Unicasa Móveis - Relações com Investidores

The Company / Productive and Commercial Structure

Production Process

Manufacturing facility

 We have a manufacturing facility in the city of Bento Gonçalves, state of Rio Grande do Sul, with approximately 50,000 m² of space and a monthly average production capacity of over 200,000 Modules. From June 2012, we expect that our monthly average production capacity will increase to 300,000 Modules due to investments made in 2011 in our facility.

Our manufacturing facility has two plants one for the manufacturing of products for the Dell Anno and Favorita brands and the other for the production of products for the New and Telasul brands.

Our plants feature state-of-the-art technology and a versatile production model, which allow us to manufacture products only after orders have been placed while still delivering them quickly (no later than 10 days per order), making it possible to maintain low inventory levels of finished products. Our production of Modules totaled 1.5 million in 2009, 1.8 million in 2010 and 1.7 million in 2011.

Product research and development - (R&D)

Each year, between February and May, we launch a new collection for each of our brands. Additionally, collections of existing products are updated throughout the year, improving functionality and including new colors, textures and accessories among other qualities in order to provide to Dealers, shopkeepers and customers an updated portfolio based on national and international market trends.

The R&D process consists of a series of steps and activities developed by integrated multi-disciplinary teams in order to ensure the launch of high quality products and provide customers with a complete solution in customized furniture and fixtures. Our product concepts are developed by a team of in-house architects, designers and engineers, split into creation and development groups, such groups being individual and independent for each brand. These professionals are responsible for interpreting national and international market trends in design, fashion and architecture and implementing them in our annual portfolios.

Our R&D professionals are experts in design, marketing, consumer behavior and product development and are constantly seeking new references and researching and studying new trends in the furniture and fixtures industry. Their main research sources are:

  • attending national and international fairs and events where they observe the predominant trends and news within the furniture and fixtures industry;
  • researching new materials and accessories with suppliers;
  • monitoring online and offline media dedicated to the furniture market, and;
  • consulting with a European company based in London dedicated to consumption trends in the home-decor universe.

In order to complement the R&D process, our professionals take part in the development of the following departments: commercial, architecture, marketing, engineering and products. This integration is key to our process of launching new products into the market. We understand that the interaction among these areas improves and hastens the development process, consequently allowing a better focus on, providing innovative, high quality and commercially appealing products to customers and clients.

The main goal of the R&D process is to create products aligned with the market positioning and competitive strategy adopted for each brand, focused on developing patterns, designs, colors, textures, modules, fittings, accessories, finishings and inter-product complementation.

 

Production process

 

The simplified flowchart below shows the production process through the arrival of our products to Exclusive Dealers and Multibrand Sales Points:

 

The production process starts with the development of projects in Exclusive Dealers, made by architects or technicians with dedicated software (Promob). Customers actively participate in the project conception and in the choice of products that will be part of the room they are working on. For this reason, and in order to prepare qualified service and sales teams, we provide a training support structure to the Dealers of our products through Unicasa Corporate University, which offers guidance on products and project development, furniture module assembly, post-sales, people and business management.

After completing the project development stage, the Exclusive Dealership forwards the customer orders to our sales area, along with the respective projects that, after the system processes them, will start our production plans. For Multibrand sales points, where the product line only includes standardized furniture, the Dealer only needs to submit the clients’ orders to us for the production plan to begin, therefore there is no need to develop a specific project.

The next step after ordering and project submission, when applicable, is the forwarding of client orders to our Production Program and Control (Programa de Controle de Produção, or PCP) area to construct the production plans utilizing our integrated manufacturing systems. These systems issue purchase orders for raw materials, accessories, packaging, and other materials to be used in the manufacturing of the products included in client orders and develop an adequate production plan in order to minimize input losses and ensure timely shipping of products, improved cost control and optimized planning for the use of resources.

As a rule, all suppliers must meet the deadlines for the supply of raw materials and inputs used in our production process. Notwithstanding, there are minimum inventory policies to ensure our customers’ demands can be met for many months.

After the drawing up of production plans, the production of Modules begins, and consists of the following stages: cutting, finishing, drilling, stocking, packaging and shipping in four production centers as described below:

Cutting Center: Consists of cutting machines that cut MDF and MDP sheets used for producing Modules.

Finishing Center: Consists of forming and edge banding machines that perform grooving, lowering, edge banding and finishing of MDF and MDP sheets used for manufacturing Modules (45°, beveling forms).

Drilling Center: Consists of fully automated drilling machines which perform many types of drilling in MDF and MDP sheets used for preparing Modules. This is the last stage of parts processing.

Packaging Center: Consists of sorting conveyor belts on which parts and components are sorted to compose the Module to be packaged and forwarded for shipping.

In the packaging center, Modules are monitored through optically scanned bar codes affixed during the production process, allowing us to control orders ready for shipping. In the shipping area, the monitoring of Modules is done through optical scanning when products are shipped to Dealers and shopkeepers. In June 2011, an optical bar code scanning system was also deployed in Exclusive Dealers and Multibrand Sales Points to check all Modules received and verify their compliance with orders sent to the factory.

Currently, 92% of our portfolio of products is manufactured in our factories. The remaining material consists of special parts such as pieces with different finishings and measures than those manufactured in our factories and accessories such as knobs, wire parts, aluminum doors and lamps customized to complement the product lines and that are manufactured by outsourced companies. In some cases, we ship required inputs directly to outsourced companies (MDF and MDP sheets) to manufacture special parts. The quality control of products manufactured by outsourced companies follows the same criteria as for the products we manufacture ourselves. Outsourced products are manufactured based on technical designs provided by us. In order to check the quality control of third-party manufacturers, our technicians conduct an on-site inspection of their production line in order to check, among other aspects, the origin of materials used, as a means to ensure the quality of the final product.

We use the PreActor system to optimize our machinery and labor, which performs production flow control and allows maintenance to be scheduled in advance without interfering with the production schedule. Additionally, we use a Production Management System (Sistema de gestão da Produção, or SSP), integrated with PreActor, which enables real time tracking of pieces during production, ensuring adequate management of materials and people involved in the process. Our methods and process and product engineering areas constantly work to develop new production flows and changes in the layout of production units in order to increase our productivity.

Our factory uses state-of-the-art machinery and equipment that were acquired from the best global suppliers in the industry. We are focused on serving the market with high quality products and are committed to meeting our delivery deadlines and lowering production costs. Investments are directly focused on improving the quality of our products, the flexibility of our production chain, reducing costs (inventory of finished and unfinished products) and loss reduction.

 

Brands

We invest heavily in marketing campaigns for our brands, using fashion models, celebrities, designers and renowned architects, to obtain high visibility in the interior design, architecture and fashion industries and with our target customers. Each of our brands complements the others by reaching different groups of customers, and they are known for their quality among customers and throughout the interior design market. Our brands are:

  • Dell Anno: Our premium line, intended for the upper and upper-middle income brackets, Dell Anno offers products with greater added value, contemporary design and minimalist concepts, differentiated through its identification with the fashion world;  
  • Favorita: Established as an intermediary brand in terms of price and target customers, Favorita is intended for the upper-middle and middle income brackets. Our marketing strategy is to associate this brand with complete and versatile solutions, so that it is recognized for excellence in terms of price and quality;  
  • New: Intended mainly for the middle and lower-middle income brackets. New is targeted at the intelligent, practical use of space, style and competitive pricing. Started in January 2009 in order to benefit from Brazil’s growing consumption, New has proven to be a successful concept.  
  • Telasul: Our "entry brand", targeted mainly at the lower-middle and lower income brackets, Telasul is sold to both the “ready-made” furniture market through Multibrand Sales Points, and the customized furniture market, through both Exclusive Dealers and Multibrand Sales Points, thus reaching a wide customer base.
  • Casa Brasileira: Created in 2013, through studies of everything that has the face of Brazil, the Brazilian House is the Brazilian way of being, uniting references from all regions and states of our country, besides being the first brand company to work with the the franchise model.
  • Unicasa Corporate: mark for the corporate segment, created to meet the increasing demand due to the 2014 World Cup and 2016 Olympics Games as well as the sector of hotels, commercial developments and builders.

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Dell Anno Favorita New Móveis Casa Brasileira Unicasa Corporate

Rodovia Federal BR 470, Km 212, 930 - Bento Gonçalves - RS - CEP: 95707-540 - Caixa Postal: 2505 - Phone: +55 (54) 3455 4444 - SAC: 0800 6464 226Developed by Anderson Triacca Ideas Design