The design and manufacture of hot tub covers has come a long way since the early days. Hot Tub Works is proud to use a fully computerized design, cutting and sewing process to ensure that covers are made to exact dimensions.
But computers can’t do it all, we tried computerized stitching, and you know what? Our seam team does a better and faster job. And our designers double check all designs before it is sent into production. In other areas of production, we have other vital team members that perform precise functions, as your new hot tub cover moves through our state of the art assembly line.
From design and layout, to boxing for shipment, we have used the Kaizen method of continuous improvement to fine tune every step of the process. If you’re interested in how we do it ~ how we make America’s most popular hot tub cover, and do it with the highest marks for customer satisfaction ~ read on.
Whether you are ordering online, or filling out our spa cover dimensions form, or just calling us with dimensions and some information about your spa, your order begins with our experienced team of cover techs – who know all the pitfalls of spa cover ordering, and have a process to root out errors – even if your dimensions are wrong!
Our order team can process over 250 spa cover orders per day! We’ve recently added yet another team member in this dept. (10 people now!) to help customers with order placement. They carefully check each order and confirm all details before forwarding your spa cover onto our production team.
In Production Control, our hot tub cover designers take the measurements and information about the spa, along with all of the specifications for the cover design and feed it into our CAD program. A CAD file is produced which is the digital design of your spa cover. using computerized design, we are able to send the measurements to our cutting machines, which begins our manufacturing process.
The CAD file is first sent to the Foam Room. Our technicians load the proper size, thickness and weight onto the cutting machine, which verifies the correct foam core is being used. The computerized cutting table quickly cuts the foam into the exact shape specified by the CAD file, with a least amount of waste possible. After the foam is cut and tagged with the manuf. number, it rolls down the line to be reinforced with a steel channel, and then vacuum-sealed. Wrapped in one or two layers of 6-mil vinyl sheeting, the ends are double heat welded, and then the air is sucked out, resulting in a super snug plastic barrier around the foam core, which prevents tears or rips, and locks out moisture.
Next, the CAD file is sent to the Vinyl Room. Technicians choose the correct color vinyl, and lay the bolt on the feeding machine. As it rolls out across the table, the vinyl is inspected for any imperfections before the automated cutting machine carves a quick and correct cut, in just the exact size. The vinyl is tagged with the same manufacturing number as the foam, and the vinyl heads to the Sewing Room.
In the Sewing Room, our seam team takes pride in the quality of their stitches, between top and side panels, skirts, handles, zipper and scrim. With over 25 seamers in this department, it’s one of the largest (and noisiest). Besides sewing the ‘bag‘ for the foam cores, there are 27 different reinforcement points that are stitched up tight by the seam team. With the integration of the original CAD file prompting the sewing machines and seamers, we have the most state of the art sewing room in the business.
Onto the Assembly Room! In here, we ‘marry’ the vacuum-sealed foam cores with the vinyl bag and zip up the reinforced edge. Now, two quality control inspectors view every spa cover from all angles, making 24 different quality checks on every cover. After the cover is certified as ready to ship, it makes a short trip via rolling cart to the packing and shipping area.
In the Shipping Room our team packs your cover in a heavy gauge plastic, and then slides the cover into a right sized box, choosing one of 30 different box sizes we stock. Once it’s boxed up, it’s ready to go, and is immediately weighed and labeled for shipment, and rolled down the gangway for one of our 3 daily pick-ups.
~ The manufacturing process for spa covers seems complicated, but we have it down to a science of efficiency. But that’s not our only secret – people love working here. We try hard to create a low-pressure manufacturing environment. We don’t bonus our teams on increasing production, we bonus them on reducing mistakes, material waste and accidents.
Here’s a video of our hot tub cover factory, if you want to really see how the best hot tub covers are made!