Sewing plant

We can provide our clients with a comprehensive process including the design and production of limiter upholstery series.

Szwalnia

Top quality

In the production of upholstery we use the highest quality of certified leather and fabric with a wide selection of colours, with various structure and thickness.

Regardless of the ordered volume of serial production, we guarantee perfect quality finish.

Szwalnia

 

Apart from leather seat upholstery, Carlex Design specialises in trimming other elements such as:
/ dashboard,
/ centralised under-floor piping,
/ door cladding,
/ handbrake lever,
/ gear shift boot,
/ carpets,
/ door pillars,
/ headliner,
/ clock casing

PRODUCTION LINE

Machinery

We have a modern machinery, which we keep developing and adding to, in order for our products to meet top standards. In the production we have introduced the 5S and KAIZEN methodology on STANDARD level. All the types of produced upholstery have a full TRANSIBILITI code.

Szwalnia

ARMRESTS AND BACKRESTS

/ Single needle flat sewing machines /

/ Twin needle sewing machines posted on a pillar /

/ Twin needle flat sewing machines /

SEATS AND HEADRESTS

/ Single needle flat sewing machines /

/ Twin needle sewing machines posted on a pillar /

/ Twin needle flat sewing machines /

Speedometer top cover pad

/ Single needle flat sewing machines /

/ Twin needle sewing machines posted on a pillar /

Our production lines can be retrofit, which makes it possible to produce short series of limited upholsteries.

carlex design limited sewing plant 04

PRODUCTION PROCESS

Szwalnia

Prototyping

Prototyping is a key stage, directly before parts are produced. This is when a team of designers, engineers and sewing room employees cooperate on creating the final prototype, according to top technical standards for production, user comfort, durability, safety and aesthetics.

PROTOTYPING PROCESS

PROTOTYPING PROCESS

INSPECTION OF THE UPHOLSTERY

TECHNICAL ANALYSIS OF THE SOLUTIONS

DISMANTLING THE TRIMMING

PREPARING A TEMPLATE FOR THE UPHOLSTERY

SEWING THE FIRST VERSION OF THE UPHOLSTERY

FITTING THE UPHOLSTERY

ANALYSING THE TRIMMING, INTRODUCING CHANGES, ADJUSTING THE TEMPLATES

TRIAL SEWING AFTER THE AMENDMENTS

FITTING THE UPHOLSTERY

SEWING THE MODEL FOR PRODUCTION

DIGITALISATION OF THE FILES

PREPARING THE TECHNICAL DOCUMENTATION – OPERATIONAL CHARTS, CUTTING CHARTS

CREATING HARD TEMPLATES FOR PRODUCTION

Serial production

Serial production is organised in accordance with lean management principles. The production process is streamlined so that material flow is as short as possible and optimised to suit the employees and the manufacturing process.

PRODUCTION PROCESS
Szwalnia

PRODUCTION PROCESS

CONTROLLING MATERIAL SUPPLIES

PREPARING MATERIALS FOR PRODUCTION (LEATHER – LABELLING DEFECTS ON THE MATERIAL AND HANDING IT OVER FOR CUTTING)

CONTROLLING THE QUALITY OF MATERIAL AFTER CUTTING

MATERIAL LAMINATION (LEATHER - FOAM)

QUILTING THE SELECTED ELEMENTS (ON THE SEWING AUTOMATED MACHINE)

EMBROIDERING A PATTERN ON SELECTED ELEMENTS

HOT STAMPING ON SELECTED ELEMENTS

QUALITY ASSURANCE

PACKAGING AND DISPATCHING

Conditioning

We have the opportunity to make leather carpets and to condition other interior elements with customised embroideries, embossing or quilting.

Szwalnia

EMBOSSING

QUILTING

EMBROIDERY

Examples of our projects

mercedes-benz vito
mercedes-benz vitox

Mercedes-Benz

Vito

mercedes-benz x-class exy
mercedes-benz x-class exyx

Mercedes-Benz X-Class

Exy

nissan navara navy
nissan navara navyx

Nissan Navara

Navy

jeep wrangler
jeep wranglerx

Jeep

Wrangler

skater powerboats 438 rockette
skater powerboats 438 rockettex

Skater Powerboats

438 Rockette

mercedes-benz sprinter
mercedes-benz sprinterx

Mercedes-Benz

Sprinter