Levi One-tone type: Even if the "materials" are different, we want to unify the color. The story behind the production of the popular Levi One-tone type chair

Even if the materials are different, we want to unify the colors. The story behind the production of the popular Levi one-tone chair

ITOKI's popular chair series "Levi," released in 2018, will be renewed in the fall of 2024. The theme is one-tone color. The challenge of unifying the color of the seat, caster legs, and backrest required a great deal of ingenuity from the perspectives of development, technology, manufacturing, and materials. We take a look behind the scenes at the birth of "Levi One-Tone Type," which was completed through repeated trial and error on-site and the power of the team.

Yosuke Okano (Development) Chair Development and Design Office, Development and Design Division 1, Development and Design Department, Production Headquarters

Production Headquarters, Development and Design Division, 1st Development and Design Department, Chair Development and Design Office

Yosuke Okano (developer)

Masaya Kunimi (Technology) Production Technology Section, Shiga No. 2 Manufacturing Department, Kansai Factory, Production Headquarters

Production Technology Section, Shiga No. 2 Manufacturing Department, Kansai Factory, Production Headquarters

Masaya Kunimi (Technology)

Hitoshi Shimomura (Manufacturing) Manufacturing Division, Kansai Factory, Shiga No. 2 Manufacturing Department, Manufacturing Section

Production Division, Kansai Factory, Shiga No. 2 Manufacturing Department, Manufacturing Section

Hitoshi Shimomura (manufacturing)

Katsuhiko Nomura (Materials), Production Division, Kansai Factory, Shiga No. 2 Manufacturing Department, Engineering Section

Production Headquarters Kansai Factory Shiga No. 2 Manufacturing Department Engineering Section

Katsuhiko Nomura (Materials)

Airiko Amiura (Interview) Chair Development and Design Office, Development and Design Division 1, Development and Design Department, Production Division

Production Headquarters, Development and Design Division, 1st Development and Design Department, Chair Development and Design Office

Airiko Amiura (Interview)

Combining one color is harder than I thought...

Amiura - The "Levi One-Tone Type" was released in December 2024. Please tell us about your role and the points you are particular about.

Okano (Development): Levi, which was launched in 2018, was well-received by customers for its simple color scheme and comfortable seating. For the renewal, we began an internal initiative to create a space where the colors of the table and chairs were unified, and we decided to unify the colors of the seat, caster legs, and backrests. The design was also partially changed, and I was in charge of changing the design and process, working between the planning and manufacturing departments. I particularly struggled with the design of the new gas cylinders that were introduced for the renewal.

Nomura (Procurement): As the materials manager, I worked hard to procure paints to reproduce the desired colors. Matching the colors of different materials was a particularly difficult task. Our manufacturing partner helped us adjust even the smallest details of the color.

Kunimi (Technology): The biggest change in the manufacturing process was to the gas cylinder that adjusts the chair height. To give the chair a sleeker appearance, we decided to reduce the outer diameter of the casters by 10 mm. This meant lowering the reference position of the gas cylinder and adjusting the position of the seat. We had to change the processing method, and that trial and error is a fond memory.

Shimomura (Manufacturing): I was in charge of coloring the armrests and legs of the chairs. It was a challenge to try a new color, and since the color changes depending on the temperature and humidity, it was difficult to get the color I wanted. After many tries, I was really happy when I finally got a color that I was satisfied with.

Amiura:Even though the shapes look the same, there were a lot of difficulties in developing them...!

Comparison of new and old casters

Masaya Kunimi points to the support of the chair

Making the casters smaller would have caused users to feel uncomfortable, wondering, "Is the height different?" After much trial and error, we adjusted the height of the gas cylinder to make up for the 10mm difference!

A series of impressive moments! Improvements to the processing equipment that supported development in a short space of time

Amiura: I heard that it was developed in a short period of time. What kind of ingenuity did you use?

Okano (Development): It was my first time to coordinate the colors and tones of parts. Planning began in the winter, and the problem was discovered in the spring, so we struggled with it for about three months. It took a while to find the optimal solution for the tapered part of the gas cylinder, and I remember that the person in charge of manufacturing later cooperated quite a bit in adjusting the schedule.

Kunimi (Technology): Yes, that was the part that worried us the most after we discovered the problem. Up until now, the only existing products we had processed had an outer diameter of 50.2 mm. The new Levi is 50 mm. That slight difference caused problems during processing, so we worked hard to create a jig (*) that would fit the 50 mm outer diameter. It was a difficult job, but we all shared the same desire to somehow finish it. I'm grateful to my colleagues who were in charge of design and manufacturing.

Okano (Development): When we completed the jig, we were all impressed, saying, "It's amazing that we can do something like this!" It also led to increased efficiency, and it really showed us the power of a team.

* Jig: A specialized tool or device used to fix or position parts at manufacturing or processing sites.

Gas cylinder processing jig

Painting site

The factory has also evolved to produce the new Levi. The gas cylinder processing jig has been improved to make it removable and adaptable to various shapes. Once mass production begins, rows of paints are lined up at the painting site.

Nomura (Materials): When it came to procuring paint, we asked our paint supplier to adjust the color. The color had to match the resin material, and we struggled with making those fine adjustments. By being more specific in person rather than just over the phone, such as "I want it to be a little brighter" or "Make the color a little lighter," we were able to communicate more smoothly and they were able to accommodate even our small requests. As a result, we felt we were able to work together more closely to make the project a reality.

Shimomura (Manufacturing): We had no idea what the new colors would turn out like, and they changed slightly when they dried, making it difficult to adjust, which was a real challenge. However, after much trial and error, we got the hang of it and were able to accurately adjust the colors.

Amiura: So it must have been a struggle to develop the jig and add new colors!

The one-tone Levi turned out better than I could have ever imagined!

Amiura: As a creator, please tell us about the pride of "Levi One Tone" that you would like us to pay attention to!

Okano (development): The moment I saw the chairs lined up in one tone, I was amazed at how beautiful the space could be.

Shimomura (Manufacturing): I was impressed to see that the resin parts and the paint matched perfectly, and that even though the materials are different, they can be finished in one tone.

image_05.jpg

Office chairs lined up in the hallway

Nomura (Materials): I was impressed by how much a chair with a unified color can change the impression. And it was only thanks to the united efforts of our partners that we were able to achieve this color. I expressed my gratitude to them after it was completed.

Okano (Development): I don't think many people will look at the gas cylinder, but I would like everyone to see the attention to detail that went into making it. The design is sophisticated and finished in a beautiful single tone. I think it will blend in naturally in the office and give a sense of security.

Levi one-tone type (left) and existing product (right)

Levi in 4 colors by Jin Shimomura

Compared to existing products, it comes in four colors perfect for a cozy office!
Left image: Levi one-tone type (left) and existing product (right)

Shimomura (Manufacturing): Looking at the finished chairs, I can really see the new added value that comes from unifying the colors. Increasing the variety of paints and taking the extra step in manufacturing gave me confidence that "we can offer new possibilities to our customers."

The Levi One Tone chair was released in December 2024. The one-tone design brings harmony and calm to the entire space. Experience the sense of security you'll feel every time you sit on it.

Related products/solutions

*The department, position, and system are those at the time of the interview and may differ from the current information.

CONTACT

For all inquiries, please click here.