In a green area, directly linked to the company management offices and facilities, Porro production develops on a total 20,000 covered square meters, divided between the historical factory dating back to 1968 and the new unit built in the year 2000. Porro systems and collections are manufactured in a series of wide and enlightened departments, painted in white, perfectly in line with the minimal and essential languages, always featured by its furnishing units, where light stands out.
The different production steps follow one other – from the first processing to packaging up to the final shipping in perfect order, cleanness, essentiality, safety and care for the environment, perfectly matching manual and nearly handicraft processing activities to completely automated steps profiting from the latest production units and technologies, once more in a perfect balance between innovation and tradition as well.
Thanks to a uniquely designed factory with a perimeter entirely made of glass walls and a roof that is 50% glass and 50% photovoltaic panels that generate energy, and to working hours that change with the seasons, the Porro production plant operates using natural light without consuming electricity for 80% of the days in a year. This results in an improved quality of the workplace for employees, better quality control of wood and other materials, and an incredible reduction in energy consumption.
New production process with lean approach
Specialised in the production of strongly architectural modular system, Porro has a natural propensity to make a bespoke product, which became “structural” by virtue of the technological innovation of its production processes. Thanks to significant investments supported by the recent regulations on the evolution toward industry 4.0, is online the new plant which replaced the production of standard size panels with a just in time production of panels based on a customer’s order.
Among the effects of the new plant which have always been present throughout the history of the brand, we can count the replacement of modular design with compositional freedom, a qualitative increase in sizes and coverings of panels, production optimization with a reduction of waste, the elimination of warehouse inventory, and the establishment of a new relationship of “man-machine communication” with the transformation of laborers into highly specialized operators who manage the flow of information from the planning to the executive phase.
This is a historic change with which Porro faces the challenges of our time using a lean, sustainable growth approach, going beyond the rigid confines of traditional production to respond in a rapid, flexible manner to the needs of an ever more dynamic and complex market, in a journey of simplification and personalization characterizing each phase of the history of a Porro furnishing, with the goal of the highest quality.
The first panel processing. Porro production core is the panel processing (lacquered, veneered, in melamine or solid wood), the required raw material for its bookcase units, units and wardrobes. If in the case of the melamine panel, Porro profits from suitable designed papers, perfectly matching veins and grains, for the solid wood panels, Porro is one of the few companies customising its production as to sell its customers a product which only the handicraft mastery and expertise depending on a long lasting tradition can provide: a natural-looking product enriched by an industrial processing and design. The veneering and pressing department allows Porro to be internally liable for such an accurate processing, thus providing for the demanded top quality to its product surface. Then drilling is carried out on digitally controlled units.
Painting. Painting is internally managed within the company to provide for the best possible tone and quality. In the case of the panel, a veil painting is enforced, through a cascade painting unit which provides for a uniform colour or through a robot, with its mechanical arm and the automated colour change, simulating man spraying technique, thus offering for the best possible results in terms of quality. As for the collection units, asking for a manual and handicraft processing, there are the new pressurised painting booths, where temperature and moist are perfectly controlled, for a safe and healthy production process. Finally the final polishing and brightening, brushing the product with brightening pastes, carried out by outside specialised centres in compliance with the highest possible quality standards imposed by the company.
Final manufacturing steps. After painting, each unit is pre-assembled including any hardware, as to cut the final assembler requirements to the bare minimum. The production buttonhole for Porro is the new packaging department, recently entirely automated. Finally the product is moved to the shipping department: conveyor belts and counters automatically move any unit from a department to the following, throughout a production process which is constantly monitored through the information system, simply reading the bar codes on each unit, immediately telling histories and precise features as well.