Inside Production
a glimpse at a few of the people, and a little about what goes on
Hands on installation experience in the test kitchen.
Our 1926 Tannewitz, double 16" blade sliding table saw - for prototyping.
One of our computer controlled milling machines.
Our machines are good but our people are the main thing. Go Johnny! Master finisher.
Sarah started at the bottom of the production ladder more than 15 years ago - rose to lead assembly, then moved to NY to run Field Operations, then back to Seattle where they are now the Senior DIrector of the production team. Here they are reviewing flitches of veneer from one of the mills that supplies our oak. They’ll either approve or reject it based on quality, color and grain type.
We manage our material inventory, which consists of materials made to our unique specification, by using a visual system. Storage racks are set up like spreadsheets, visually indicating by how full they are when they need to be filled. No purchase order is necessary. No wasted time or effort. We use 3 and 4 step supply chains and weekly restocking to assure consistent supply.
Alonso joined us 11 years ago, has deep knowledge of our product standards and production methods, and now leads our programming, CNC and Launch teams. He is selecting panels, sequencing them, and indicating which portions of them will be used for various parts of a single project. This expert selection happens at the beginning of each project.
1/8th inch solid wood edgebanding. Milled by hand, being sanded here to an exact thickness. Next will be selected for color, cut to length and applied to all panels to provide long lasting and repairable protection to all exposed edges.
Since drawer and door fronts are selected and cut by hand, they also have to be fit for hardware by hand. Each elevation is laid out on a large easel to assure proper sequencing and grain flow as the hardware milling is completed. Brian (leads the fabrication department, highly skilled, great leader), Graham (production engineer, extremely knowledgable, ace problem solver) and Sarah (head of production).
Time for lunch in the test kitchen.
A D pull being finished.
Jed fitting a Henrybuilt pivot door hinge.
The stainless steel rods of our Opencase system.
Leather pouches for Opencase.
Countertop being milled for sink and drainfield.
Shayne, a Gompers woodworking graduate - doing some forklifting.
Drawer dividers stacked in mobile storage after magnets have been pressed into place.
Howard - New Yorker, DJ, artist - builds a wall unit.
The smaller pieces that make up much of what you touch in a kitchen or wardrobe, like this wooden colander, take an inordinate amount of production time - but they make all the difference.
Hallie, another Gompers graduate, leads the assembly group, but here is helping another team sand drawer inserts designed for spice storage. We emphasize cross-group work to promote learning and improvements and connect people.
Hard-won inventory of drawer components.
One of the most powerful 'tools' in production: the cell designed to support building of our Bar Blocks. Dedicated cells like this are created to enable hand-building to a furniture standard.
There is so much critical handwork in the process. Here Nikol, a Parson’s School of Design graduate and an unfailing positive force in the shop, is sanding a bench part.
Jed brings 40 years of magic - from playing music, making art and building furniture - to the process of building a Scoop Bench.
Dung sanding the curves of a Wave Bench. Dung has worked in the Sanding department, in Fabrication, and now in Launch - mastering each set of skills quickly.
Ben, more sanding - a subtle skill - critical to the feel of fine work.
Leslie (artist, MBA - from our Bay Area office) and Lisa (architect and head of design team in NY) in Seattle to learn a little. Sarah is giving them a lesson in sanding, and they are about to give it a shot.
We do some things no-one knows about yet.
There are 20 people in the Seattle operation who do design, engineering, software development etc. Bryan and Seth focus on product development and engineering standards. Bryan graduated from UW Architecture and leads the group - with 9 years of experience at Henrybuilt, Seth has an industrial design degree from Western Washington and is currently focused on a major redesign of our Viola Park line.
Back to production. Aaron has made a big impact in a short time from within our finishing group. Staining a wall unit. What isn't in the photo is the big innovation he made recently in how we stain.
Allen, who built our finishing operation and leads the finishing team - outside one of our 2K Poly finishing booths. Its hard to explain how significant 2K Poly has become to the quality of our product.
The standard for almost every step in our production process, is set by furniture.
Brian, approaching 10 years with the company, brings a wealth of skill and product knowledge to the final assembly process, where each project is laid out in sequence, assembly is completed and quality is finally confirmed before shipping.
Brian teaching Janet a little about assembly. Janet is one of the founders of Remodelista and joined us 3 years ago to head our Business Development effort - based in Mill Valley, California - She's always game for picking up whatever tool needs to be picked up.
Ben - kind of like seeing a rainbow.
The Flow and Quality board in assembly - a key tool in continuous improvement.
Carlos, one of the most skilled in production, beginning the wrapping process.
Our proprietary container system allows us to get your product to you safely, store it if necessary, and reuse all of the container parts over and over again.
There's a lot of pride in this place.
The main thing is what it feels like for you - to live with what we design and produce for you.