Top Plant 2012: Masco Cabinetry

Real time, just in time: Masco Cabinetry reduces lead time, waste, energy costs, and downtime.

12/17/2012


Just as kitchen cabinets are more than just boxes with doors, manufacturing them requires more than just gluing and nailing pieces of wood together.

One cabinet manufacturer that takes making kitchen cabinets seriously is Masco Cabinetry in Sayre, Pa., the 2012 Plant Engineering Top Plant winner. Masco Cabinetry manufactures kitchen cabinets under the KraftMaid, Merillat, and QualityCabinets brand names. The Sayre facility manufactures fronts and doors for the KraftMaid cabinet line, and plans to soon add the Merillat and QualityCabinets lines. The Sayre facility is one of three component plants among the 12 in the Masco Cabinetry division.

“Being chosen as a Plant Engineering Top Plant is very rewarding and humbling,” said Robert Hawthorne, plant manager of the Masco Cabinetry plant in Sayre. “Most often, we focus only on day-to-day execution and project management, and don’t take a moment to step back and look at how far we have come and the changes we have made. The Sayre facility has come a long way, due mainly to the efforts of our entire 300-employee team. I feel proud and lucky to represent this excellent group.”

Precision-cut wood pieces emerge from the outfeed side of the chop-to-size process in the dimension department. Courtesy: Louis Quattrini, MACH III PHOTOSteve White, manager of facilities, maintenance, and engineering, agrees. “We work as a plant, a whole; we’re not segregated,” said White. “We work together to reduce waste and to improve our efficiencies. We work as one.”

Communication is integral to the operation of the Sayre facility. “With about 300 employees here, if we want to win a tug-of-war, we need to have all 300 people on that rope,” said Mark Thurston, manager of continuous improvement. “One of the things that makes us successful is doing our very best to get all 300 people on that rope and pulling in one direction.”

Making cabinet components

Orders that the plant receives are entered immediately and scheduled electronically. This triggers an electronic cut bill, which is routed to the dimensioning department along with the schedule. From rough, dried lumber, the dimensioning department produces the sized sticks, or wood pieces, that will go into the final products. The cut bill contains the dimensions for each stick.

The schedule is also routed to the panel department. “We have three different panel designs,” said Margaret Miller, production supervisor. “Solid center panels are glued into blanks and are profiled downstream. Pressed panels have an MDF (medium density fiberboard) or particle board substrate with veneer pressed on both sides. Flat panels are thinner with veneer also pressed on both sides.”


<< First < Previous 1 2 3 4 5 Next > Last >>

No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Hannover Messe 2016: Taking hold of the future - Partner Country status spotlights U.S. manufacturing; Honoring manufacturing excellence: The 2015 Product of the Year Winners
Inside IIoT: How technology, strategy can improve your operation; Dry media or web scrubber?; Six steps to design a PM program
World-class manufacturing: A recipe for success: Finding the right mix for a salad dressing line; 2015 Salary Survey: Manufacturing slump dims enthusiasm
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Digital oilfields: Integrated HMI/SCADA systems enable smarter data acquisition; Real-world impact of simulation; Electric actuator technology prospers in production fields
Special report: U.S. natural gas; LNG transport technologies evolve to meet market demand; Understanding new methane regulations; Predictive maintenance for gas pipeline compressors
Warehouse winter comfort: The HTHV solution; Cooling with natural gas; Plastics industry booming
Managing automation upgrades, retrofits; Making technical, business sense; Ensuring network cyber security
Designing generator systems; Using online commissioning tools; Selective coordination best practices

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
click me