Rigidly Manufactured Kitchens, quality of the end-product

The rigidly built kitchen is designed, cut, edged, drilled, glued and built by machine. This is better known as a CAD/CAM system (Computer Aided Design / Computer Aided Manufacturing). This system enables the manufacturers to use one system for designing the kitchen and then use the design information to export all of the individual components to create the complete kitchen.

The kitchen components are batched together with up to 20 other kitchens based on material, unit colour, unit thickness, range, and door types and consequently sent to the CNC Machines (Computer Numerically Controlled). By combining all of the kitchen parts the CNC configures the individual components into the best cut patter, optimizing up to 98% of the sheet material. This means you get a very lean manufacturing process that provides Energy efficiency, reduced emission and reduced waste. Most large kitchen companies conform to environment and quality management systems EN ISO 1400 and this practice is ensured through the sole use of FSA certified timber from managed/certified forests.

After this efficient machining process comes the backbone of the kitchen, which is the construction process. Unit components are positioned in jigs or template holders and the machine then presses all of the items together, clamping them from all four sides. The parts are held in place while a UV light bonds and sets the glue in position. Following this, when the unit is removed it is square and even. It is the clamping process that provides the main rigidity of the kitchen carcasses, rather than the 6mm MDF back that comes with the unit. This backing is present simply as a façade rather than a structural aid that would stop the unit moving from side to side, as is most common in UK built kitchens.

During assembly the hinge plates which connect the doors to the carcass are inserted and all internal holes for adjustable shelves are bored. The drawer runners that enable movement of the drawer are attached very precisely by machines so that when the drawer is in motion all components are running 100% in line. This produces a smooth, silent and soft closing system. Aside from its sleek appearance, this increases the life span of the drawers.

A number of the biggest names in the industry work on what is known as a Mittelstand model. These are usually privately or family owned businesses that deal with a high value and Quality driven product, and are primarily business to business export companies. They have an emphasis on long-term profitability, and are frequently based in small rural communities close to good resources for skilled labour. This is essential because the processing plant cannot run without a highly trained and dedicated workforce.

The skilled labourer becomes involved in the process following assembly of the units and then progress down a production line to separate work stations. Prior to the door/drawer fronts being fitted the labourers manually insert internal fittings such as lemans corners, pull out larders, cutlery inserts or any internal accessories required. Next, the completed drawer boxes are inserted, drawer fronts attached and the soft close functionality checked. Full assessments are carried out at each station where the units are checked for quality; any marks or defects are quickly spotted and in such cases the individual unit would be rejected and its details scanned for immediate reproduction.

Some doors are manufactured in the same parts of the factory as the kitchens, whilst other doors are manufactured in separate parts of the plant. This is due to the complexity and delicate nature of the finishes. For example, the high gloss lacquer doors are individually sprayed in high pressure vestibules to ensure dust free environments, guaranteeing the equal level of thickness of lacquers between coats. The end-result of this is an increased depth of lustre, only achievable from a lacquered finished kitchen. The typical number of coats for the average Hi-gloss and Satin (matt) Lacquered finish is between 5-7 coats.

Throughout this entire process the movements of all materials and components is monitored by the central CAD/CAM system by way of barcodes. At each stage, the system will have scanned in the information of all parts involved and tracks their progress to ensure that each unit is built within the allocated/required time slots.

After production the furniture is ready for packaging and at this stage each unit or individual item is both boxed and coded. Up until this point individual barcodes have tracked the items through the assembly line but the entire product is now wrapped in a box, packaged and barcoded, with the outside packaging displaying both the distributor and clients name, as well as its rack allocation within the storage facility (so it can be easily located). Most modern German kitchen manufacturers have automated storage facilities and their computerised systems reduce the labour requirement as well as the risk of human error by taking control of all product movements and monitoring each box's transfer from the end of the factory production line to the warehouse. Each unit is allocated a space as directed by its barcode and this allocated spot becomes filled with all related items of the product order and will remain there until the point of required delivery. At the time of dispatch, the System will retrieve all order items from their allocated shelving area and move them to a container for delivery.

In summary, quality of the end-product is dependent upon the quality of the materials, as well as labour force used within the course of manufacture. All of the processes used throughout the entire production cycle guarantee an exceptional level of quality and efficiency, and conform to government and environment accreditations for high quality standards. Furthermore, the use of timber that is PEFC certified and extracted only from managed forests helps guarantee the lifespan and durability of the end-product. Whilst the manufacturing processes aren't necessarily unique, the German attitude towards these processes most definitely is; they use the right materials, the right people and they are prepared to spend that little bit more to ensure their products are truly up to standard. The combination of these factors and the proof of the finished product truly substantiate the Germans reputation for quality kitchens, a reputation they can proudly stand by and which will prevail for many years to come.