If you walk into a mid-size Anji office chair factory at 9 AM on a Tuesday, you see something that looks chaotic but is actually a well-tuned production line. Here is what happens at each station, from raw parts to packed carton.

Station 1: Backrest sub-assembly

Mesh backrest frames arrive from the moulding partner across the street. At Station 1, workers stretch mesh fabric over the plastic frame using a tensioning jig. The mesh is hot-pressed into place using a 90-second cure cycle. Output: backrest sub-assemblies, stacked on racks.

Station 2: Seat foam pour

Larger factories pour their own foam; smaller ones receive pre-cut foam from foam suppliers. Either way, Station 2 wraps foam in an upholstery skin (PU, fabric, or mesh) and stitches it tight. Output: completed seat pans.

Station 3: Mechanism prep

The synchro-tilt or single-tilt mechanism arrives pre-assembled from the mechanism supplier (often a 5-minute drive away). Station 3 attaches the tension knob, tilt-lock lever, and seat-slider rails if applicable. Output: mechanisms ready to mount.

Station 4: Gas-lift prep

Class 3 or 4 gas lifts arrive boxed from Camal, KGS, or Stabilus. Station 4 checks each lift for serial number, attaches the dust shroud, and stages them in batches. No assembly here — just QC and staging.

Station 5: Five-star base prep

Aluminium or nylon five-star bases arrive in bulk. Station 5 attaches the casters (5 per base), applies any cosmetic finish, and stacks them.

Station 6: Main assembly

This is the central station. One worker has the seat, mechanism, gas lift, and base in front of them on a rotating jig. The mechanism is bolted to the underside of the seat. The gas lift drops through the mechanism. The base is press-fitted onto the bottom of the gas lift. Cycle time: 60-90 seconds.

Station 7: Backrest mount

The backrest sub-assembly (from Station 1) is bolted onto the rear of the mechanism. This is the highest-defect station — if torque is wrong here, the backrest wobbles within months. Quality factories have torque-controlled drivers.

Station 8: Armrest mount

Armrests (1D, 2D, 3D, or 4D — already pre-assembled at the armrest supplier) are bolted onto the mechanism. The orientation matters — many returns come from mis-installed armrests.

Station 9: Function test

Worker sits in the chair. Tests height adjustment, tilt, lock, swivel. Failures here go back to the appropriate sub-station. Pass rate on quality factories is 95-98%.

Station 10: Disassembly for packing

Chairs ship knocked-down (KD) for container efficiency. At Station 10, the chair is broken into 4-5 components: seat + backrest, mechanism, gas lift, base, armrests in their own bags. Each component gets wrapped in foam and bagged.

Station 11: Carton pack

The 5 components plus assembly hardware (bolts, washers, Allen key) and the multi-language manual go into a single double-wall carton with corner protectors. Carton seal, label, and stack onto pallets.

Line cycle time

A well-run line outputs 25-40 chairs per hour with 8-12 workers. That maps to 200-320 chairs per day per line. A typical mid-size Anji factory has 4-8 lines running. Output: 1,000-2,500 chairs per day. The biggest factories run 6,000+ chairs per day across multiple buildings.

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