12 Steps to a car seat
All materials that arrive at the warehouse are visually controlled to assess the quality. They are then stored in designated areas that allow easy identification and FIFO fulfillment.
Once received, the leather hides are checked for several criteria, some quantitative such as thickness and others qualitative like the patterns or visual aspect of the surface of the leather.
The leathers are supplied to the cutting area in accordance with FIFO. There they are visually controlled once more and then put on tables. Cutting devices featuring blades are placed on these tables to fit the maximum area possible of the leather. The table is then pressed and the cutting tools cut the parts according to the shape required to assemble the car seat.
Once the parts are cut they need to be prepared for sewing. To ensure that the sewing complies with the standards, the edges of the parts are skived, thus ensuring minimal grain and roughness on the areas to be sewn.
Most customers require their leathers with foam on the back to obtain a special fit of the part on the cover. In the lamination process, foam and leather are thermally sealed, exiting the lamination machine as one single part only.
Cut parts inspection
After lamination, individual parts are quality checked. Some leather defects are enhanced after the application of heat. This step is very important to ensure that all the parts are perfect for sewing. Each one of them is stamped to guarantee a 100% check.
All seat covers require fabric or PVC materials. The necessary parts are cut on automatic CAD CAM machines featuring drills and blades that can process several layers of raw material at once. At the end of these machines the parts are checked to ensure that quality standards are reached.
All materials required for the seat cover are transported to the sewing area already prepared in accordance with the production order. In the preparation area, all the various types of material required for sewing one seat cover are arranged on the carts.
The sewing lines are oriented by the type of seat cover part and typically there are around 20 to 25 people and 25 to 30 sewing machines. This means that some operators work on more than one machine during the sewing process.
When the sewing is complete, the seats are inspected and controlled. Some extra operations may also be performed in the inspection area.
Packaging is where all seat covers are placed in cardboard boxes as requested by the customer. Orientation, individual protection and delivery quantities per box are some typical requirements. In addition, all parts are label controlled, thus giving COINDU total control of the process with regard to traceability.
In the expedition area, the labels are printed for each pallet and the necessary documentation is prepared for the delivery of the finished covers to the customer. Depending on the final customer, special documents such as pick lists, dispatch notes or custom bills are issued.