We are constantly challenging ourselves to find a better way with the ultimate aim of perfection. Two of our senior managers have recently received the Lean Black Belt accreditation from the University of Limerick. We are also ISO 9001 accredited.
Production processes have been especially planned, tooled and integrated to answer the need to work with a wide range of materials from solid woods to veneers and inlays, laminates and foils.
Our factory is often asked to rise to unprecedented challenges by some of today’s foremost designers, seeking solutions to incorporate unusual design details using metal, glass, lighting, marble, granite, etc… in the manufacturing process.
Surfaces are completed with the latest technology to provide the toughest finish and meet FIRA 6250 ‘severe’ ratings.
Machine Hall
It is a long way from the craftsmanship of 1902 when a chair was crafted from a local Ash tree by hand. The majority of the production is carried out by machinery. However, with that said, we ALWAYS buy the best in machinery. In fact, in recent years, the company spent over €2M on new, top of the class, sophisticated machinery.
Ultra Violet Finishing
We use ultra violet finishing as standard. The ultra violet finishing process involves a series of sanders, lacquer rollers and dryers. The furniture is processed in component form to ensure uniformity of finish.
It is assembled later. This system gives a superior finish which conforms to BS6250 severe use. No other finish comes near for durability, toughness and resistance to water, solvents and even acid.
Assembly
This is where care and craftsmanship come into play. Accurate and carefully made components are put together with precision and attention to detail. When we were learning to make furniture to the Danish standard, we were taught the significance of the joint to the structure of the finished product so that each piece is meticulously manufactured to meet the design.
We also use a Danish high precision spiral groove dowel which is oven dried before use, giving a far superior and stable joint.
Samples and Specials
We listen and recognise a client’s need for a prototype or sample room. To this end, We have a dedicated sample room/specials facility. It is, in other words, a smaller version of the main factory with its own staff, machinery and facilities.
Each sample room is treated in exactly the same way as a full project. A project manager is appointed who manages and cares for it from start to finish. We know that the sample room is vital and is the reference point for the client and the full contract.
Packing, Transport, Distribution and Fitting
We often say there isn’t much point in making furniture that looks great in the factory unless we can maintain its beauty all the way to the hotel room. That is why we pay so much attention to this area. We carefully wrap and pack each piece of furniture and label it with its destination room number, to ensure that it gets to the correct location on site.
The furniture is stacked on pallets, shrink wrapped and banded to give maximum protection. On site the pallets are unloaded, broken down and the furniture items are carefully distributed to the correct rooms – all under close supervision of our Site Manager.
Our fitting teams are expert at their jobs ensuring that the final product is installed with the care and skill that it deserves.
