by CAIRO, Ga. — In late April, Home News Now visited the upholstery manufacturer here to get a better understanding of its business model and manufacturing operations. The visit presented a look at the company’s vertical operations which include frame production, foam fabrication and the cutting of fabric for its extensive line of sofas, loveseats, sectionals, chairs and sleepers. Employing about 340 workers, most of whom are on the manufacturing side of the business, its production model in both Cairo and Coolidge, Georgia, is built for speedy delivery to customers across the U.S. For a glimpse of some of these capabilities, scroll down through the slideshow below.
Woodhaven employees send layers of fiber through a cutting machine that produces specific sizes of material used in upholstery production.
A machine cuts large blocks of foam into smaller sections to be used in sofas, sectionals and other seating.
An employee moves stacks of foam that have been cut to specific sizes for specific pieces of upholstery in the Woodhaven line.
Woodhaven workers are seen piecing together wood components that will be used in an upholstery frame. Materials are stacked on either side so they have access to what they need to keep the process moving quickly.
More assembly is seen being done on the production line, with additional wood components well within reach.
Another angle of a frame in process at the Woodhaven Cairo, Georgia, plant.
Workers affix layers of fiber to an upholstery frame in progress.
Workers staple fiber and fabric to an upholstery frame that is getting closer to being a finished product.
A worker affixes a dustcover to the bottom of a swivel chair. The outside of the frame has already been upholstered and had vinyl applied.
Here two workers are seen filling back cushions for sofas and sectionals.
Here a worker is seen moving plywood boards through a machine that has been programmed to cut them into smaller pieces.
Here a similar machine is seen performing the task of cutting the pieces into pre-programmed smaller sizes and shapes.
Another worker is seen operating a CNC machine used to cut and shape wood components used in upholstery frames. These and several other CNC machines help improve the yield the company gets from various wood pieces and panels.
Workers are seen placing machined wood components on a sorting line.
This is a view inside Woodhaven’s 5,000-square-foot showroom in Coolidge, Georgia.
More Woodhaven upholstery frames are seen inside the Coolidge showroom.
Sleeper sofas are an important part of the Woodhaven line. This model is seen inside the company’s Coolidge showroom.
This is one of several Woodhaven sectionals on display in the Coolidge showroom.
