When Serta Simmons built their new factory in Houston they had one clear objective – efficient quality mass production.
This factory employees over 100 factory workers who man the different assembly stations. From layers of textiles, memory foam, and the metal box springs required to manufacture two of the top-selling brands in the United States – Serta and Simmons Beautyrest.
“Making a bed is like making a sandwich, but with high-tech machinery,” Jeff Collier, plant manager said, pointing to four large quilters spitting out mattress toppers.
After the recent partnership with Mattress Firm, the nations largest retailer, Serta Simmons production has been working around the clock to meet this high demand.
It’s estimated that Serta Simmons currently own 40 percent of the mattress market share.
To ramp up production, Serta Simmons has invested $100 million directly to open additional factories in Houston, Seattle, Moreno Valley, and Windsor Locks. These projects are notes as on schedule with the first of the four new plants to come online this summer. The other three are projected to open by the middle of 2018.
“We knew before the Mattress Firm deal that we needed more capacity,” Traub said. “It would have been difficult to fulfill the demand of Mattress Firm without these new plants.”
To date, Serta Simmons currently operates 39 plants across the United States and Canada.
With such demand requires building new factories at just under 300,000 square feet. To put this into context, Serta Simmons operated a factory for 19 years at one-fourth of that size. With a company history spanning over 150-years operation, manufacturing and execution is an intricate part of their corporate DNA.
This new Houston based factory is equipt with twenty-four shipping dock. That has doubled their old capacity. On any given day 20 – 35 semi-truck trailers drop off raw materials and pick up literally hundreds of mattresses. It’s also important to note this factory doesn’t just have the ability to mass produce a single product line. The mattresses produced prices range from $300 to over $5,000 dollars.
“The new manufacturing plant near us not only helps foster the collaboration between our two companies, but also allows us to meet our customers’ demand for the latest in sleep technology products at a compelling value,” Mattress Firm president and CEO Ken Murphy said in an email.
“Underlying demand for mattresses is related to population growth,” Seth Basham, an analyst with Los Angeles-based Wedbush said. “There’s enough demand.”