Cell Production

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:

Product Development
& Mold Making

Pressing

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.

CNC Routing

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.

Additional Processes

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.

Finishing

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.

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