Furniture retailer Coricraft has managed to replace R79.59-million worth of imports with locally manufactured products between the second quarter of 2024 and the second quarter of 2025, creating 23 jobs and shifting the production of 5 000 units to its Epping factory in Cape Town.

The company also recorded a 38% improvement in sewing efficiency and an 8.3% rise in overall factory performance between the second quarters of 2024 and 2025.

These gains follow a localisation programme that was implemented at Coricraft’s Epping facility in partnership with the Localisation Support Fund (LSF) and industrial engineers from Dizani Consulting.

Through the introduction of “lean” manufacturing practices, real-time monitoring and standardised planning, factory efficiency improved from 36% at the start of the programme in 2022 to 50% when it concluded in May this year.

The lean manufacturing principles were applied to systematically improve efficiency, reduce waste, and align production with actual demand. The company implemented time-and-motion studies to identify inefficiencies and standardised workflows to ensure consistency and reduce errors. Production layouts were optimised for smooth material flow, while a pull system was introduced so products were made only as required, limiting excess inventory.

Moreover, daily performance tracking using dashboards and accountability routines created visibility into productivity and encouraged continuous improvement.

Meanwhile, the “5S” methodology – sorting, organising, cleaning, standardising, and sustaining – was embedded to maintain an orderly, efficient workspace.

Collectively, these measures enabled Coricraft to raise sewing efficiency by 38%, improve overall factory performance by 8.3%, and expand local production of units previously imported.

“By producing more locally at Coricraft, we are securing jobs, strengthening suppliers, and proving that South African manufacturing can compete at scale,” Coricraft and The Foschini Group (TFG) Home group director Shani Naidoo said.

The localisation drive has had spillover effects across the value chain, with much of the timber, board and foam used in Coricraft’s upholstered furniture now sourced domestically.

LSF CEO Irshaad Kathrada said on September 23 that the initiative underscored how localisation could stimulate demand across upstream industries.

“The Coricraft initiative is a powerful demonstration of the impact localisation can have on jobs and growth in South Africa. By embedding lean principles and localising production, we’ve not only secured opportunities within the Epping factory but also supported dozens of suppliers and ancillary industries across the country,” he said.

The intervention aligned with the Furniture Industry Master Plan, adopted in 2021 by the Department of Trade, Industry and Competition and the South African Furniture Initiative (SAFI), which aims to strengthen competitiveness in the domestic furniture sector.

Coricraft’s parent company, TFG, has made localisation a central strategy across its brands, including @Home.

TFG CEO Anthony Thunström said the results of the Coricraft localisation programme reflected the group’s long-term focus on rebuilding domestic manufacturing capacity.

“This shows TFG’s commitment to world-class local manufacturing that creates jobs, builds resilience, and reduces reliance on imports,” he said.

SAFI CEO Greg Boulle said the lessons from Coricraft’s turnaround were applicable to the wider industry.

“Coricraft’s lean manufacturing transformation proves that every furniture manufacturer in South Africa can dramatically improve their competitiveness – regardless of size. By embracing lean principles and fostering a culture of continuous improvement, manufacturers can slash production costs, maximise returns on their investments, and go head-to-head with cheap imports.”

Coricraft has indicated that the localisation initiative will be expanded, with further product ranges earmarked for local production.