About Us / Factory Direct Savings
About the FactoryIn 2006 the idea of a super efficient through-put factory began to grow. Because our factory's production is determined by direct customer sales through our stores, a scalable and adaptable manufacturing system was created by fusing J.I.T. (Just In Time) manufacturing concepts and eliminating W.I.P. (work in process) handling. Less than a year and a half later, we produced our first mattress out of the new facility and knew that we had a facility that was to be fair, one of the most advanced and efficient in the world.
How We RollScalability, nimbleness and the ability to adapt to any market conditions were key components in the design of our facility, featuring an infrastructure that can double production capacity literally overnight, cross dock flow and little to no warehousing of finished product; the new Denver Mattress manufacturing facility is a highlight reel of efficiency...but don't worry it's not all work on the inside, we've got a really neat paint job on the walls too.
Not only does our process create one of the most efficient mattress assembly lines in the world, it also ensures that it is one of the most consistent. Because we own our own nationwide truck fleet that is routinely delivering products to our chain of stores, we can use a single super-efficient factory to produce our mattresses and piggyback them to anywhere in the country. By not having multiple factories, managers and workers, we are able to maintain high quality control standards, and deliver a more consistent product at or below the cost of multiple factory producers.