DAILY UP FURNITURE
Resumen del proyecto
Background
A home textiles manufacturer in Nantong carried out pre-shipment sorting in its production and packing workshop in 2019. The workshop contains rows of shelving and work tables. The task involved centralised inspection and temporary placement of chair cushions across multiple fabrics and colourways within the existing space, covering mixed-batch handling, colour matching and counting.
Requirements and challenges
- Mixed-batch colour matching across fabrics: A single batch contained cushions in different fabrics and colourways, requiring separate checks under both natural light and workshop lighting to prevent colour crossover or misplacement.
- Temporary stacking without compression damage: Cushions needed to be stacked in multiple layers pending inspection. Stacking method and height had to prevent edge creasing, filling displacement or surface indentation.
- Shelving and work table coordination: The inspection area sits directly beside the packing tables. Placement had to allow easy second retrieval without obstructing main walkways or disrupting the packing flow.
Specification and solution
- Zoning by inspection sequence: Cushions were divided into small groups by fabric type and colourway, arranged in sequence along one side of the work table, with turnover space reserved for each group.
- Controlled stacking height: Based on cushion thickness and recovery, each stack was limited to 8 layers, with thin non-woven interleaving between layers to reduce friction and compression marks.
- Use of existing shelf beams: Cushions passing initial inspection were placed onto nearby shelving in shipping-order sequence, from outer to inner positions, with labels facing outward for easy quantity rechecking.
Delivery and outcome
- Approximately 60 cushion sets processed per day, each completing fabric verification, colourway confirmation and surface inspection without affecting the packing line's original pace.
- Sorting covered 3 rows of shelving in the workshop, involving approximately 180 cushion pieces, all counted and located by shipping batch.
- Compression marks and misplacement rate held within 1%, a marked improvement over the previous ad hoc stacking method, with recheck time reduced by roughly one third.
Client feedback: With this arrangement, locating colourways and counting quantities is much faster. There is no more rummaging before shipment, and cushion edges are essentially free of indentations.
