0:00:03 > 0:00:06Where are you going? It's not there. There is the beginning of the shop.
0:00:06 > 0:00:08I'm completely lost.
0:00:08 > 0:00:10Love it or loathe it,
0:00:10 > 0:00:14the world's largest furniture shop has shaped the way we live.
0:00:14 > 0:00:16As soon as you're in, you can't get out, can you?
0:00:16 > 0:00:19You spend and spend and spend, really.
0:00:19 > 0:00:21Founded in 1943,
0:00:21 > 0:00:24Ingvar Kamprad established Ikea as a global brand
0:00:24 > 0:00:28before his recent death at the age of 91.
0:00:28 > 0:00:33His unique approach to business still guides staff today.
0:00:33 > 0:00:36I've always seen Ikea as more of a movement than a company.
0:00:37 > 0:00:40For the first time in its 75 year history...
0:00:40 > 0:00:41Hej-hej!
0:00:41 > 0:00:45..Sweden's most famous export has granted our cameras worldwide access.
0:00:45 > 0:00:46Namaste!
0:00:47 > 0:00:51We filmed the £34 billion operation over the course of a year...
0:00:51 > 0:00:54It is a big machine. It needs to be fed.
0:00:54 > 0:00:56..following their rapid global expansion...
0:00:58 > 0:01:02We're just entering one of the biggest markets in the world.
0:01:02 > 0:01:04I think that we're writing some history, actually.
0:01:04 > 0:01:08..discovering what it takes for a new product to make it to the shelves...
0:01:08 > 0:01:12So, I wanted to do a cot and a coffin, so I approached Ikea with that idea
0:01:12 > 0:01:14and they just said, "No, you're joking."
0:01:14 > 0:01:17..and learning the secrets of how it became one of the largest
0:01:17 > 0:01:21and most influential companies in the world.
0:01:21 > 0:01:26It is creativity versus commercialism and finding that beautiful balance.
0:01:51 > 0:01:53Every morning before the customers arrive,
0:01:53 > 0:01:57each of Ikea's 399 stores restock their shelves.
0:01:59 > 0:02:03I just received this and I have no clue where they go in.
0:02:03 > 0:02:04Follow the arrows!
0:02:04 > 0:02:06HE CHUCKLES
0:02:07 > 0:02:11In Helsingborg, Sweden, one employee has recently been promoted.
0:02:18 > 0:02:21But Jesper Brodin is no ordinary member of staff.
0:02:21 > 0:02:25He's worked for the company for 20 years, and just two days ago,
0:02:25 > 0:02:28became the fifth CEO in its 75-year history.
0:02:32 > 0:02:34Lots of butterflies in the stomach.
0:02:34 > 0:02:38Obviously, like anybody stepping into a new job, you think about,
0:02:38 > 0:02:42"Will I manage? Can I really add any value?
0:02:42 > 0:02:44"Will I make any sense?"
0:02:44 > 0:02:46And then you kind of figure it out.
0:02:46 > 0:02:50But this is my - what can it be? - seventh or eighth job in Ikea.
0:02:50 > 0:02:53So, maybe tenth job in life, so...
0:02:53 > 0:02:57..you tend to get a little bit more relaxed, also.
0:02:57 > 0:03:02But I also have a humble approach to it and don't overestimate your own importance.
0:03:02 > 0:03:08Jesper may be in charge, but he's starting his new job on the shop floor
0:03:08 > 0:03:12to get a better understanding of how the business works.
0:03:12 > 0:03:15The biggest learning so far this morning is the inefficiency
0:03:15 > 0:03:18in the unpacking, where some things are ready to sell
0:03:18 > 0:03:21and some things still need a lot of handling.
0:03:21 > 0:03:25Anything he learns could be rolled out in stores around the world.
0:03:27 > 0:03:31It can look like a detail, but when you start to do the math in Ikea, it's huge.
0:03:40 > 0:03:432.4 million Swedish krona.
0:03:43 > 0:03:47So, a quarter of a million euros, about there.
0:03:47 > 0:03:49That's just one store. How many stores do you have?
0:03:49 > 0:03:51We're opening number 400.
0:03:52 > 0:03:53So, yeah, 400.
0:04:01 > 0:04:04- They must have one good one out of that!- I know!
0:04:04 > 0:04:07On the outskirts of Sheffield, a new store is taking shape.
0:04:07 > 0:04:11Do you want us to take them next door or do you want to sit them down?
0:04:11 > 0:04:13What do you want to do? It's five to.
0:04:13 > 0:04:18Six months into the build and management are introducing the project to the local press.
0:04:20 > 0:04:22We are a company that actually has a purpose
0:04:22 > 0:04:26and our purpose is to create a better everyday life for the many people
0:04:26 > 0:04:28and we'd like to do this through home furnishings.
0:04:28 > 0:04:33Yeah? Because we have a very strong belief that everybody deserves a good home, yeah?
0:04:33 > 0:04:38Gillian Drakeford is country retail manager in the UK.
0:04:38 > 0:04:41I'm really excited today that we're actually at this point,
0:04:41 > 0:04:44because most of the customers are saying, "Well, if I want to shop,
0:04:44 > 0:04:47"I either have to go south to Nottingham or north to Leeds,"
0:04:47 > 0:04:50so, yeah, this is a good thing for us.
0:04:50 > 0:04:53And it's fantastic to see the steel frame because once you have the steel frame,
0:04:53 > 0:04:56it moves very, very quickly.
0:04:56 > 0:05:00I am so pleased that I am the store manager of Ikea, Sheffield.
0:05:00 > 0:05:04Bringing the Ikea brand onto a new market is incredibly exciting and,
0:05:04 > 0:05:07of course, the number one question you all want to know is,
0:05:07 > 0:05:08"When is it going to open?"
0:05:08 > 0:05:12I can assure you nobody wants to know that more than me and this team sitting here!
0:05:12 > 0:05:13LAUGHTER
0:05:13 > 0:05:17But it will be as soon as our construction team tell us it's watertight.
0:05:18 > 0:05:22One of the company's most experienced managers, Gary Deacon,
0:05:22 > 0:05:23will be in charge of the store.
0:05:25 > 0:05:29I did build Belfast, and I built and managed Dublin,
0:05:29 > 0:05:33and now I'm building Sheffield, and I was also incredibly fortunate
0:05:33 > 0:05:36to run Wembley when it was the biggest store in the Ikea world,
0:05:36 > 0:05:37so how lucky does that make me?
0:05:39 > 0:05:41With the store due to open in July,
0:05:41 > 0:05:46the team have just seven months to recruit and train 500 new employees.
0:05:47 > 0:05:51These 500-odd jobs that you will be creating, will they make a big impact here, do you think?
0:05:51 > 0:05:55I think today, if you are passionate about home furnishings,
0:05:55 > 0:05:57you must be so excited that Ikea is coming,
0:05:57 > 0:06:03and, of course, for anybody to be told there are 500 real jobs coming, that must give those people hope.
0:06:03 > 0:06:04- ALL:- Whoo!
0:06:15 > 0:06:17The stores are nothing without products.
0:06:18 > 0:06:21Every year, hundreds of millions are mass-produced.
0:06:23 > 0:06:29One of their biggest sellers is the Billy bookcase, with one sold every ten seconds.
0:06:32 > 0:06:34For the last 40 years,
0:06:34 > 0:06:36they've been made in southern Sweden
0:06:36 > 0:06:40by one of the company's longest serving suppliers, the Gyllensvaans.
0:06:45 > 0:06:48It's here we produce a lot of furniture for Ikea.
0:06:48 > 0:06:50The Billy bookcase, for example.
0:06:51 > 0:06:54And here is my sister.
0:06:55 > 0:06:59My sister's husband. No, my daughter's husband!
0:06:59 > 0:07:00HE LAUGHS
0:07:01 > 0:07:06- My brother's sons, Morten and Philip.- Hej!- And my son.
0:07:06 > 0:07:07Hello.
0:07:07 > 0:07:10How many family members are in your company?
0:07:10 > 0:07:11I think it's nine.
0:07:12 > 0:07:13But I have to count.
0:07:13 > 0:07:14I think it's nine.
0:07:17 > 0:07:18That's my father.
0:07:20 > 0:07:24This is the letter my father got from Ingvar.
0:07:24 > 0:07:25It is our first contact with Ikea.
0:07:27 > 0:07:29What does it say?
0:07:29 > 0:07:30We want to buy furniture.
0:07:31 > 0:07:36And they did. Starting with just 120,000 units a year,
0:07:36 > 0:07:38growing to millions today.
0:07:39 > 0:07:41This is Morten.
0:07:41 > 0:07:46He is in charge of purchasing and contact with Ikea.
0:07:46 > 0:07:49- You've got the hardest job? - The toughest job. I think so, yeah.
0:07:51 > 0:07:55The factory takes delivery of sheets of chipboard before cutting...
0:07:56 > 0:07:58..laminating with protective foil...
0:08:00 > 0:08:02..packaging and sending to Ikea.
0:08:06 > 0:08:09This is the area where we receive the chipboards.
0:08:09 > 0:08:12We receive about 700 tonnes daily,
0:08:12 > 0:08:17and it is about 19 to 22 trucks every day coming with chipboard.
0:08:17 > 0:08:19This is a very big volume in the factory.
0:08:22 > 0:08:27The Gyllensvaans' factory is Ikea's biggest supplier of Billy bookcases.
0:08:27 > 0:08:30We produce about 170,000 weekly.
0:08:38 > 0:08:41This is the box folder where we make the box,
0:08:41 > 0:08:43and here we put in protection
0:08:43 > 0:08:46to protect the furniture that we have in the flatpack.
0:08:54 > 0:08:58We try to be more and more efficient every year
0:08:58 > 0:09:00so we can lower the prices
0:09:00 > 0:09:04as Ikea is expecting, and we can produce more furniture every year.
0:09:08 > 0:09:12Follow me. Let's go to breakfast.
0:09:12 > 0:09:16Until recently, the factory supplied over 6 million Ikea products globally.
0:09:16 > 0:09:18A few years ago,
0:09:18 > 0:09:21we delivered the Billy bookcase to the whole world.
0:09:21 > 0:09:26We delivered worldwide, to Asia, to Australia, all over.
0:09:26 > 0:09:29And we lost the volume to Asia.
0:09:30 > 0:09:35Mainly because Ikea wants to buy furniture more locally.
0:09:35 > 0:09:37- Was that hard?- It's a challenge.
0:09:39 > 0:09:44Yes. Billy is a bookcase that many producers want to produce.
0:09:44 > 0:09:48Huge volumes, quite a simple bookcase.
0:09:48 > 0:09:51We lost 600,000 bookcases.
0:09:51 > 0:09:52- Yes.- Approximately.
0:09:52 > 0:09:55- 10%?- Yes, 10%.
0:09:56 > 0:09:58We lost.
0:09:58 > 0:10:04We have never fired anybody because of lack of work, no.
0:10:04 > 0:10:05You can never feel confident.
0:10:08 > 0:10:10You never know, never know.
0:10:14 > 0:10:17To keep their 240 staff in work,
0:10:17 > 0:10:21Eric and Morten have been trying to secure a lucrative contract
0:10:21 > 0:10:24for a new range of cupboards called Platsa.
0:10:24 > 0:10:30If we get the Platsa deal, we will get to produce about 700,000 doors
0:10:30 > 0:10:35to the Platsa range, and it is for North America and North Europe.
0:10:35 > 0:10:38They have already produced a small number,
0:10:38 > 0:10:41which failed a water damage test at Ikea's lab in Almhult,
0:10:41 > 0:10:43putting them three months behind schedule.
0:10:44 > 0:10:49The challenge is to fix all the surface demands.
0:10:49 > 0:10:53Very, very tough surface demands for water.
0:10:53 > 0:10:54We have to solve it.
0:10:54 > 0:10:56You only have one client, right?
0:10:56 > 0:10:58Yes, one client, one customer.
0:11:02 > 0:11:05The factory is one of hundreds worldwide
0:11:05 > 0:11:07mass-producing flatpack furniture.
0:11:10 > 0:11:14The decision whether to give the Gyllensvaans the contract will be made
0:11:14 > 0:11:18at design and production HQ in Almhult.
0:11:18 > 0:11:23Platsa is a new range coming in that Gyllensvaans has been part of quoting.
0:11:23 > 0:11:28As it seems right now, they will have 45% of the matrix.
0:11:29 > 0:11:33Simply, we have to make sure that the products are being produced and sold
0:11:33 > 0:11:40under the brand of Ikea, that they manage the daily life in a family at home.
0:11:40 > 0:11:44You should be able to spill out a couple of coffee or a glass of water
0:11:44 > 0:11:48without destroying the furniture, simply.
0:11:48 > 0:11:50So, that is what the task is about.
0:11:57 > 0:11:59- Hej.- Hej. Hello again.
0:11:59 > 0:12:03Olof Ahlberg is in charge of the Platsa contract.
0:12:03 > 0:12:05After they failed the water test,
0:12:05 > 0:12:10he is concerned about the factory passing a retest and hitting the delivery schedule.
0:12:10 > 0:12:12What I see as a risk is that...
0:12:12 > 0:12:14Because, I mean, if we don't manage this,
0:12:14 > 0:12:19there is a possibility, of course, to place the matrix at the other supplier.
0:12:19 > 0:12:24Now, we have been working with this for at least two, three months.
0:12:24 > 0:12:28We need to make progress, otherwise he takes the decision.
0:12:28 > 0:12:29Because time is flying, of course.
0:12:29 > 0:12:35- Also in this case, we're getting closer and closer to first production and so on.- Yes, yeah.
0:12:35 > 0:12:38You saw the letter down there and the demands,
0:12:38 > 0:12:44it is the same today as it was in... Before.
0:12:44 > 0:12:48It is high demands, good quality, right price and then they buy.
0:12:50 > 0:12:51This is a happy factory.
0:12:53 > 0:12:56We are very important for the area, also.
0:12:56 > 0:12:58Our workers feel that we can work together.
0:12:58 > 0:13:00Hej-hej!
0:13:00 > 0:13:02My father did it this way,
0:13:02 > 0:13:07and every year you had to produce faster and better quality.
0:13:07 > 0:13:09They put the pressure on us and we...
0:13:10 > 0:13:12- Try to live up to it.- Yes.
0:13:12 > 0:13:15You look a little bit worried, I must say.
0:13:15 > 0:13:18It creates a bad feeling in my stomach.
0:13:24 > 0:13:28The factory won't get the contract until they pass a retest.
0:13:29 > 0:13:32Ikea have some very high standards, don't they?
0:13:32 > 0:13:37Yeah, I think the customer demands, they increase year by year,
0:13:37 > 0:13:39and, of course, that puts requirements on us, Ikea,
0:13:39 > 0:13:42and also the suppliers and our partners.
0:13:42 > 0:13:47So, for sure, it is tough demands on quality, for instance,
0:13:47 > 0:13:50and we can't compromise on that area.
0:13:50 > 0:13:52But it's also a business?
0:13:52 > 0:13:54It is business in the end, for sure.
0:13:54 > 0:13:57No question about it. We need to secure the demands.
0:14:17 > 0:14:19This is where all these products that you see here,
0:14:19 > 0:14:22they are born here, they started here.
0:14:22 > 0:14:23Like the PS Maskros lamp.
0:14:23 > 0:14:26That idea started here and then it has been developed
0:14:26 > 0:14:28and sold all over the world.
0:14:28 > 0:14:32James Futcher is starting work on a quirky new collection.
0:14:32 > 0:14:38- Can we catch up later about the stuff you missed?- Yes.- OK, cheers.
0:14:38 > 0:14:40Aimed at a younger market,
0:14:40 > 0:14:44James and the team are showing some ideas to his boss,
0:14:44 > 0:14:45head of design, Marcus Engman.
0:14:47 > 0:14:52- OK.- Yes, we have products that are a little bit more open for interpretation.
0:14:52 > 0:14:54One of them being this leg set.
0:14:54 > 0:14:58- It comes in sections. - Then you put together your own legs?
0:14:58 > 0:14:59- Yes.- That's one thing.
0:14:59 > 0:15:01- What's more, then? - Build your own rug.
0:15:04 > 0:15:06So, it comes in maybe a kit
0:15:06 > 0:15:07with certain cut shapes.
0:15:07 > 0:15:10- OK. All in all, that would be quite nice, actually.- Yeah.
0:15:11 > 0:15:15Many of our customers, especially the younger generation,
0:15:15 > 0:15:17they want to have products that are unique,
0:15:17 > 0:15:19and each product looking different,
0:15:19 > 0:15:22so it's a big change for us to see how we can work with
0:15:22 > 0:15:24mass production, but make unique products.
0:15:30 > 0:15:32Hanna, when you've finished there,
0:15:32 > 0:15:36could you bring up the ceramic 3-D drawings?
0:15:36 > 0:15:38- Yeah.- Cheers.- Thanks.
0:15:38 > 0:15:42One of Ikea's newest designers, Hanna-Kaarina,
0:15:42 > 0:15:44is pitching some of her ideas into the collection.
0:15:46 > 0:15:48What's your idea?
0:15:48 > 0:15:50A vase.
0:15:50 > 0:15:54I was thinking that we always try to make everything exactly the same,
0:15:54 > 0:15:59but maybe we could use the whole manufacturing process in a different way,
0:15:59 > 0:16:03and actually make pieces that are based on the same shape,
0:16:03 > 0:16:05but everything becomes unique.
0:16:05 > 0:16:09When you take it out from the mould, you just place it on the surface.
0:16:09 > 0:16:12You use your hands, so basically it's going to be...
0:16:12 > 0:16:15also unique pieces.
0:16:15 > 0:16:17Have you done it before?
0:16:17 > 0:16:18- By mistake!- OK.
0:16:19 > 0:16:24So, it's actually embracing a mistake?
0:16:24 > 0:16:26Yeah. I think that could be quirky.
0:16:26 > 0:16:28- That could be really cool.- Yeah.
0:16:28 > 0:16:31Today, we make everything the same in big volumes,
0:16:31 > 0:16:37but Hanna's got this idea of sticking a finger in each vase
0:16:37 > 0:16:39or handprint, to make it different.
0:16:39 > 0:16:41I mean, that's really crazy, but when you think about it,
0:16:41 > 0:16:45it's really fun and it makes mass production
0:16:45 > 0:16:47in a different way.
0:16:47 > 0:16:50We can have mass production with uniqueness.
0:16:50 > 0:16:52Do you think that each one will come out different?
0:16:52 > 0:16:54Yeah, I think so.
0:16:54 > 0:16:57If we just play a bit with the clay as well.
0:16:57 > 0:17:01It's quite nice to do something a bit more experimental.
0:17:01 > 0:17:04That's not what Ikea is usually doing,
0:17:04 > 0:17:10so that's a nice chance to shake the system as well, a bit.
0:17:10 > 0:17:12Why do you want to shake the system?
0:17:12 > 0:17:14Just for fun!
0:17:20 > 0:17:23I think the challenges are cost.
0:17:23 > 0:17:25That if it started to become too expensive,
0:17:25 > 0:17:29then we don't really fulfil what we want to do at Ikea.
0:17:29 > 0:17:34The next stage is to get the supplier to really understand what our idea is.
0:17:34 > 0:17:36To be on the factory floor,
0:17:36 > 0:17:40to work with the specialists in the ceramic factory,
0:17:40 > 0:17:42in the production line,
0:17:42 > 0:17:45and make that idea work within the process
0:17:45 > 0:17:49so we can produce thousands of vases that are different.
0:18:02 > 0:18:06It's going to be exciting to see how Hanna's idea comes to fruition.
0:18:06 > 0:18:11Yeah. And if we have to modify the shape, as well,
0:18:11 > 0:18:13let's see what we have to do.
0:18:13 > 0:18:17Hopefully they have some ideas to see how we can make the idea work.
0:18:20 > 0:18:24Hanna-Kaarina's design is so unusual,
0:18:24 > 0:18:27she and James have come to meet with a supplier who is used to
0:18:27 > 0:18:29mass-producing millions of products for Ikea.
0:18:32 > 0:18:37- It's not such an industrialised set-up so far, so it seems promising.- Yeah.
0:18:39 > 0:18:43They start by inspecting a sample with the supplier's management.
0:18:46 > 0:18:49- Yes.- But the vase has no imperfections.
0:18:51 > 0:18:53I don't think they fully understand.
0:18:53 > 0:18:56It's actually about doing something, provoking a discussion.
0:18:56 > 0:18:58So then we can talk about all the steps.
0:18:58 > 0:19:00Yeah, because what we can actually do here...
0:19:00 > 0:19:03- Yeah, like squeeze one.- Yeah.
0:19:04 > 0:19:06Then it's also,
0:19:06 > 0:19:08I kind of think it's not about you doing it,
0:19:08 > 0:19:12it's actually about having a discussion, because I don't think they understand it fully.
0:19:12 > 0:19:16From what we've seen, what could be possible that they could do in production?
0:19:16 > 0:19:19IN ENGLISH:
0:19:22 > 0:19:23But we don't want that.
0:19:26 > 0:19:30That's what we want. It is to understand what can we do
0:19:30 > 0:19:34within the production steps so then we can design something.
0:19:34 > 0:19:35A little bit frustrating.
0:19:35 > 0:19:38I thought the supplier would have been more prepared
0:19:38 > 0:19:40and we would have had more samples,
0:19:40 > 0:19:41and be really able to dive in
0:19:41 > 0:19:45and to see how we could create this imperfection.
0:19:45 > 0:19:49In general, it's a question like how much we can modify.
0:19:49 > 0:19:52- Maybe that's too much.- Yeah.
0:19:52 > 0:19:55- Is it just a level of... just a little?- Yeah.
0:19:55 > 0:19:58It's how do we achieve something that looks different.
0:19:58 > 0:20:00IN ENGLISH:
0:20:08 > 0:20:10That's fine. That's even nicer.
0:20:10 > 0:20:12Ah, OK.
0:20:12 > 0:20:15Then that one actually has a story, it belongs to that person,
0:20:15 > 0:20:17that's their fingerprint.
0:20:19 > 0:20:22Here we can make handmade individual products that are
0:20:22 > 0:20:26available for the many people, because it will be in a price picture.
0:20:30 > 0:20:32But I think that's where we need to go through the steps -
0:20:32 > 0:20:35how do we do it so we get the right price?
0:20:35 > 0:20:37It's like a give and take relationship.
0:20:37 > 0:20:40It seems the bosses have finally understood,
0:20:40 > 0:20:46but the real test will be tomorrow, when the team return to see the workers make prototypes.
0:20:46 > 0:20:49We want Hanna to have all of the drawings ready tomorrow,
0:20:49 > 0:20:51so then we can bring up the discussion again.
0:20:51 > 0:20:53Are these shapes possible?
0:20:53 > 0:20:55It's all fun making something that looks good,
0:20:55 > 0:20:58but if it's not at the right price, then you can't afford to buy it.
0:21:08 > 0:21:10- HE SINGS:- # She told me she missed school today...#
0:21:16 > 0:21:18Since the press launch,
0:21:18 > 0:21:21the Sheffield store has fallen a month behind schedule
0:21:21 > 0:21:25and is now due to open in August, just 16 weeks away.
0:21:25 > 0:21:29When we get on site now, you're going to say to me, "Gary, that store's not opening."
0:21:29 > 0:21:31You look at it now and you think, really?!
0:21:31 > 0:21:34Are people going to be shopping in that? Is that going to be finished?
0:21:34 > 0:21:37Not this August, you're thinking next August.
0:21:37 > 0:21:39No, seriously, you are. Look at that.
0:21:39 > 0:21:40Seriously, can you believe?
0:21:40 > 0:21:45We need eight weeks to shop fit it, so eight weeks before, they've got to hand that over.
0:21:45 > 0:21:47The lift shaft at the back still isn't in.
0:21:47 > 0:21:51There's no lift. There's no roof on this half, is there?
0:21:51 > 0:21:55Can you see a roof? That's not watertight, is it?
0:21:55 > 0:21:56You need it to be watertight?
0:21:56 > 0:21:58HE LAUGHS
0:21:58 > 0:22:01Otherwise the trades can't come in. The electricians, the plasterers.
0:22:01 > 0:22:04Nobody can start until it's watertight, so let's go and meet them
0:22:04 > 0:22:05and see what they've got to say.
0:22:23 > 0:22:2516 weeks from now.
0:22:25 > 0:22:2716 weeks.
0:22:27 > 0:22:30It is hard to believe, isn't it, we're going to stand here in 16 weeks
0:22:30 > 0:22:32and that's going to be an operating unit.
0:22:32 > 0:22:36But I trust. I keep saying I trust, don't I? I trust. I do trust.
0:22:44 > 0:22:46Well, it needs to, doesn't it?
0:22:46 > 0:22:49Cos there's no back end and no roof at the moment.
0:22:49 > 0:22:51- Eh?- There's no back end and no roof.
0:22:51 > 0:22:53HE LAUGHS
0:22:54 > 0:22:57He seems to think it's OK! He knows.
0:23:02 > 0:23:03When do we go watertight?
0:23:05 > 0:23:07Overall watertight will be by mid-June.
0:23:07 > 0:23:09Mid-June?! Oh, Christ.
0:23:14 > 0:23:17OK, Adil, if you'd like to go With Gareth.
0:23:17 > 0:23:21With Gary worried about the build, on the other side of town,
0:23:21 > 0:23:23a massive recruitment drive has begun.
0:23:24 > 0:23:28The Steel City, there were so many people that lost their jobs
0:23:28 > 0:23:31and morale went really down, so I think it's a great boost for the city,
0:23:31 > 0:23:37that Ikea is coming to Sheffield. Exciting.
0:23:37 > 0:23:38Come on, I don't bite!
0:23:38 > 0:23:43Ikea have had over 4,500 applications for just 500 jobs.
0:23:43 > 0:23:48Can I have the next group for... # Getting to know you. #
0:23:48 > 0:23:53Maria Crosby will be the logistics manager at the new Sheffield store,
0:23:53 > 0:23:56and is part of the team responsible for recruiting staff.
0:23:56 > 0:23:57Can you go and get me a form?
0:23:57 > 0:24:00Can you get me one of those candidate sheet forms?
0:24:00 > 0:24:03They're not just looking at CVs and skills.
0:24:03 > 0:24:06At Ikea, it's all about having the right personality.
0:24:06 > 0:24:10We don't want everyone to be the same, we're not robots.
0:24:10 > 0:24:13We just want to be similar. Yeah?
0:24:13 > 0:24:18The culture and values in Ikea, it's the same here in England, in Sheffield,
0:24:18 > 0:24:22as it is in Dubai or Spain or, obviously, Sweden.
0:24:22 > 0:24:25It doesn't matter what Ikea you go into, it's exactly the same.
0:24:27 > 0:24:31The team are looking for people who possess the eight key values
0:24:31 > 0:24:34that Ingvar Kamprad founded the company on in 1943.
0:24:38 > 0:24:42OK, so humbleness and willpower, simplicity, togetherness...
0:24:44 > 0:24:47This is where I get stuck. Cos they're my three.
0:24:48 > 0:24:50My three, my three that I hold dear.
0:24:50 > 0:24:53Humbleness and willpower is a massive one for me.
0:24:53 > 0:24:55Togetherness is also amazing.
0:24:55 > 0:24:58Without togetherness, we have nothing.
0:24:58 > 0:25:01This is very different to any other company you've ever worked in.
0:25:01 > 0:25:04It really is. I can't stress that enough.
0:25:04 > 0:25:08Being able to have the opportunity to work in that box is amazing.
0:25:08 > 0:25:09What I want you to do,
0:25:09 > 0:25:14and I know some of you might be a little uncomfortable doing it, but we don't bite at all.
0:25:14 > 0:25:19I just want you to say hello and where in the store do you think you can see yourself working.
0:25:19 > 0:25:22I'm Tom, I live in Greenhill in Sheffield.
0:25:24 > 0:25:29Where I see myself in Ikea would definitely be something customer facing.
0:25:29 > 0:25:31The way I see it, it's helping people.
0:25:33 > 0:25:35Hi, I'm Luke, I currently...
0:25:35 > 0:25:38I live in Rotherham and currently work for Poundland...
0:25:40 > 0:25:43..as a replenisher/sales assistant,
0:25:43 > 0:25:48but I am willing to climb the ladder in any business.
0:25:48 > 0:25:49Have you enjoyed today?
0:25:49 > 0:25:51INAUDIBLE RESPONSE
0:25:52 > 0:25:55So, getting to work for 5am, would that be an issue?
0:25:56 > 0:25:58I could ask my mum to drop me off.
0:26:00 > 0:26:03- She won't mind.- Excellent, so you'll be able to...
0:26:03 > 0:26:05I'm fully flexible.
0:26:05 > 0:26:10I do it to look after my family, cos I pay my mum board.
0:26:10 > 0:26:12We pay £8.45 an hour.
0:26:12 > 0:26:15- Is that to anyone? - To anyone, yeah.
0:26:16 > 0:26:18- Is that OK?- Yeah.- OK.
0:26:18 > 0:26:23He was a very, very humble, very much a family person, which is,
0:26:23 > 0:26:25in terms of values, that really, really fits.
0:26:25 > 0:26:28But he was also determined and eager.
0:26:28 > 0:26:30It seemed to go well, the interview?
0:26:30 > 0:26:32Yeah, yeah, it went really well.
0:26:32 > 0:26:35What were you and Maria talking about?
0:26:35 > 0:26:37- Was she called Maria?- Yeah. - I thought she were called Claire!
0:26:37 > 0:26:39INTERVIEWER CHUCKLES
0:26:39 > 0:26:43OK, so, Luke, you can say, I want to be a manager.
0:26:43 > 0:26:46I want to be the best I can be.
0:26:46 > 0:26:47I want to know what that looks like.
0:26:47 > 0:26:51I didn't know Ikea even existed, I'll be honest with you.
0:26:51 > 0:26:53I thought it were Lidl at first.
0:26:53 > 0:26:56They've got a nice uniform, but this one's just yellow.
0:26:58 > 0:27:00You look like a McDonald's straw in it or something.
0:27:05 > 0:27:07Almost look a bit emotional! Bless her!
0:27:07 > 0:27:09You get that sometimes, don't you?
0:27:09 > 0:27:13Keep your eyes out for Luke. He'll be my manager soon!
0:27:48 > 0:27:55- Hello.- How are you?- It will be interesting to see the samples today.- It will.- Yeah.
0:27:55 > 0:27:58Having failed Ikea's strict water test regulations,
0:27:58 > 0:28:02Morten is preparing a new batch of cupboard samples to be reassessed.
0:28:03 > 0:28:09The first time we failed because of the 16 hour water requirements.
0:28:09 > 0:28:11It is like a water test.
0:28:11 > 0:28:13Take a drop of water,
0:28:13 > 0:28:16put it under a glass for 16 hours, and then it should make
0:28:16 > 0:28:19no structure change or visible changes to the board.
0:28:21 > 0:28:26The last samples failed when the external foil wrap blistered.
0:28:26 > 0:28:30This is the new foil that we are testing.
0:28:30 > 0:28:34Just making ten samples and then send to the test lab.
0:28:34 > 0:28:38Let's just hope also that it can pass all the tests.
0:28:38 > 0:28:42The foil is glued to MDF panels using a specialist machine.
0:28:44 > 0:28:46The board is coming out.
0:28:49 > 0:28:51The surface is looking good.
0:28:54 > 0:28:58But we have to look closer to really see if it's perfect.
0:29:03 > 0:29:07Last year, we cut down some shifts and we have kept all the people,
0:29:07 > 0:29:12but we lost some volume to Asia and now we are fighting to get it back.
0:29:25 > 0:29:26If this test doesn't succeed,
0:29:26 > 0:29:30I'm quite hesitant that we will get this volume,
0:29:30 > 0:29:34so failure is not really an option for us right now.
0:29:34 > 0:29:36We have to succeed with the test.
0:29:36 > 0:29:38It looks good to me.
0:29:45 > 0:29:46Then we have problems.
0:29:56 > 0:30:02Ikea test more than 15,000 products a year in their hi-tech purpose-built lab.
0:30:03 > 0:30:05The first sign - no photography, right?
0:30:12 > 0:30:14This is where the magic happens.
0:30:17 > 0:30:19This is where we make all the mechanical testing
0:30:19 > 0:30:22for all different kind of furnitures,
0:30:22 > 0:30:24like chairs, like sofas, like beds.
0:30:27 > 0:30:32We have another room here where we test textile and surfaces,
0:30:32 > 0:30:35especially the surface resilience to different fluids and so on.
0:30:38 > 0:30:41Today, I have a sample from Gyllensvaans.
0:30:41 > 0:30:44And I am testing cold liquids, water.
0:30:51 > 0:30:54So we have the still water and a filter paper...
0:30:55 > 0:30:56..which I put on the surface.
0:30:59 > 0:31:01And I leave it there for 16 hours.
0:31:15 > 0:31:17The test is ongoing right now.
0:31:17 > 0:31:19We're coming to an end when it comes to time,
0:31:19 > 0:31:22where we need to make sure we have the tests in place.
0:31:24 > 0:31:27Otherwise we will jeopardise the sale starts, etc.
0:31:27 > 0:31:30It has been some hiccups and failures along the road.
0:31:30 > 0:31:37If not, we need to move on and place the matrix and the volume at another supplier.
0:31:37 > 0:31:39I think they are a little bit nervous, yes.
0:31:44 > 0:31:47Now I am looking for some kind of a change.
0:31:47 > 0:31:52I am looking for any mark, or if I see some bubbles or structure change.
0:31:54 > 0:31:56If I see a strong mark, it will fail.
0:31:56 > 0:32:02If I see some small or large structure change, it will also fail.
0:32:02 > 0:32:06The Gyllensvaans will find out if they've passed the test in 24 hours' time.
0:32:07 > 0:32:10We are very thorough when we do the assessments,
0:32:10 > 0:32:13so we won't let any bad samples get in the store.
0:32:21 > 0:32:27So they could touch in this, anywhere in this striped part.
0:32:27 > 0:32:30James and Hanna-Kaarina have been struggling to translate
0:32:30 > 0:32:32their imperfect vase idea to the supplier.
0:32:39 > 0:32:42I think it's something, when we go into the factory,
0:32:42 > 0:32:43when we start to pull it out,
0:32:43 > 0:32:47Hanna can actually start to explain what her idea is.
0:32:47 > 0:32:49IN MANDARIN:
0:32:56 > 0:32:58Now that management understand,
0:32:58 > 0:33:03the big test is whether the workers can actually create Hanna-Kaarina's maverick idea.
0:33:03 > 0:33:10The big final thing is to really physically pick the vase out of the mould.
0:33:10 > 0:33:14Here we go. Have you explained to him not to be careful?
0:33:14 > 0:33:16I am worried that it's going to go wrong.
0:33:16 > 0:33:19IN MANDARIN:
0:33:29 > 0:33:32Relax. You know, it's not about being careful.
0:33:32 > 0:33:34If he needs to put his fingers in to get it out...
0:33:39 > 0:33:41Now take it out. Yeah, brilliant.
0:33:41 > 0:33:44Put it down. Yes, that's it.
0:33:44 > 0:33:47- That's one.- Perfect!
0:33:47 > 0:33:49That was actually the magic moment.
0:33:49 > 0:33:50They actually understand it.
0:33:50 > 0:33:52It looks like it's possible.
0:33:52 > 0:33:54I wouldn't say we've solved it all.
0:33:54 > 0:33:57Sort of happy, but confused at the same time.
0:33:57 > 0:34:00Maybe it's going to be OK.
0:34:01 > 0:34:03Now they know the factory can make the vase,
0:34:03 > 0:34:08James is keen to ensure each one being unique hasn't added too much to the price.
0:34:08 > 0:34:13How did it look, do you have rough price ideas on the imperfection?
0:34:13 > 0:34:16That's quite important, to know roughly where we are on those.
0:34:16 > 0:34:20If you just take that green one, what price?
0:34:20 > 0:34:21Cos, I mean, that's not far off.
0:34:21 > 0:34:24IN ENGLISH:
0:34:30 > 0:34:31That's quite a lot.
0:34:32 > 0:34:37The team will find out the final price when the vase samples arrive in Sweden in a few weeks' time.
0:34:40 > 0:34:41But I'm a little bit worried.
0:34:42 > 0:34:44I mean, how much are those vases going to be?
0:34:44 > 0:34:47Cos, I mean, it's not much difference in material.
0:34:56 > 0:34:58With just two months until the grand opening,
0:34:58 > 0:35:01the Sheffield store has a roof, but it's still not finished.
0:35:02 > 0:35:04Recruitment, however, is complete.
0:35:07 > 0:35:11Are you ready for this? Do you want to know why it's called Ikea?
0:35:11 > 0:35:14Because they've got the I at the start of his first name,
0:35:14 > 0:35:18then they've got the K at the start of his second name.
0:35:18 > 0:35:20Took it all in, didn't he?
0:35:22 > 0:35:27Luke has landed one of the 500 jobs and is about to start his in-store training.
0:35:27 > 0:35:29- INTERVIEWER:- Why do you think you got the job?
0:35:29 > 0:35:34Because I've got experience in retail, and I like customers.
0:35:34 > 0:35:36What do you think the customers will be like at Ikea?
0:35:36 > 0:35:39Well, they're all from Sheffield, mostly, aren't they?
0:35:39 > 0:35:43So they're going to have banter. They're going to have a laugh.
0:35:47 > 0:35:49As the Sheffield store isn't finished,
0:35:49 > 0:35:52new recruits are learning the ropes in Nottingham.
0:35:52 > 0:35:54You see how the number ends in 20?
0:35:54 > 0:35:57So, anything with a number that is 20 or bigger means a forklift has to
0:35:57 > 0:36:01get it down. Everything else below is available for the customer.
0:36:01 > 0:36:03My job is replenishment.
0:36:04 > 0:36:07We have to get all the pallets done before the shop opens.
0:36:10 > 0:36:12I think, for me, it's more than just stacking shelves.
0:36:12 > 0:36:15I want the co-workers engaged with the product as well, and what we sell,
0:36:15 > 0:36:17and be passionate about it.
0:36:17 > 0:36:19Half of these things, I've never seen my life.
0:36:19 > 0:36:20I don't even know what you'd use that for.
0:36:20 > 0:36:24I don't even know what you use that for.
0:36:24 > 0:36:26If I looked at that, I'd have thought it was something
0:36:26 > 0:36:28you play Russian roulette with.
0:36:29 > 0:36:31You know when you go to the casino and chuck that ball in?
0:36:31 > 0:36:33That's what I'd this it was.
0:36:33 > 0:36:37Some days are very hectic, so you do have to have a bit of speed
0:36:37 > 0:36:40about you and have a keen eye for detail.
0:36:40 > 0:36:42I know what it's for.
0:36:42 > 0:36:43Pineapple. So, yeah.
0:36:43 > 0:36:44Pineapple splitter.
0:36:46 > 0:36:48Oh, no, it's an apple slicer.
0:36:48 > 0:36:49Not a pineapple one.
0:36:49 > 0:36:50HE SMIRKS
0:36:58 > 0:37:01Gary? You can ring the bell.
0:37:01 > 0:37:04- Ring the bell?- Or stand and stare, whichever is most effective.
0:37:04 > 0:37:05BELL RINGS
0:37:07 > 0:37:12The UK's top managers are assembled to hear an important update
0:37:12 > 0:37:14about the Sheffield store.
0:37:14 > 0:37:16So, that's the team that I've been working with
0:37:16 > 0:37:18for the last nearly 11 months now. You can't quite see it,
0:37:18 > 0:37:21but if you were to look closely at Kate and Laura,
0:37:21 > 0:37:23you will see how much they have aged in 11 months.
0:37:23 > 0:37:25LAUGHTER
0:37:25 > 0:37:27That's what opening a new store does for you.
0:37:27 > 0:37:28It's working with you, Gary.
0:37:28 > 0:37:30LAUGHTER
0:37:30 > 0:37:34- I just throw it out and you bat it back.- I did.
0:37:34 > 0:37:37OK, so, in terms of date,
0:37:37 > 0:37:40for the last eight weeks, we have been opening on the 31st of August.
0:37:40 > 0:37:43I think you have all received an e-mail to say now it is likely to be
0:37:43 > 0:37:44the 28th of September.
0:37:44 > 0:37:47You will get your invite, and I look forward to having what I hope will
0:37:47 > 0:37:51be a wonderful day with you, on what is looking like the 28th of September.
0:37:51 > 0:37:53Thank you.
0:37:53 > 0:37:54APPLAUSE
0:37:58 > 0:38:00- Well done.- Thank you very much. You were super.
0:38:00 > 0:38:02- Good, wasn't it?- Yes.
0:38:02 > 0:38:05As a company, we never like to say "Put back, delayed."
0:38:05 > 0:38:07We don't like to use that language.
0:38:07 > 0:38:11But, ultimately, it was hoping to open in July.
0:38:11 > 0:38:13Then we had a revised date of August 31st.
0:38:13 > 0:38:17Then, at the last minute, the very 11th hour, almost the 12th hour,
0:38:17 > 0:38:21we got this delay again of four weeks to the end of September.
0:38:21 > 0:38:24The truth is, we'll lose 6 million of sales by not opening,
0:38:24 > 0:38:26and therefore that will have an impact on the cost picture.
0:38:26 > 0:38:32And that means we need to look at how do we find that additional sales, yeah?
0:38:32 > 0:38:36So, will it come from pushing Gary and the team to really secure
0:38:36 > 0:38:39and over-perform? Ultimately, I have agreed with my board
0:38:39 > 0:38:46that our organisation will deliver the goals that have been set, and we just need to do that.
0:38:51 > 0:38:54Although the Sheffield building is now watertight, they're having to
0:38:54 > 0:38:57delay the opening to allow time to prepare the interior.
0:39:03 > 0:39:07It always feels a little bit of a disappointment when you have to move the date.
0:39:07 > 0:39:11But you can now see why we were not opening on the 31st of August.
0:39:11 > 0:39:14The 28th of September will be a super day, when we open.
0:39:17 > 0:39:20Having opened Belfast and Dublin, it's that always wanting to know,
0:39:20 > 0:39:22can you do better than you did last time?
0:39:22 > 0:39:26I think the pressure on Sheffield is that when we opened Dublin,
0:39:26 > 0:39:30I think it was accepted that it was the best store opening that we had ever achieved.
0:39:30 > 0:39:32Of course, because I was the guy who opened Dublin,
0:39:32 > 0:39:35I always knew that if I got Sheffield, it is another level.
0:39:35 > 0:39:38And of course, if it's not, it will be so personal.
0:39:38 > 0:39:39It will hurt me like hell.
0:39:48 > 0:39:51The test results of the Gyllensvaans cupboard samples are back.
0:39:54 > 0:39:57The latest data says that we passed the test.
0:39:57 > 0:40:01So now we finally have an approved test for Platsa.
0:40:01 > 0:40:05And we have a go-ahead on the business, together with Gyllensvaans.
0:40:05 > 0:40:06Even though it's passed,
0:40:06 > 0:40:10Ikea aren't placing the full order until they're satisfied the factory
0:40:10 > 0:40:13can produce the required volume to their strict standards.
0:40:14 > 0:40:19I sure hope they have the assembly line and all parts of the factory
0:40:19 > 0:40:21in place, or prepared, simply. Yes.
0:40:29 > 0:40:33We've got Platsa, and it's a lot of work.
0:40:34 > 0:40:37The initial order is 200,000 units,
0:40:37 > 0:40:40to be delivered in just three months' time.
0:40:40 > 0:40:44I hope it goes faster, because we are in a really hurry.
0:40:57 > 0:40:58Problem in the machine.
0:40:58 > 0:41:02The plastic got loose and got caught up in the machine,
0:41:02 > 0:41:04so we need to redo it.
0:41:04 > 0:41:06- INTERVIEWER:- You don't need delays, do you?- Not at all.
0:41:07 > 0:41:10Producing the Platsa, alongside the Billy bookcase,
0:41:10 > 0:41:13means the factory is stretched to the limit.
0:41:14 > 0:41:18Quite stressful. Very hard to catch up when you stop for a while.
0:41:30 > 0:41:31Plastic got stuck in the oven.
0:41:31 > 0:41:33We don't understand what is wrong.
0:41:37 > 0:41:40- Oh!- Smoke comes from that machine.
0:41:44 > 0:41:46Something wrong with the lift,
0:41:46 > 0:41:49something wrong with the electronic motor on that one.
0:41:49 > 0:41:53- It needs to be fixed.- INTERVIEWER: - You are having a bad day?- Yes.
0:41:55 > 0:41:56Stressful day.
0:41:58 > 0:42:02Once the first batch is ready, Olaf will be visiting to sign off
0:42:02 > 0:42:05the entire multi-million pound contract.
0:42:05 > 0:42:07If we can't deliver in time,
0:42:07 > 0:42:13then I think it will be a business consequence for the future.
0:42:14 > 0:42:16Ikea needs to have reliable suppliers.
0:42:21 > 0:42:24Yes, we like it like this. It's not boring at all.
0:42:35 > 0:42:37- Oh, great, Christina. - Here is the box.
0:42:37 > 0:42:40- Hello.- Did they just come today?
0:42:40 > 0:42:42Yes. Just come, really fresh.
0:42:42 > 0:42:45- I hope they haven't broken. - Hope not!
0:42:45 > 0:42:48Hanna-Kaarina's imperfect vase samples have arrived.
0:42:50 > 0:42:54When we open this package, I think it's going to be make or break.
0:42:54 > 0:42:56It will either be smiley faces or sad faces.
0:43:00 > 0:43:01Ah!
0:43:03 > 0:43:04Not too bad.
0:43:06 > 0:43:08I'm happy that the shape is not too much...
0:43:08 > 0:43:10It's not too distorted, is it?
0:43:10 > 0:43:11So it's actually quite good.
0:43:12 > 0:43:13Whoa!
0:43:19 > 0:43:21What do you think, Hanna, are you pleased?
0:43:21 > 0:43:23I think it looks quite nice, actually.
0:43:23 > 0:43:26- I was a bit worried it might look a little bit childish.- Yeah.
0:43:28 > 0:43:30I'm pretty happy, actually.
0:43:30 > 0:43:34I'm sort of... I feel I'm relieved that it's...
0:43:34 > 0:43:37I was a bit stressed, to be honest.
0:43:37 > 0:43:39Yes, it seems promising, actually.
0:43:39 > 0:43:41Seeing the samples and seeing that they have
0:43:41 > 0:43:45actually understood the concept and they can produce pieces that are unique,
0:43:45 > 0:43:46it's really good for us.
0:43:46 > 0:43:49Almost a little bit lost for words. It looks like it's going to work.
0:43:49 > 0:43:50Really exciting.
0:43:50 > 0:43:53It will be very interesting to see what other people think.
0:43:55 > 0:43:57It's decision day.
0:43:57 > 0:44:00James needs to present the design to the business team for final approval.
0:44:00 > 0:44:04So, this is the final collection meeting that we have invited you to today.
0:44:04 > 0:44:08So, this is actually where we decide what the collection will consist of.
0:44:08 > 0:44:11They've agreed a cost with the supplier, which will allow
0:44:11 > 0:44:16other stores to sell the vase at a suitable recommended price.
0:44:16 > 0:44:19- The price point is 12.90 for this one.- For this one?- Yeah.
0:44:19 > 0:44:22And then we have the smaller one.
0:44:22 > 0:44:239.99.
0:44:24 > 0:44:29As the team deliberate, all Hanna-Kaarina can do is wait for news.
0:44:31 > 0:44:35What I like about Hanna is she puts her heart and soul into everything.
0:44:36 > 0:44:40And you can see that she wants to succeed and make it.
0:44:40 > 0:44:43You can see that she goes that extra mile.
0:44:45 > 0:44:49When briefing at this project, we actually approached Hanna-Kaarina,
0:44:49 > 0:44:50one of our own in-house designers.
0:44:50 > 0:44:53How could you challenge that thing, mass production,
0:44:53 > 0:44:55everything looks the same?
0:44:55 > 0:44:57How could you make something look different?
0:44:57 > 0:45:00She had some super stupid, crazy ideas.
0:45:00 > 0:45:04Why don't we press a finger or poke a ceramic pot to make it different?
0:45:04 > 0:45:07The first samples you see here were actually done just as we left.
0:45:07 > 0:45:11They were just getting it. But do you like the idea?
0:45:11 > 0:45:14Do you think...? It's very different.
0:45:14 > 0:45:16All of our glasses look exactly the same.
0:45:16 > 0:45:19Here, we're allowing for... You know, they will be in the store,
0:45:19 > 0:45:22lined up slightly different with this human touch.
0:45:22 > 0:45:25Looking at these marks, I don't see that as handmade,
0:45:25 > 0:45:30I see it as somebody punching on purpose from different sides.
0:45:30 > 0:45:34It's a tricky process to get them to destroy the perfect mould.
0:45:34 > 0:45:41For me, I work in the square area of Ikea, I would be very much, like,
0:45:41 > 0:45:42I don't think I'll get it.
0:45:42 > 0:45:46You are used to finding the mass production at Ikea.
0:45:46 > 0:45:49You kind of feel like this must be a defect.
0:45:49 > 0:45:54Personally, I think that it'll work, if the communication is really, really clear.
0:45:54 > 0:45:56I think it's really interesting and super exciting.
0:45:56 > 0:46:00I think we will need everybody behind it to get it to work
0:46:00 > 0:46:03from explaining in supply, communication,
0:46:03 > 0:46:04even forecasting and selling.
0:46:04 > 0:46:07Because it's very different, like you say, Nikolai, it's not the norm.
0:46:14 > 0:46:17After two hours, a decision is made.
0:46:20 > 0:46:22- Hello.- Hanna.
0:46:23 > 0:46:26- Moment of...- Well done.
0:46:26 > 0:46:27- We made it.- Really?
0:46:27 > 0:46:29- No, we did. We had the meeting today.- OK.
0:46:29 > 0:46:30It went really well.
0:46:31 > 0:46:33- It's going to happen.- Nice.
0:46:33 > 0:46:37You must be a little bit excited. It could be your first product in Ikea.
0:46:37 > 0:46:41Yes. I like starting with the crazy stuff, it's good.
0:46:42 > 0:46:45I think the exciting thing is we're going to go for it.
0:46:45 > 0:46:49It's going to be between 60,000 and 70,000 pieces of these vases.
0:46:49 > 0:46:51- So, I think that's super exciting. - That's a lot.
0:46:51 > 0:46:57Many people will be able to have an Ikea Hanna-Kaarina affected vase.
0:46:57 > 0:47:00Yes, that's crazy.
0:47:00 > 0:47:01We did it.
0:47:12 > 0:47:15Sometimes I think I should cycle around the store,
0:47:15 > 0:47:17get there quicker to the meeting, wouldn't we?
0:47:17 > 0:47:20If you were not following me now, I could just borrow that bike.
0:47:20 > 0:47:22With just six days until the big opening,
0:47:22 > 0:47:25Gary's called a crisis meeting to discuss
0:47:25 > 0:47:29one of the most important parts of the store - wardrobes.
0:47:30 > 0:47:33I honestly want to start by saying it's awesome.
0:47:33 > 0:47:36I think the store looks absolutely super.
0:47:36 > 0:47:38Except Pax.
0:47:38 > 0:47:41Pax wardrobes are one of Ikea's biggest sellers.
0:47:41 > 0:47:44Stocked in every store around the world,
0:47:44 > 0:47:46they're available in multiple combinations.
0:47:46 > 0:47:49There's 130 combinations.
0:47:49 > 0:47:50I think we are showing 15.
0:47:50 > 0:47:53- 23.- Out of 130.
0:47:53 > 0:47:5524 combinations.
0:47:55 > 0:47:58- Really?- Yes.- One, two, three...
0:48:00 > 0:48:04..four, five, six, seven, eight, nine, ten...
0:48:04 > 0:48:07..11, 12, 13, 14, 15.
0:48:07 > 0:48:08I still get 15.
0:48:10 > 0:48:11Adam, show me why you get more.
0:48:14 > 0:48:16You're calculating just with closed, right?
0:48:16 > 0:48:19- Not open? So you're not counting with doors on.- OK.
0:48:21 > 0:48:24I believe that if any of my neighbours now come
0:48:24 > 0:48:27to buy a wardrobe, yeah, that is not a wardrobe.
0:48:27 > 0:48:30Put some doors on it for me and it's a wardrobe.
0:48:30 > 0:48:32What you show me here is the inside of a wardrobe.
0:48:32 > 0:48:34I'd say, yeah, that's true.
0:48:34 > 0:48:36That's the inside of a wardrobe.
0:48:36 > 0:48:39I don't think something without a door, in my opinion,
0:48:39 > 0:48:41should be called a wardrobe.
0:48:41 > 0:48:43I don't. But if you tell me it should,
0:48:43 > 0:48:46then I can agree on that one that we disagree.
0:48:50 > 0:48:54If you take the whole Ikea range, in most countries,
0:48:54 > 0:48:56absolutely in the UK,
0:48:56 > 0:49:00in all 19 stores today, the number one cash machine is bedrooms.
0:49:00 > 0:49:03The wardrobes takes us the most money.
0:49:03 > 0:49:06So, it's the one that if you want to walk round today and say,
0:49:06 > 0:49:10"What looks amazing," you would always want to start with Pax wardrobes
0:49:10 > 0:49:13and freestanding wardrobes, because they're where the money comes from.
0:49:13 > 0:49:16We have a combination of nearly 200 doors to show
0:49:16 > 0:49:20and we've decided to show 15 out of 200.
0:49:24 > 0:49:27With Gary determined to have the perfect opening,
0:49:27 > 0:49:29his mind is turning to the big day itself.
0:49:30 > 0:49:35- INTERVIEWER:- Is the success of Ikea Sheffield personal for you?- Yes.
0:49:36 > 0:49:41When we open the door, will there be 100, 300, 500, 1,000?
0:49:41 > 0:49:43I'm going to say 500.
0:49:43 > 0:49:45If there's more than 500 people,
0:49:45 > 0:49:49I'm going to say that's exceeded what I expected.
0:49:49 > 0:49:54If there's only 300 or 400 people, at 9.55, I guess, deep down inside,
0:49:54 > 0:49:56I will be a little bit disappointed.
0:50:04 > 0:50:07Olaf is on his way to conduct a delivery inspection
0:50:07 > 0:50:08at the Gyllensvaans factory.
0:50:10 > 0:50:15Simply, if Gyllensvaans wouldn't pass the first delivery inspection,
0:50:15 > 0:50:21we would not be OK to send deliveries out from the factory, simply.
0:50:22 > 0:50:25And, of course, that would jeopardise the time plans.
0:50:25 > 0:50:28There would be potential risks of delays and so on.
0:50:29 > 0:50:33And, of course, that is something that we try to avoid.
0:50:36 > 0:50:38With the production issues ironed out,
0:50:38 > 0:50:42today's visit is to make sure the cupboards are up to standard.
0:50:42 > 0:50:45We're going to have a check, it's called the first delivery inspection.
0:50:45 > 0:50:49So, they check all the issues regarding quality of the product,
0:50:49 > 0:50:51of the packaging, the pallets and everything,
0:50:51 > 0:50:55so it's according to what they need.
0:50:55 > 0:50:58- INTERVIEWER:- So, it's pretty intense?- Yeah.
0:50:59 > 0:51:01It's make or break.
0:51:01 > 0:51:06Pass today and they'll secure the entire contract of 700,000 units.
0:51:06 > 0:51:09It's really important that we get success
0:51:09 > 0:51:15in this first delivery inspection, so we get this range, so we can continue to grow with Ikea.
0:51:15 > 0:51:20So we can have all these workers coming every day and doing their job.
0:51:20 > 0:51:22It's important for the community.
0:51:25 > 0:51:28Success hinges on passing a vital drop test.
0:51:28 > 0:51:31It's one of the tests that is really important to pass,
0:51:31 > 0:51:32with the packaging.
0:51:32 > 0:51:35It simulates that the customer will drop the box,
0:51:35 > 0:51:38and we have added protection inside the box
0:51:38 > 0:51:40so it doesn't hurt the product inside.
0:51:40 > 0:51:43- INTERVIEWER:- So, in an hour's time, Ikea are going to do this test?
0:51:43 > 0:51:45- Yes.- Why are you doing this so late?
0:51:45 > 0:51:49We've done it before, but then we had sample boxes.
0:51:49 > 0:51:51Now we have boxes from the real production.
0:51:51 > 0:51:55So, we want to make sure that they have the same quality as the samples
0:51:55 > 0:51:57that we have received before.
0:51:57 > 0:52:00- This has only just come in, has it? - Yes, yesterday.
0:52:00 > 0:52:01- So it's really last-minute? - Yes.
0:52:05 > 0:52:06They've just arrived.
0:52:08 > 0:52:12- Welcome.- Thanks.
0:52:12 > 0:52:15It's the final step before go-ahead.
0:52:15 > 0:52:17So, it would be nice to have to tick off and say,
0:52:17 > 0:52:20"Yes, now we're ready to go, finally."
0:52:28 > 0:52:31Nervous and excited at the same time.
0:52:31 > 0:52:35The product is dropped from a height of 40 centimetres.
0:52:35 > 0:52:37OK.
0:52:37 > 0:52:39Yes.
0:52:52 > 0:52:54It's passed. You don't see it,
0:52:54 > 0:52:58there is no damages or anything on the surface.
0:53:03 > 0:53:05The Gyllensvaans win the contract.
0:53:09 > 0:53:12As always, Ikea will keep a close eye on production.
0:53:15 > 0:53:19I would say slowing down, if you are having that mind-set,
0:53:19 > 0:53:22that attitude, that is dangerous for a company.
0:53:22 > 0:53:24Then you become kind of fat and lazy
0:53:24 > 0:53:26and the competitors will catch up.
0:53:26 > 0:53:31It never stops. If we want to grow, we cannot just be satisfied.
0:53:31 > 0:53:33We need to continue all the time.
0:53:44 > 0:53:46- INTERVIEWER:- What time have you been here since?
0:53:46 > 0:53:48- What time is it now?- It's about 7am now.
0:53:48 > 0:53:51I've been here since 4am.
0:53:51 > 0:53:54- How come?- Well, I thought people would be queueing up.
0:53:54 > 0:53:56But there's no-one here yet.
0:53:56 > 0:53:58Test, one, two, one, two.
0:53:58 > 0:54:02I didn't come with my wife, because they say that a trip to Ikea is,
0:54:02 > 0:54:06could become a relationship breaker, even for the strongest relationship,
0:54:06 > 0:54:09with the amount of arguments and what have you that you could have.
0:54:11 > 0:54:14Julie Dore, Olivia Blake.
0:54:14 > 0:54:18Why do I keep mixing the names up and saying Julie Blake and Olivia Dore,
0:54:18 > 0:54:20when it's Julie Dore and Olivia Blake?
0:54:21 > 0:54:25After months of preparation, as Gary prepares his speech,
0:54:25 > 0:54:27anticipation outside is building.
0:54:30 > 0:54:32We thought there'd have been a bigger queue.
0:54:32 > 0:54:33A really big queue.
0:54:38 > 0:54:39Hello, good morning. Oh, no.
0:54:43 > 0:54:48Good morning, everybody, and a warm welcome to the UK's 20th store.
0:54:48 > 0:54:53I begin by giving an extended welcome to His Excellency,
0:54:53 > 0:54:56the Swedish ambassador, Torbjorn Sohlstrom.
0:54:56 > 0:55:01And to the leader of our council, Julie Dore.
0:55:01 > 0:55:04And to all of you who have travelled here at your own expense,
0:55:04 > 0:55:08thank you very much, I appreciate you being here.
0:55:08 > 0:55:10APPLAUSE
0:55:10 > 0:55:12Can I ask, do we know if people are queueing?
0:55:12 > 0:55:14Do we have a small queue, any queue?
0:55:14 > 0:55:16Is it 50, 20?
0:55:16 > 0:55:20- 100?- 50 to 60.- 50 to 60. OK.
0:55:25 > 0:55:27- INTERVIEWER:- What brings you down to Ikea?
0:55:27 > 0:55:29Well, it's my wife's birthday today.
0:55:29 > 0:55:32She wanted to come. That's why we're here.
0:55:32 > 0:55:33Birthday meatballs!
0:55:33 > 0:55:35Logistics, are you ready?
0:55:35 > 0:55:36CHEERING
0:55:36 > 0:55:38Customer Relations, are you ready?
0:55:38 > 0:55:39CHEERING
0:55:39 > 0:55:41Gillian Drakeford, are you ready?
0:55:41 > 0:55:43Yes!
0:55:43 > 0:55:45Yes! Gary Deacon, are you ready?
0:55:45 > 0:55:46Oh, yes!
0:55:48 > 0:55:50Let's get that door open.
0:55:51 > 0:55:54CHEERING
0:55:57 > 0:56:00After a six-hour wait, Chris is the first customer through the doors.
0:56:07 > 0:56:08CHEERING
0:56:08 > 0:56:11Adam. Adam, why have you not pegged them back?
0:56:11 > 0:56:12Look at the queue.
0:56:12 > 0:56:15Ever the perfectionist, Gary has one more niggle.
0:56:18 > 0:56:20Come this way. Come this way.
0:56:20 > 0:56:23It's quicker. Come this way, it's quicker.
0:56:23 > 0:56:24There we go. There we go.
0:56:28 > 0:56:32Look at the queue. What do you think it is, 700?
0:56:33 > 0:56:38- It's more than that. There's 1,000. - 1,000 people? 1,000 people.
0:56:38 > 0:56:42He believes 1,000 plus. Closer to 1,000 than 700.
0:56:42 > 0:56:45- 1,000 plus.- 1,000 people.
0:56:45 > 0:56:491,000 people. More than 1,000 people.
0:57:00 > 0:57:06Marta Garcia from the business team has a sales update
0:57:06 > 0:57:08with the all-important figures.
0:57:08 > 0:57:11So, are we level or are we up? We're not down.
0:57:11 > 0:57:14I know we're not down, we're too busy to be down.
0:57:14 > 0:57:16Are we level or are we up?
0:57:16 > 0:57:18What do you think? How much?
0:57:18 > 0:57:21- Up.- Yes, by how much, do you think?
0:57:21 > 0:57:24I would be happy with £10,000.
0:57:24 > 0:57:27I would be an exceptionally happy man at 20,000.
0:57:27 > 0:57:32We are at £35,000 up on our goal today so far.
0:57:32 > 0:57:35- Are you serious?- Yes. - You swear?- I promise you.- 35,000 up?
0:57:35 > 0:57:36Yes.
0:57:36 > 0:57:38That is awesome!
0:57:38 > 0:57:41It's a promising start,
0:57:41 > 0:57:45but there's a long way to go to plug the shortfall caused by the delay.
0:57:45 > 0:57:48Show me the money. Show me the money.
0:57:48 > 0:57:49Show me the money!
0:57:51 > 0:57:54- Next time...- So, these room sets will go.
0:57:55 > 0:57:58We will not have this walkway, and that's revolutionary.
0:57:58 > 0:58:04To design for Ikea, we have to design for all the people,
0:58:04 > 0:58:05all around the world.
0:58:05 > 0:58:08So, now we're going into India.
0:58:08 > 0:58:10An Ikea bag on the market.
0:58:10 > 0:58:11The potential is enormous.
0:58:11 > 0:58:15I don't think that we understand what we're getting into.
0:58:15 > 0:58:20Uncover the mysteries of flatpack, everyday design and brand names.
0:58:20 > 0:58:22To find out more, go to...
0:58:24 > 0:58:28..and follow the links to the Open University.