manufacture

A Behind the Scenes look at how your furniture shapes up and ships out...

You've seen the perfect couch and equipment for your business, but what exactly does it take to make the couch of your choice?
When Francis Kenny turned to Beautelle for her salon order, time was of the essence. The 20 year old Secret Health & Beauty Salon in Barnes was being refurbished with a brand new-look salon, inspired by minimalist spas- white and creams, chic and understated.
We take an insiders look at how Francis' salon order was manufactured here in the UK by Beautelle....

bespoke

assembly 

2. Steel & Foam

The order process beings...
Francis' specific order requirements are entered into the Beautelle computer system to produce factory documentation and initiate the order production process. Purchasing checks stock of parts, materials and the required steel is ordered by the buying department- it will take four or five days to arrive. Meanwhile foam stocks are checked and allocated for the order.

1. The Big Decision

Francis Kenny talks at length to Beautelle's senior advisor, discussing the different options available on the electronic Couch Ranges she has seen on the website. Various couch additions and options are considered such as castor wheels, couch widths and upholstery-plus the recently introduced hydraulic lever that makes adjusting the back and foot sections easier. After liaising with the customer, complimentary salon equipment such as trolleys and operator chairs are chosen to suit the salon's refurbished look and our unique customer service options are explained. Francis needs to book a date and time for her delivery and full installation will be carried out on-site. She is advised that it will take four weeks to manufacture to her specific requirements.
 

3. Cut & Shape

The steel is delivered.

Now it can be cut and drilled to length, put into product-specific jigs and welded.

It has to undergo stress testing next, before its sent to the paint shop.

4. Spray & Bake

The cut steel is powder coated to the customer's specified finish- in this case, white. After the parts are sprayed they will be baked in a very hot oven - the whole process takes three to four days.

5. Tried & tested

Assembling the treated steel couch parts is no mean feat - this is highly skilled work. With this particular order trolley framework is also assembled.

The hydraulic pumps and the electronic motors are connected and tested.

5. Needle & Thread

Frances' chosen upholstery is precision-cut and prepared for sewing.
An industrial sewer joins together the cut pieces of upholstery to form a shell for each couch section. Every section is sewn separately, together with face bungs, chair tops etc. Each order is then matched to board and foam sets ready for upholstering.

6. Fit & Finish

Quality control checks the framework for any pit marks or scratches.

An upholsterer takes the sewn shells for each section of the couch, stool and chair and upholsters it onto the cut board and foam. This process is timed as close as possible to despatch date to keep the upholstery in pristine condition.

The sections are then quality controlled and set aside ready for on-site finishing in the five beauty rooms at Frances' salon- although couches and chairs are normally assembled at the factory.

7. Check & Go

 The couch framework and upholstery sections, pre-assembled trolleys, chairs and accessories are checked against the order documentation, then wrapped or boxed and loaded into one of the Beautelle vans ready for next-day installation.

Frances phones to ask for six more stools to go with this order- due next day! Factory staff work late into the night to accommodate this extra requirement.

8. An Early Start

Installation day - delivery is scheduled for 8.30am so two support technicians set off at 5.30 am and arrive at the salon for 8.15am to talk through the logistics with Francis before unloading. The equipment is then assembled and set up in each treatment room before the senior technician checks and demonstrates each item. At 2.30pm Frances checks the equipment and signs the satisfaction documents.

When the senior customer advisor telephones to check progress, Frances orders an extra couch!

9. The Final Word...

A final word from Francis Kenny proprietor of Secret Health & Beauty Salon-

" I needed a complete overhaul and to improve the quality of my couches and equipment. I liked what I saw of the Beautelle beds; they had what I needed and the price was right".

Secret Health & Beauty Salon

64 Church Road; Barnes, London.SW13 0DQ

Tel: 0208 3929640

fit & finish