Top Plant 2012: Masco Cabinetry

12/17/2012


The panels are then sanded and placed onto a cart, ready to be married up with the stiles and rails for the next step in the process. The sticks created in the dimension department are used to frame the door. In the cabinet-making industry, the sticks that create the outside frame of the door are referred to as stiles. However, before the sticks and panels are assembled, the sticks are routed to the molding department where their inside profiles and final dimensions are formed. The panels and sticks are then assembled and clamped. Once the glue has dried, the doors receive the outside profiles, are finish-sanded, and routed to shipping.

An operator assembles the panel, stiles, and rails during the door rail process at Masco Cabinetry. Courtesy: Louis Quattrini, MACH III PHOTOThe doors and cabinet fronts are not stained or varnished at the Sayre plant. “That’s done during final cabinet or finished product assembly at another plant,” White said. “That way, the shells and components are stained the same color and shade.”

Reducing lead time

White said the lead time for making cabinet doors and fronts at the Masco Cabinetry Sayre plant was 21 days. “Now, our lead time is three days,” said White. “We made the three-day lead time our goal; we achieved it, and we’re still striving to improve. Eliminating inventory and reducing work in process has contributed significantly to our success in reaching this goal.”

The sticks are cut in real time from the cut bill. “They’re cut in real time so when the center panels come off the sanding line, the exact size and quantity of sticks are pulled from the dimension department and routed to the molder,” White said. “Our work in process between the sanding line and the clamps is four hours maximum. The longest Courtesy: Louis Quattrini, MACH III PHOTOwork in process time is waiting for the solid panel glue joints to dry. It’s all about getting as close to just-in-time processing as possible.”

The Sayre plant has eliminated workflow buffers from its manufacturing processes because buffers increase work-in-process (WIP), inventory costs, and the cost of production. “We strive to have right-piece-flow or single-piece-flow as much as possible, which allows us to reduce inventory and lead times,” White said. “Actually, those buffers we used to have added to our lead time.”

Production lead Tim Porter agrees. “Adding inventory between machines allows time for production to continue if a machine goes down,” said Porter. “However, we’ve taken the Lean approach: prevent the breakdowns all together. If you have no work in process between your processes and something goes down, you will eventually affect both downstream and upstream processes anyway. So correct the failing process, and make it better. Work-in-process buffers may seem like ‘comfort levels,’ but they really just get in your way.”

In the final inspection area, employees enure that products meet Masco's quality criteria before they are shipped. Courtesy: Louis Quattrini, MACH III PHOTOReducing WIP also reduces waste. “When the wood sits around in racks or around the machine lines, it could become damaged,” Miller said. “The sooner we can move it through, the fewer defects we have, the less motion we have, and the less inventory we have.” There is no finished stock inventory in the Sayre facility.

Continuously improving

Identifying and eliminating waste is fundamental to Lean manufacturing. “Lean is an area that the Sayre plant thrives on,” said Hawthorne. “Our challenge is keeping all of the activity focused on our goal of ‘Free, Perfect, Now.’ Sayre makes heavy use of value stream mapping to keep all projects and Kaizens focused on improving the customer experience.



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...
Prescriptive maintenance; Hannover Messe 2017 recap; Reduce welding errors
Safety standards and electrical test instruments; Product of the Year winners; Easy and safe electrical design
Safer human-robot collaboration; 2017 Maintenance Survey; Digital Training; Converting your lighting system
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Future of oil and gas projects; Reservoir models; The importance of SCADA to oil and gas
Big Data and bigger solutions; Tablet technologies; SCADA developments
Automation modernization; Predictive analytics enable open connectivity; System integration success; Automation turns home brewer into brew house
Commissioning electrical systems; Designing emergency and standby generator systems; Paralleling switchgear generator systems
Natural gas for tomorrow's fleets; Colleges and universities moving to CHP; Power and steam and frozen foods

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.
Featured articles highlight technologies that enable the Industrial Internet of Things, IIoT-related products and strategies to get data more easily to the user.
Compressed air plays a vital role in most manufacturing plants, and availability of compressed air is crucial to a wide variety of operations.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Maintenance Manager; California Oils Corp.
Associate, Electrical Engineering; Wood Harbinger
Control Systems Engineer; Robert Bosch Corp.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me