Hop aboard
the Seto-Oohashi line from Japan
Railway's Okayama Station and travel
20 minutes on the express train.
Ride through a tunnel and the scenery
suddenly changes from rice paddies
and fields into the blue ocean of
Setonaikai. Soon, the train approaches
Kojima station, the last stop on
Honshu, the main island of Japan.
Kojima, with the third largest population
in Kurashiki-city, embraces Washuzan,
the point where the Setonaikai National
Park begins, and is a well known
scenic area. On the other hand,
the city has been known for long
as one the nation's major centers
of textile industry and today its
massive amount of production qualify
Kojima to be called Japan's "Holy
Land of Jeans."
The history of textile in Kojima
can be traced back to the mid Edo-era.
In the 18th century, new rice fields
were developed throughout the country.
Kojima was no exception and numerous
land reclamations were carried out.
However, salt residue in the land
which originally was part of the
ocean made it unsuitable for growing
rice. Moreover, Kojima has very
small amount of rain that there
is even a saying: "dry weather in
Kojima, good harvest throughout
the rest of Japan." So the weather
too was not suitable for growing
rice either.
"If rice doesn" It grow, grow other
crops." It can be easily imagined
that great effort was put into a
search for a crop to substitute
rice. Through trial and error the
land proved capable of producing
high quality cotton wool, which
has been grown in Japan since the
beginning of 17th century (it is
said that cotton was traded at higher
prices than rice back then). This
was how cotton production began
in Kojima---the base for future
textile manufacturing.
Back then cotton produced around
Kojima and the southern parts of
Okayama Prefecture were graded high-quality
alongside Mikawa Wata (cotton produced
in the old province of Mikawa, the
current Aichi Prefecture). In a
region that produced such fine materials,
it was only natural that cotton
goods production would follow. In
1978 at Tanokuchi, Kojima; production
of Sanada Himo began. A Sanada Himo
is a flat woven cotton cord named
after Sanada, Masayuki (a feudal
lord during Japan's warring-states
period) who wrapped this cord around
the hilt of his sword. This Sanada
Himo became well-known for its quality
and merchants of Kojima peddled
them throughout the country. By
the 19th century, production spread
outside of Tanokuchi to a wide area
around Kojima to location such as
Ogawa-mura and Kami-mura (the current
Kamino-cho).
In the mid-19th century, production
of Tabi (foot cover worn with a
Kimono) began at Akasaki-mura (the
current Akasaki), and the foundation
for secondary manufacturing was
established. In the Meiji period,
Samurais were forbidden from carrying
swords and demand for Sanada Himo,
used mainly when wearing swords,
dropped dramatically. Production
shifted to products for the general
public such as Tabi, wicks, puttees,
and Hakama (skirt worn over kimonos)
material. Among those products,
Taitaitsu (cord used to hold Chinese
skirts), Benpatsu Himo (string used
for Chinese style pigtails), and
Kanjin Himo which was used as waist
sash in the Korean Peninsula were
products that became great commercial
hits for Kojima. Kojima textile
had already been introduced to countries
across the ocean from this time.
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There is a person who is referred
to as "Father of Gakusei Fuku (school
uniforms worn by students)." He
is the founder of Kojima Orimono
Co. Ltd., Zenpei Yamori. In 1921,
he bought 20 treadle sewing machines
and began making Gakusei Fuku. While
the uniforms were still not common
back then, material was not difficult
to obtain locally and cutting and
sewing skills for a Tabi could be
immediately put to use allowing
an easy business transition from
Tabi production. In the Showa period,
Gakusei Fuku quickly spread throughout
Japan. Accordingly, many changed
their trade and by the outbreak
of the Pacific War, 90% of the nation';s
Gakusei Fukus were produced in Kojima.
Kojima prospered as the home of
Gakusei Fuku during the Showa period.
Tanimoto, Masashi who joined Kanewa
Hifuku (current JOHNBULL) in 1954
and is still actively involved in
the work process looks back at that
time:
"Many young female workers from
around Kyusyu, Shikoku, and Yamaguchi
came here for a job. There were
many dorms in the city and no vacancies.
The city was flourishing. The streets
were full of young girls on Sundays."
Kojima's Gakusei Fuku business reached
its height, but it was hit by the
recession starting in 1964---the
post Tokyo Olympic Games economy
slowed down. Demand for Gakusei
Fuku was also declining just at
that moment and it was clear to
all that Kojima has reached yet
another turning point.
In 1965, the first jeans manufacturer
was born in the Kojima district.
Maruo Hifuku, who had manufactured
Gakusei Fuku and work wear, succeeded
in producing the first pair of jeans
made in Japan and introduced its
product to the market. Ooshima,
Toshio who worked for Maruo Hifuku
says:
"There were already secondhand clothes
stores all over the country back
then, and used jeans sold well.
Ivy League look was popular throughout
the world. Ivy meant copying the
way American students dressed on
campus and they wore jeans more
than they did cotton pants. However,
VAN, a retailer which was immensely
popular at the time, only carried
cotton pants. We thought, why not
manufacture jeans, and that's how
it began."
A long period of trial and error
followed. Needles of an ordinary
sewing machine could not sew together
the thick fabric. Domestic textile
wouldn't fade. Threads broke easily.
There were a series of unsuccessful
attempts. With the hard work of
the staff they finally managed to
begin production. The jeans were
branded "BIG JOHN." This brand name
comes from the company's President
Ozaki, Kotaro's first name "Ko-Taro"
"Taro" is a common male name similar
to "John" in English and "Ko" means
"little," and the two put together
is "Little John." Since "little"
was thought inappropriate for a
startup business, "big" was used
instead and that is how they came
up with "BIG JOHN."
Their jeans did not sell much for
a few years after going on the market.
This changed when color jeans using
24 color denims imported from the
U.S. made BIG JOHN's name known
throughout the country. Soon their
blue denim jeans started selling
as well. In the 70's jeans came
really into fashion. Back then,
"no sooner they were produced than
they were sold out" says Ooshima.
Jeans were sold after being washed
and dried in the sun, however with
the retailers in a rush to obtain
the goods, there were times (like
when bad weather continued) that
jeans were shipped only half way
dry. So great was the demand that
there were people who "wanted the
product, no matter in what state
it actually was !"
Manufacturers in Kojima that formerly
produced Gakusei Fuku and work clothes
entered the jeans market one after
another--"JOHNBULL" and "DOT" in
Akasaki, "BigBell" in Tanokuchi
to name a few. The foundation as
"Holy Land of Jeans" was formed
in the 70's. Kojima's jeans industry
claimed 70% share of the production
within Japan.
From Sanada Himo to Taitaitsu and
Kanjin Himo. From Tabi to Gakusei
Fuku. And then, on to jeans. Kojima's
textile industry has survived keeping
up with time by changing its products.
Without its strength and flexibility,
Kojima as "Holy Land of Jeans" would
not have made it, says Tanimoto.
"(In the last half century,) products
have changed and we experienced
both good and bad economies. Looking
back, the period seems long and
yet short. There was no time to
stop and think. Even today, Kojima
has nothing if textile is taken
away from it. It feels like our
land ---which is a dead-end--- is
now fully opened to the outside
world."