As part of our Kaizen philosophy, in 2019 we converted our manufacturing process to cell production, permitting us to reach our goal of lean manufacturing. This method allows us to move product as quickly as possible through a cell, minimizing lead times and reducing waste.
Each cell is composed of multiple different machines which consolidate the processes required to produce a specific type of product. We are currently operating 8 cells, 6 of which produce product while the other two are used for product development and veneer preparation. With the implementation of these changes, Seatply is fully prepared to meet the industry’s growing needs.
Processes within a cell:
& Mold Making
SEATPLY’s expert technicians design and build all pressing tools in-house and optimize them to the client’s specific requirements, allowing them to maintain the highest quality.
An extensive library of stock pressing tools is available, allowing the client to save time and money. With tools numbering in the hundreds, a project can be ready to move to production quickly and efficiently.
18 Heat Induction Presses
12 Radio-Frequency Presses
There are 2 methods to cure the wood to make molded plywood. Most upholstery grade parts and some of the large exposed grade panels are produced using radio frequency presses. However, for complex exposed-grade components such as one-piece shells, parts with multi-thickness and exposed-wood parts, heat-induction presses are used. To complement their North American production capacity, SEATPLY also operates 20 presses in Malaysia.
8 5-axis CNC Routers
Once the molded plywood panels are pressed, they are machined on a 5-axis CNC router. These sophisticated computer-controlled routers allow the production of a large variety of consistently uniform and concise upholstery and exposed grade components.
Each part is sanded, metal inserts are installed, and verified for quality assurance. After these steps are completed, the parts coming out of each cell are for the most part ready to be shipped.
Optionally, SEATPLY offers a full finishing service. Their automated state-of-the-art finishing line has the capacity to stain, seal and top-coat seats, backs and shells using 100% water-based products. The end product is unparalleled in quality and beauty.