Sealy has established Asia's largest production facility in Korea, which has become the fastest-growing branch among its global operations. The new Yeoju factory, twice the size of the previous facility, aims to serve as a global supply hub for the entire Asian market.
On September 7, Sealy held a media day to unveil the new factory located in Yeoju, Gyeonggi Province, covering a total area of 15,183 square meters (approximately 4,590 pyeong).
The factory features a 'one-stop' production system that handles everything from raw material inspection to production, quality and safety checks, finished product management, and shipping. The daily maximum production capacity will increase from 300 to 500 units based on an 8-hour workday, with an overall production target of 75,000 units for the year.
The decision to build a large Asian hub factory in Korea is rooted in the overwhelming trust in 'Made in Korea' products and the rapid growth of the Korean market.
A Sealy Korea representative stated, "Currently, we operate one spring factory and four mattress factories in China, but 'Made in Korea' products are recognized as premium among local consumers, with high trust in quality and technology. The Yeoju factory will serve as a core base symbolizing Sealy's premium quality and the value of Korean manufacturing, playing a crucial role in leading our premium strategy across the Asian market."
Since CEO Yoon Jong-hyo took office in 2012, Sealy Korea has recorded an annual growth rate of around 20%. Yoon noted, "While the growth of the Chinese market has slowed due to recent U.S.-China tensions and local economic downturns, Korea has maintained the highest growth rate and market value among all Sealy branches worldwide, thanks to the continuous expansion of premium demand. We have built Asia's best one-stop production base just ten years after establishing the Yeoju factory in 2016, starting with OEM production in 1998."
Sealy plans to significantly increase exports of finished products to major Asian markets, including Kazakhstan, Mongolia, and China, based on the excellent production infrastructure of the Yeoju factory.
With the opening of this new factory, Sealy is also making a strategic move to produce key mattress components, such as titanium coils (springs), domestically. Previously, the company imported titanium alloy springs from factories in Australia and China, but ongoing global supply chain disruptions due to war, typhoons, and currency fluctuations have heightened the need for localized production.
Kim Jung-min, Sealy Korea's marketing executive, explained, "As our sales scale increases, we are preparing to establish our own spring production facility near the Yeoju factory to reduce import dependence and increase the localization rate. With annual coil demand exceeding 100,000 units, establishing a domestic production chain will help secure logistics cost savings and supply stability."
Unlike competitors that operate large automated production facilities, the Yeoju factory adheres to a strict '100% custom order' and 'artisan manual work' approach.
In the production area with an 11-meter ceiling, skilled technicians carry out all processes manually, from sewing borders using sewing machines to assembling titanium springs. Each order is matched one-to-one, with barcode labels attached, minimizing storage time in the logistics area until delivery.
The production process incorporates a 'lean production' method, ensuring that no defective products move to the next stage, even catching a single loose thread on-site. The core technology developed in collaboration with orthopedic specialists, known as 'Posturepedic,' maximizes resilience and durability through two heat treatment processes, setting it apart from competitors.
Additionally, to ensure a comfortable working environment, the production area operates 16 large ceiling fans and precisely controls temperature and humidity, maintaining a top-level safety verification system through radon detectors (RAD8) and regular certifications from the Korean Standards Association (KSA).
Kim added, "Sealy can produce over 110 different types of products in small quantities. In the future, we will strengthen production targeting the growing global market for motion beds."
* This article has been translated by AI.
Copyright ⓒ Aju Press All rights reserved.