(Image credit: Apartment Therapy )

Last month I flew down to visit the Hickory Chair factory over two days and had an incredible deep dive into how fine furniture is made in this country and how Hickory Chair (founded 1911) has managed to adapt and succeed in the currently VERY challenging economic environment. Come along for a tour.

(Image credit: Apartment Therapy )
"Yes, we're in Hickory, NC!"

Hickory Chair is the high end part of Furniture Brands, a big conglomerate that has bought up a bunch of furniture companies over the years, including Broyhill, Thomasville and Lane.

>> Hickory Chair
>> Furniture Brands

(Image credit: Apartment Therapy )
Queen Charlotte - Charlotte Airport, Charlotte, NC

Hickory is run relatively independently by a remarkable CEO named Jay Reardon. He has totally refocused and transformed the company over the past 10 years drawing inspiration from the Japanese business models at companies like Toyota (Jay recommended an amazing book, Zapp!, which is about this as well and which I'm currently reading).

(Image credit: Apartment Therapy )

With this approach, every employee is treated like an owner and called on to constantly help find new efficiencies and better ways of doing things. The esprit de corps on the factory floor and the number of shifts and improvements that they had made as a group was staggering.

(Image credit: Apartment Therapy )
(Image credit: Apartment Therapy )

And then there's furniture building.

From cutting wood into "sticks" to the final upholstered sofa or dining table getting wrapped for shipping, everything is done in one large building at Hickory Chair and it is a remarkable process. It took us two full days to see everything. It takes an average of eight total work hours to make a piece of furniture, and what you will see below are many of the steps along the way.

Oh, and one other thing. Despite the rigor of these jobs, the factory workplace is run by men and women, young and old, and it was great to see older women with tool belts on as well as big men with tattoos carefully cutting fabric.

Enjoy!

(Image credit: Apartment Therapy )
Inside Hickory Chair factory - cutting sticks
(Image credit: Apartment Therapy )
Barbara - Hickory Chair
(Image credit: Apartment Therapy )
Shadow Box created by factory workers to customized their tool station needs - Hickory Chair - invented by Julia Child!
(Image credit: Apartment Therapy )
A button machine!
(Image credit: Apartment Therapy )
Laying in leg veneer - 15 min per leg x 4 legs = 1 hour per sideboard - Hickory Chair, NC
(Image credit: Apartment Therapy )
Side tables before finishing
(Image credit: Apartment Therapy )
In the lacquer polishing room
(Image credit: Apartment Therapy )
(Image credit: Apartment Therapy )
Cutting upholstery fabric
(Image credit: Apartment Therapy )
Carving chair legs with a massive multiple router
(Image credit: Apartment Therapy )
One floor up and we're in the fabric section and about to see upholstering
(Image credit: Apartment Therapy )
On the line right before set up springs
(Image credit: Apartment Therapy )
Lining a curvy sofa frame
(Image credit: Apartment Therapy )
Great green sofa almost done at upholstery station

(Image credit: Apartment Therapy )
All done! I'm at the end of the upholstery line and this sofa is moving out to packing
(Image credit: Apartment Therapy )
Final frame - they call this "cocooning" instead of packing and this is just the first two of three layers.