Recently we paid a visit to our factory in Saraburi, a town about 100 kilometers north of Bangkok. While it is considered to be in the countryside, it is also one of the industrialized provinces in Thailand.The manufacturing plant is one of 50 Kohler plants worldwide. This is the 15th year that Kohler is in Thailand and the factories produce bathroom fixtures and other products for the global markets. The plant has become a center of excellence not only in Thailand, but in South East Asia.
On the factory tour there are many things to learn. One of the most mesmerizing is the production of the acrylic bathtubs.The bathtubs are made from acrylic material that is very thin. At first, the factory workers clean the acrylic sheets and put them in the oven for about 14 minutes to soften them. After that, they quickly take the acrylic sheets out of the oven and press them into molds to form the shape of bathtub.Once the bathtubs are formed, they will be coated with fiber glass to make them stronger. Finally, a hole is drilled into the bath that will serve as a drainage system and the edge of the bath that do not fit the shape will be cut off.Each acrylic bathtub undergoes a rigorous process of quality control and checks. All functions are tested to see whether they work properly and sufficiently for market use. When the bathtubs pass the tests, they are carefully packaged and are sent to the distributors within Thailand and South East Asia.