SIALKOT, PAKISTAN, HAS been a worldwide hub of football, or soccer ball, production since the late 1800s. British colonials paid local cobblers to recreate the balls they used at home, and production never stopped.
I established Forward Sports in 1991. In our first year, we manually produced 1,000 hand-stitched balls per month. I consider this form most effective—due to the strength of each hand stitch—but I explored new materials, panel shapes, and ways of production. By 2004, we implemented lean manufacturing principles that reduced waste and modernized production with automatic lamination, printing, and panel-cutting machines.
Now, we make hand-stitched, machine-stitched, thermal-bonded, and even airless mini balls (which never deflate), and gradually have grown production to 1 million balls per month. Our clients include Adidas and Diadora, and in 2014 and ’18,…