Case Study: Transforming Custom Kitchen Design at Plykea with AXYZ Routers.

Introduction

Founded in 2016 by two friends seeking an affordable yet high-quality solution for customising IKEA kitchen and wardrobe cabinets, Plykea has revolutionised bespoke design by customising IKEA’s Metod, Pax, and Platsa cabinets with high-quality plywood doors, drawer fronts and worktops. Offering a seamless process for homeowners and professionals a unique blend of affordability, sustainability and design-led craftsmanship to elevate their kitchens and wardrobes, Plykea combines IKEA’s functionality with bespoke design elements, delivering a handcrafted, design-led aesthetic at a fraction of the cost. From its East London workshop, their varied client base includes not just homeowners but B2Bs made up of architects, contractors and interior designers, emphasising precision, quality and sustainability.

To achieve this level of precision and scalability, Plykea turned to AXYZ routers, a pivotal decision that has defined its success.

“The INFINTE router is:
Compact and Reliable: AXYZ routers fit seamlessly into Plykea’s workshop, making them an ideal choice for their space constraints.
Cost-Effectiveness: AXYZ routers delivered high performance within budget, eliminating the need for expensive outsourcing.
Durability and Precision: Built to last, AXYZ machines offered the reliability Plykea needed for daily production while achieving the exacting standards of their custom designs.” – Ben Price, Production Manager, Plykea

The Challenge: Scaling Precision and Quality

In its early days, Plykea relied on outsourcing to meet production demands. However, as demand grew, it became evident that external manufacturing limited the company’s ability to maintain consistent quality, meet customisation requests and scale operations. The company needed a solution that would enable in-house manufacturing to maintain the quality and precision critical to its offerings. With a growing customer base and increasing demand for its custom plywood fronts, Plykea required advanced technology to streamline production while ensuring consistency and quality. The result would:

• Compact and Reliable: AXYZ routers fit seamlessly into Plykea’s workshop, making them an ideal choice for their space constraints.
• Cost-Effectiveness: AXYZ routers delivered high performance within budget, eliminating the need for expensive outsourcing.
• Durability and Precision: Built to last, AXYZ machines offered the reliability Plykea needed for daily production while achieving the exacting standards of their custom designs.”

The Solution: Adopting AXYZ Routers

Plykea brought production in-house in 2018 with its first CNC router. When asked why they changed: “Initially, the machine required manual tool changes which restricted efficiency”, said Ben Price Production manager at Plykea. Recognising the need for advanced automation, Plykea upgraded to the AXYZ INFINITE CNC router, featuring automatic tool-changing capabilities and advanced features tailored to Plykea’s needs. This investment transformed their production process.

The INFINITE router is a highly configurable CNC machine that is suitable for one-off, small batch production as well as high volume and high productivity applications, including woodworking, plastic fabrication, engineering plastic machining and so much more. For a wide range of routing operations, one can choose from high-speed spindles ranging from 5HP to 15HP. For knife cutting, choose from a tangential knife, which can be used for creasing and folding applications or an oscillating knife which can be used to process soft goods material.

When asked why Plykea chose AXYZ Ben explained the following: “The INFINTE router is:

• Compact and Reliable: AXYZ routers fit seamlessly into Plykea’s workshop, making them an ideal choice for their space constraints.
• Cost-Effectiveness: AXYZ routers delivered high performance within budget, eliminating the need for expensive outsourcing.
• Durability and Precision: Built to last, AXYZ machines offered the reliability Plykea needed for daily production while achieving the exacting standards of their custom designs.”

How AXYZ Machines Transformed Plykea’s Operations

Precision and Customisation 

AXYZ routers handle the precise cutting of Plykea’s signature plywood fronts, ensuring seamless alignment with IKEA hardware with precise placement of hinge holes and fixings. The machine also supports the company’s ability to accommodate custom sizes, from non-standard door dimensions to bespoke worktops and modular shelving units.

Efficiency Gains
The automatic tool-changing capability of the AXYZ INFINITE drastically reduced setup time and eliminated manual errors. This automation not only enhanced productivity but also allowed the team to focus on design and innovation.

Cost Savings and Profitability 

By bringing production in-house, Plykea eliminated outsourcing costs and external markups. This move not only reduced expenses but also provided the flexibility to scale efficiently. Over time, the optimised machine settings further minimised material waste, contributing to Plykea’s profitability.

Enhanced Product Quality 

By tailoring the machine’s settings to its materials AXYZ routers provided consistent, high-quality finishes to Plykea’s premium materials, such as birch plywood with veneers of oak, walnut or ash. The machine’s precision enabled cleaner cuts and superior results, enhancing Plykea’s reputation for excellence.

Increased Capacity for Innovation 

With AXYZ routers managing core production tasks, Plykea had more resources to innovate, such as introducing Ürtil modular shelving units and custom pantry designs.

Overcoming Challenges with AXYZ 

“Integrating advanced CNC technology posed initial challenges, such as learning new workflows and optimising the router for specific materials. However, AXYZ’s technical team provided exceptional comprehensive support, including prompt troubleshooting guidance and on-site assistance, ensuring a smooth transition allowing Plykea to fully leverage the machine’s capabilities”, said Ben.

Employee Engagement 

“The introduction of automation has been a positive experience for Plykea’s team. They affectionately named the AXYZ INFINITE router “Greg,” said Ben, underscoring its integration as a vital member of the Plykea family. Employees welcomed the efficiency and precision automation it brought to their workflow, viewing it as an opportunity to focus on craftsmanship and innovation. Automation has also enhanced job satisfaction by streamlining workflows and providing opportunities for advanced CNC training.

Maintenance and Reliability  

Plykea ensures smooth operation with a strict maintenance schedule, including daily cleaning, internal cleaning schedule and an annual service for “Greg.” This proactive approach minimises downtime, ensuring uninterrupted production and keeping the machine running at peak efficiency.

Future Plans  

Plykea’s success with AXYZ technology has set the stage for future growth. Looking ahead, Plykea plans to expand production capabilities and therefore aims to add another AXYZ CNC router to meet increasing demand. This addition will enable Plykea to scale its operations while still maintaining the precision and quality its customers expect.

Conclusion, Results and Benefits 

Plykea’s partnership with AXYZ routers exemplifies the power of automation in modern manufacturing. By embracing AXYZ’s cutting-edge technology, Plykea has maintained its commitment to craftsmanship while scaling operations to meet growing demand. With its dedication to quality, sustainability and innovation, Plykea continues to transform the way kitchens and wardrobes are designed, proving that bespoke design can be both functional and beautiful.

Results and Benefits:

• Improved Productivity: Automated processes reduced setup time and increased output.
• Higher Profit Margins: Cost savings from in-house production enhanced profitability.
• Unmatched Quality: The precision of AXYZ routers allowed Plykea to deliver premium products consistently.
• Customer Satisfaction: The seamless integration of custom fronts with IKEA systems delighted both homeowners and industry professionals.

Plykea has achieved unparalleled precision, efficiency, and quality, solidifying its position as a leader in bespoke kitchen and wardrobe design. With its commitment to sustainability and innovation, Plykea is poised—with the help of AXYZ machines—for continued growth and success.

For more information about Plykea: www.plykea.com Tel: (+44) 020 8064 0780.

For more information on the AXYZ range of routers: www.axyz.com