T e factory makes 30,000 tables a year and each can have up to 600 parts –that’s 18 million components in total


Jeff says: “Running the cutting machines is


the most intellectually challenging job. It can take up to two years to master the skills which include operating computer control programs, picking up exactly the right materials and lin- ing up the table, fi xtures and jigs.” In the upholstery department foam and


fabric are applied to the top part, which Jeff says is the most physically challenging part of production. But fi rst the quality of foam is tested for its density and Indentation Force Defl ection (IFD) – the amount of force needed to make a dent. Ideally, says Jeff , high density/low IFD foam is desirable for com- fort and durability. AeroCel foam, which is lightweight, contains no fi bres and absorbs sound well, is preferred. Similarly, 100 per cent polyurethane fabrics are designed to be longer-lasting and have fewer off -gases.


THE END PRODUCT Next stop is the fi nishing department where motors and other parts that move the table top and liſt it are installed. T is is also where cabinetry is added, the wood is stained, the top is married to the frame and accessories


SPA BUSINESS 4 2012 ©Cybertrek 2012


Staff work as a close team and all are cross-trained in diff erent aspects of production to prevent repetitive stress injuries, and to keep the jobs interesting


are added – there are 70 extras including the therapist-designed Boiance face rest (pic- tured), featuring water spheres embedded into the foam for added comfort. If the table passes the 20 quality tests, it’s


boxed for shipment to a possible 34 diff er- ent countries around the world. T e factory staff works as a close-knit team


and all are cross-trained in diff erent aspects of production to prevent repetitive stress injuries, and to keep their jobs interesting – the double production line for portable tables can crank out 160 units a day. Jeff says: “T ere can be up to 600 parts


in a single table, and everything must work, look good, and not make noise. It’s quite a change from our days on the commune, but our goal is still the same – to make the best products we can .” ●


THERAPIST DESIGN


T e Boiance face rest is one of 70 possible additions. It’s been designed by a therapist to give greater customer comfort


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