Once the bodies and necks are all finished and lacquered, the really nerdy stuff begins. Believe me when I say that this entire process is incredibly meticulous and every employee ensures that their respective part is done perfectly. They are then sanded down and the frets are applied by hand. The necks are carved out from blanks then given the personal touch and sculpted by one of the craftsmen in the workshop. From there, the bodies are sanded to perfection, painted, buffed and dried to ensure they are set and stable. The building process begins with a number of CNC machines, including Big Bird, the big yellow robot that takes the raw wood and carves the body blanks in the blink of an eye. This was also clear when stumbling upon a few reject bins around the factory: even the slightest of imperfection won’t make it through complete production and is discarded without hesitation. With up to 15 people working on each instrument in their respective roles along the production process, it’s safe to say that by the time something reaches the warehouse to be shipped out, every fine detail has been checked to ensure it is up to the strict qualities of craftsmanship the brand is revered for. It was clear from the moment I walked into the factory that their focus is most certainly quality over quantity. With 160 employees on staff, Ernie Ball Music Man is far from the biggest guitar company around, but that need not be their concern.
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