Upholstery and cushion section with rolls of fabric and finished seat pads

Fewer parts fewer steps fewer returns

Flat-Pack Engineering and Assembly Design

A flat-pack product is really two products: the furniture, and the twenty minutes the customer spends building it. The second one is where returns come from, so part count, hardware organisation and the instruction sheet are engineered rather than left to the end.

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Step by step

How This Runs

Eight stages, each with a decision that belongs to the buyer as much as to the factory.

Part count review

Every part that can be pre-assembled at the factory is one less step at home.

Joint selection

Fixings chosen for the tool the customer will actually have.

Hardware pack organisation

Hardware sorted and numbered to the assembly steps.

Instruction drafting

Step drawings produced per model, language-free where possible.

Assembly trial

The sample is assembled from the carton as a customer would.

Carton design

Carton built around the part set, not around a standard box size.

Drop and stack check

Packing checked against the handling the shipment will actually get.

Sign-off

Carton drawing and instruction sheet approved before production.

In detail

What Each Stage Actually Decides

Part count reviewEvery part that can be pre-assembled at the factory is one less step at home.
Joint selectionFixings chosen for the tool the customer will actually have.
Hardware pack organisationHardware sorted and numbered to the assembly steps.
Instruction draftingStep drawings produced per model, language-free where possible.
Assembly trialThe sample is assembled from the carton as a customer would.
Carton designCarton built around the part set, not around a standard box size.
Drop and stack checkPacking checked against the handling the shipment will actually get.
Sign-offCarton drawing and instruction sheet approved before production.