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head of research,
poses behind a
Krusning pendant
lampshade. Opposite:
Employees gather in
the common area at
the Ikea Democratic
Design Center.
In a stunning
global expansion,
the Swedish homefurnishings giant
has been quietly
planting its blue and
yellow flag in places
youd never expect.
Pay attention,
Wal-Mart: You could
learn a few things.
By Beth Kowitt
Photographs by
Andrew hetherington
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The best
thing for
making
your home
more
beautiful
is to take
away ugly
things,
says Ikeas
lighting
manager.
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Ikeas
factory
in lmhult
makes
about
7million
kitchen
cabinet
fronts
a year.
171
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Assembly
Required
Theres an
internal
nickname
for
products
that take
too long to
assemble:
Sometimes
we call it
a husband
killer.
proud of it, says Allan Dickner, the deputy manager of packaging. We try to minimize it.
He walks through the evolution of packaging a
particular floor lamp. It started in a rectangular
box wrapped in plastic with lots of wasted space inside. Now comes the logistics wet dream, Dickner
says as he shows the final resultL-shaped boxes
that can be nestled against one another like puzzle
pieces. In the early days designers resisted having
their floor lamps cut in half for aesthetic reasons,
but today not one comes in a single piece.
The magic of flat packing allows goods to be
jammed into shipping containers without wasting
any space. Wasted space means wasted money and
is also environmentally unfriendly. I hate air, says
Dickner. In the beginning of the 2000s, the company
did an internal air hunt competition. The winner,
who received a two-week vacation to Thailand, came
up with a better way of transporting tea lights. They
had been packaged loosely in a bag, but a Dutchman
had the idea of stacking them in rows and vacuum
sealing them. The metal cups encasing the candles
were redesigned to sit neatly on top of one another.
It was rocket science, Dickner marvels. Ikea then
borrowed from another very Nordic industry in
constructing a machine that could sort them. We
looked at how to pack fish sticks, he says.
But Dickner admits that sometimes Ikea has gone
overboard with flat packing, putting too much of a
burden on customers. To ensure it doesnt take three
hours to put together a tiny inexpensive item, the
instruction-manual teamwhich crafts some 1,400
assembly instructions a year, featuring a gender-neutral cartoon character called the assembly figureis
sometimes called on to give input that might impact
the manufacturing process. New employees
who arent yet accustomed to the ways of the
Allen wrench are brought in to do assembly
tests. Theres an internal nickname for products
that take too long to put together. Sometimes,
Dickner says, we call it a husband killer.
t may not be noticed by everyone, but in
recent years Ikea has been killing far fewer
husbands. The company has accomplished this
modest feat in large part through improving
its product design. As much as it has doubled
down on market research and logistics, Ikea
has been relentless in its focus on design.
Engman, Ikeas design manager, and his
team come up with some 2,000 new products
every year, including redesigns of existing items.
Marianne and Knut Hagberg, a brother and sister
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Ingvars Empire
In 1943, at age 17, Ingvar Kamprad
founded IkeaI for Ingvar, K for
Kamprad, E for the family farm Elm
taryd, and A for the village of Agun
naryd, Sweden, where he grew up.
Early versions of the logo included an
accent over the E to give the com
pany an international flaira hint of
Kamprads global ambitions.
More than 70 years later, Kam
prad is still a mythical creature
around Ikea, with much of the
company culture spread through
lore about the patriarch. Take the
naming of products. The tale goes
that Kamprad, who says he is partly
dyslexic, christened various prod
uctsbeds after places in Norway,
fabrics and curtains after Scandina
vian girls names, flowers, or plants,
and bookcases after certain profes
sionsbecause names were easier
to keep track of than numbers. He
loves to tell that story, says Juni
Wannberg, who is a guide in the
Ikea Museum in lmhult.
The running narrative on Kam
At Ikeas
distribution
center in
lmhult, pallets
are stacked
and retrieved
through a fully
automated
process. The
center starts
prepping in the
spring for the
launch of
the catalogue
in August.
ever worked on was a lamp made from the same material as egg cartons. I thought that was very crazy,
he says, but we proved the technique was possible.
If air is the enemy in shipping, it is the ally in
design. The more air in our products, the better,
says Engman, who started working at Ikea when he
was a teenager, pushing trolleys. (His dad was an
Ikea product developer and came up with the idea
for the Klippan, a round, informal sofa, after seeing
how his kids wore out the furniture.) In the design
center, Engman points out a table under development that consists of two trays cobbled together. Its
hollow center means the use of fewer materials. Its
legs even attach without screwspart of a general
move at Ikea to try to simplify assembly. Fittings
can constitute about a third of a products cost and
are also a hassle for customers.
Ikeas designers look well beyond the furniture
industry for expertise when it comes to trimming production costs. Theyve commissioned a
shopping-cart manufacturer, for instance, to massproduce a new table and a bucket maker to punch
out a chair. As the price of wooden drums declines,
Engman has considered using a drum supplier for
round tables. The same goes for materials such as
cork, which is in greater supply as wine bottles increasingly employ screw tops and plastic stoppers.
So, too, design inspiration comes from everywhere. Engman points out a folding table that he
saw in bars and restaurants throughout China. It
FEEDBACK beth_kowitt@fortune.com
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