Standards costly for bedding producers
By David Perry -- Furniture Today, April 23, 2006
St. Charles, Ill. — Bedding producers will incur both up-front and long-term costs in complying with a new federal mattress flammability standard, according to the Lilly Management Group.
And, execs with that consulting group said, those costs could quickly add up for bedding makers based on the breadth of their product offerings.
The new federal standard, which takes effect on July 1, 2007, requires producers to pass three burn tests of prototype models for each bed in their line. At an average cost of $700, which includes manufacturing, the burn test and freight, the prototype testing will not be an inexpensive process, LMG executives say. That's why smart prototyping is so vital, the execs say.
For example, a realistic product line offering, including innerspring, foam-encased and foam core models, a choice of firmnesses and various panel quilts and foundations, could represent up to 80 construction variations. Smart prototyping will not only help cover all 80 variations, but also will reduce the total number of prototypes needed, and the costs associated with them.
Bob Sabalaskey, LMG's vice president of manufacturing and product engineering, reviewed those projected costs at a recent seminar on the new federal standard. The Lilly Management Group is now offering its FR-PRO compliance program, which it says is the most comprehensive FR program available.
Sabalaskey was vice president of research and product development at Serta, which was the first national bedding producer to introduce open flame resistant bedding. He is joined at the Lilly Management team by Ed Lilly and Susan Ebaugh, both former top executives at Serta.
Reviewing the types of costs that bedding producers will bear as a result of the new federal flammability standard, Sabalaskey listed these up-front costs:
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Marketing, sales and manufacturing costs in the FR components review.
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Full-scale screen testing costs.
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Prototype selecting and testing costs.
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The costs of system changes.
Long-term costs, he said, will include:
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The costs of the FR components selected.
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The costs of maintaining a quality assurance program.
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Recordkeeping costs.
Sabalaskey said the FR-PRO program capitalizes on LMG executives' past experiences with FR components and product specifications.
"We know what works, what doesn't work and what to look for when developing products and processes," he said.
The compliance process can be long, frustrating and costly for many producers unfamiliar with the procedure, he added. "Manufacturers need to know how compliance will affect their marketing and sales programs, how to evaluate FR components and perform finished product testing, and how to prepare for full-scale production."
The FR-PRO program helps producers analyze the issues, evaluate component options, prepare for production, and maintain compliance, LMG said.
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Experts: Start flammability changes now
May 7, 2006 -
Lilly launches consultancy on FR compliance
Feb 12, 2006
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