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Cutting shop | FURNITURE FACTORY |
Here, in the Cutting Shop, leather and upholstery fabric are cut by using special templates for each model of furniture. In the Cutting Shop the whole production process is defined at least in two ways.
First, quality control. It is implemented as early as at this stage of production. Each cutter is personally responsible for both the quality of cutting and the quality of the material they cut on their tables.
In other words, before cutting the cutters perform initial screening of the material. This is especially important for leather: while putting a ready-made leather cover onto a frame and soft foam-rubber components, even a small, earlier unnoticed, wrinkle can turn into a knob-like defect at the final stage. One of the most important characteristics of high-quality leather furniture is that it must be ideally smooth. As a result of such rigorous screening up to 10% of the leather pieces prepared for cutting are rejected.
Second, personal responsibility. All the cutters at FALKE Möbel are versatile specialists working with all the models manufactured at the Factory.
A specific feature is that each cutter is responsible for a whole article of a certain model of furniture for which they make the whole set of upholstery. Thus the cutter is aware of the model as a whole and responsible for the quality of each fragment of the pattern. This arrangement helps for the workers to realise that they are creating a “family product”, upholstery for a whole model, not merely thoughtlessly pipelining its faceless components.
After the cutter’s work is done, it is scrutinised by the shop foreman who assesses the quality of cutting and the material itself. Only after that the cuttings are passed on to the Sewing Shop.
For FALKE Möbel even minor flaws in finished products are totally unacceptable. Once there was a case in the Factory’s history when a defect in a piece of leather was so small that it was hardly noticeable even on a finished product. The article, nevertheless, was withdrawn from the lot and disassembled, and the flawed parts were replaced.
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