The past few weeks have been challenging when it comes to getting inventory, especially mattresses. We used to get mattress trucks each week, reliably, from each supplier. We’ve seen our lead times grow from 1 week to 2 weeks to 1 month, and now it’s 6 to 8 weeks. Why is this happening?
- Spunbond is used to encase coil units for mattresses. It is also used by federal agencies for PPE (personal protective equipment) and Clorox wipes. There is a nationwide Spunbond shortage that affects the manufacture of coil units.
- Needlepunch is a material that is being used as a substitute for Spunbond, but it slows the manufacturing of coils by 40%.
- Covid-19 isn’t our only issue, unfortunately! Foam is now on allocation due to the recent hurricanes in Louisiana. FXI is one of the country’s largest foam suppliers, and the damage to their plant has affected the availability of “TDI”, which is the key chemical ingredient in polyurethane foam manufacturing. It is projected that mattress manufacturers may only receive 70 – 80% of the foam that they order over the next several weeks.
- One of our suppliers is pursuing numerous options to recover, including alternate sources for coil units, as well as manufacturing their own coil units.