For decades, North Carolina was known as the furniture capital of the world. And while thousands of jobs have been lost here, there's optimism the industry will rebound.
In Graham County, Stanley Furniture is operating its only plant in the United States. Carlton Craig is in charge of product safety and compliance at the Robbinsville operation. "It's going against the tide of manufacturing in the United States, and it's my belief we need more manufacturing not less."
Bill Jefferson started working here after losing another manufacturing job to someone in Mexico. "I was actually devastated. It was one of the hardest things I've had to deal with in my life."
While all of Stanley's other furniture is made abroad, workers here precisely craft the young America line. Craig says, "We go above just being compliant. We want to be the safest product on the market."
It's a risk for Stanley executives who are betting moms and dads will pay more for safer products- bucking a trend where a cheaper price often trumps higher quality.
Bob Harold, Operations Manager, of the young America division explains, "Our plan is to be able to show people they're wrong. There are certain situations with a niche product, where the consumer will buy a product." Sales are aimed at the worldwide market, even targeting parents in China.
Here at home, the economic future for this rural Carolina community is riding on Stanley's success.
Graham County Manager Mickey Duvall says, "Stanly to Graham County means everything. At any given time they will employ up to 600 jobs. Without Stanley it would be very hard for our community and Graham County to sustain itself."
The county, along with help from the North Carolina Rural Center and the Golden Leaf Foundation, has invested more than a million dollars to modernize and retool the aging plant. Automation is expected to trim production costs and perhaps trim jobs.
"We've got to change processes. We cannot continue to do the processes that have been around since the 1960's. We have to revamp the plant," Harold explains.
Customers now special order what they want to limit inventory overhead.
It's a strategy Kellex Furniture in Morganton is using too.With 5 different furniture lines, the upholstery company creates commercial custom furniture for hotels and health care businesses, and now- home markets too.
Charlie Rice launched the company in the same plant where Hickory Hill used to operate. "This area is still rich with craftspeople. There's a great supply network we count on everyday. And it's a great resurgence and rebirth of an industry we all thought was gone."
A lot of it did leave, says Scott Darnell, President of Burke Development, Incorporated. But, "Fifteen thousand people are still employed in the industry.
A lot left but a lot are still here. It is surprising furniture companies are looking to add employees."
"The advantage we have that we can never forget is we are still closest to our customer." Rice adds, "This may be the time for domestic makers to see the greatest opportunities because there is a movement back to the US production company."
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