GRADO BASE CAMP VISIT: Pouring Tens of Millions into Building a 20,000-SQM Powerhouse

The five-floor factory layout integrates different production stages seamlessly, culminating in the creation of exquisite furniture pieces.

TO INFORM WHERE THE “CENTER ORGAN” OF GRADO IS


GRADO's center organ, our manufacturing base in Deqing County, Hangzhou City, represents a pinnacle of modernity in craftsmanship. The factory once reached 12,000 square meters and now has been developed to the next level, and acquired cutting-edge machinery sourced from around the world. Japanese CNC milling machines and German tabletop drilling machines stand alongside innovative 3D printers, ensuring precise and efficient production processes. Adhering to modern 6S management practices, the factory creates a responsible and quality-focused working environment.


In parallel with these modern standards, we place a strong emphasis on the art of handmade craftsmanship, showcased in "The House of Craftsmen".  Collaborating with five artisans boasting over 15 years of experience in furniture manufacturing, we integrate our expertise into the product development journey. These artisans are deeply involved in the entire process, adding a touch of warmth and tradition to the cutting-edge manufacturing practices.


Our commitment to excellence is further exemplified by its global sourcing policies. Seeking out top suppliers worldwide, materials including Danish wood, New Zealand wool, Italian leather, and Finnish, Russian, and American wood are brought together. The fusion of these quality materials with craftsmanship from China and chemicals from Sweden underscores Grado's dedication to delivering premium products and experiences.


From the factory's history to its current state, the manufacturing operations have evolved significantly. Formerly equipped with traditional machinery like engraving machines and sewing machines, the factory now boasts 251 pieces of advanced equipment. This includes sophisticated tools such as pneumatic cutoff saws for wood cutting, double-sided planers for wood preparation, and square hole slotting and drilling machines for refined wood processing. Additionally, specialized equipment for tasks like fabric cutting and upholstery maintenance has been added to elevate the manufacturing processes at GRADO.


The factory's expansion and advancement are evident in recent tens of millions of investments, which have made a 20,000-square-meter powerhouse a possibility with a team of 134 skilled employees. The five-floor factory layout integrates different production stages seamlessly, culminating in the creation of exquisite furniture pieces. As an illustration, the production process of a sofa at GRADO exemplifies the meticulous craftsmanship and attention to detail that defines the brand. The journey from selecting premium materials to the final product embodies Grado's commitment to creating furniture that embodies both elegance and quality.


1F: LANDING PLACE FOR UP-AND-OFF-LOAD


2F: INVOLVING ALL ON-PROCESS INCLUDING MATERIAL(LEATHER, FOAM…) STORAGE, SEWING WORKSHOPS, PACKAGING, AND UPHOLSTERING STATIONS, WOOD AND METAL WORK GROUPS


3F&4F: WAREHOUSE FOR READY-MADE PRODUCTS


5F: HANDCRAFTED POLISH-UP



EXAMPLE: PRODUCTION PROCESS FOR SOFA MANUFACTURING


PROCESS FLOW CHART



1. Cutting Wooden Frame

  • CNC cutting machine, suitable for cutting irregularly shaped boards
  • Straight-edge cutting machine, ideal for cutting wood and relatively regular-shaped boards


2. Nailing Wooden Frame

  • Preparation before nailing: arranging and classifying raw materials for efficiency
  • Using Russian imported pine wood for multi-layer board connection, in addition to nails, wood glue is also necessary


3. Priming

  • Basic components of priming: sinuous springs, paper-wrapped steel bars, straps, and mesh fabric
  • Use 3.8mm direct high-manganese steel sinuous springs for durability
  • Paper-wrapped steel bars: for comfort and synchronous springing
  • Plastic spring clips: no abnormal sound
  • Extra-wide 7cm straps: for comfort


4. Cutting Cotton

  • Using the environmentally friendly high-rebound sponge


5. Attaching Cotton

  • Spraying adhesive
  • Attaching


6. Cutting

  • Manual cutting
  • Fully automatic cutting machine: high accuracy, 10 times efficiency improvement


7. Sewing & Filling

  • Filling equipment: semi-automatic filling machine
  • Weight weighing equipment: to ensure consistent internal filling
  • Using Northeastern Eiderdown as a substitute for traditional duck feathers
  • Reducing 95% of foul odors, greatly improving comfort


8. Assembling

  • Handicraft
  • Processes that robots cannot replace


9. Quality Checking

  • Certificate of qualification, stamped and approved


10. Packaging

  • Sanitary treatment
  • Boxing and sealing
  • The packaging cardboard weight is 250 pounds
  • Using honeycomb cardboard packaging regardless of cost


11. Warehousing

  • Carefully check the labels
  • Only if the information is confirmed as correct, can the product be ware-housed


Designers Introduction