A leading mattress manufacturer in South Korea upgraded to NAIGU Mattress Production Line and increased daily output by 45%, cut labor costs by 40%, and reduced shipping volume by 70%.
Case Details
Customer Background
A leading mattress manufacturer in South Korea, specializing in high-quality spring and foam mattresses for both domestic and international markets. Before upgrading their production facility, the company relied heavily on semi-manual processes, which limited daily output and increased labor dependency.
Challenges
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Low Production Efficiency: Manual processes restricted production capacity to only 120 mattresses per day.
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High Labor Costs: Over 20 operators were required for stitching, compression, and packing.
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Logistics Pressure: Uncompressed mattresses consumed large shipping volumes, raising transportation costs by nearly 30%.
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Inconsistent Quality: Variations in manual stitching and packing affected final product consistency.
Solution
The company implemented the NAIGU Mattress Production Line, equipped with:
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Integrated Conveyor & Handling System to minimize manual transfer and improve workflow.
The installation and operator training were completed within 4 weeks, enabling a smooth transition from manual to automated production.
Results
After adopting NAIGU’s solution, the customer achieved significant improvements:
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Daily Output: Increased from 120 to 175 mattresses per day (+45%).
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Labor Efficiency: Reduced manpower demand from 20 operators to 12 operators (40% savings).
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Shipping Volume: Compression & roll packing reduced shipping space by 70%, cutting logistics costs by nearly 30%.
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Product Quality: Consistent stitching and packing improved customer satisfaction and reduced defect rates.
“Thanks to NAIGU’s production line, our factory runs faster, more stable, and more cost-efficient. We can now compete globally with confidence.” – Production Manager, Korea
Future Plans
The Korean manufacturer is now considering expanding its factory capacity by adding a second NAIGU production line to meet rising export demand, particularly in Southeast Asia.
