Chinese facility. A newly
developed state-of-the-art decoration department incorporates manufacturing processes
adapted from different industries.
The Foothill Ranch facility in California manufactures high-performance sunglasses,
prescription frames and lenses and assembles most of Oakley’s eyewear products. The
production of Oakley apparel, footwear, watches and certain goggles is outsourced to
third-party manufacturers.
The manufacturing facility in Campinas (Brazil) produces both plastic and metal frames for
the Brazilian market. In September 2012, Luxottica launched the first locally designed and
produced Vogue prescription collection for this market. In 2013, the Company plans to
add the production of select Ray-Ban, Arnette and Oakley collections.
Luxottica also operates a small plant in India serving the local market.
In 2012, the Group’s manufacturing facilities produced a combined total of approximately
Three main manufacturing technologies are involved: metal, acetate slabs and plastic
(injection molding).
Approximately 40% of the frames were metal-based, and the remaining frames were
plastic.
The manufacturing process for both metal and plastic frames begins with the fabrication
of precision tooling and molds based on prototypes developed by in-house designers and
engineering staff.
METAL FRAMES
The manufacturing process for metal frames has approximately 70 phases, beginning
with the production of basic components such as rims, temples and bridges, which are
produced through a molding process. These components are then welded together to
form frames over numerous stages of detailed assembly work. Once assembled, the metal
frames are treated with various coatings to improve their resistance and finish, and then
prepared for lens fitting and packaging.
PLASTIC FRAMES
Plastic frames are manufactured using either a milling or an injection molding process.
In the milling process, a computer-controlled machine carves frames from colored plastic
sheets. This process produces rims, temples and bridges that are then assembled, finished
and packaged.
In the injection molding process, plastic resins are liquefied and injected into molds. The
plastic parts are then assembled, coated, finished and packaged.
75 million prescription frames
and sunglasses.
2012 FRAMES
MANUFACTURED
BY MATERIAL
> PLASTIC-BASED FRAMES
> METAL-BASED FRAMES
40%
60%