Top Plant 2012: Masco Cabinetry

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


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 2013 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...
Sister act: Building on their father's legacy, a new generation moves Bales Metal Surface Solutions forward; Meet the 2015 Engineering Leaders Under 40
2015 Mid-Year Report: Manufacturing's newest tool: In a digital age, digits will play a key role in the plant of the future; Ethernet certification; Mitigate harmonics; World class maintenance
2015 Lubrication Guide: Green and gold in lubrication: Environmentally friendly fluids and sealing systems offer a new perspective
Drilling for Big Data: Managing the flow of information; Big data drilldown series: Challenge and opportunity; OT to IT: Creating a circle of improvement; Industry loses best workers, again
Pipeline vulnerabilities? Securing hydrocarbon transit; Predictive analytics hit the mainstream; Dirty pipelines decrease flow, production—pig your line; Ensuring pipeline physical and cyber security
Cyber security attack: The threat is real; Hacking O&G control systems: Understanding the cyber risk; The active cyber defense cycle
Designing positive-energy buildings; Ensuring power quality; Complying with NFPA 110; Minimizing arc flash hazards
Building high availability into industrial computers; Of key metrics and myth busting; The truth about five common VFD myths
New industrial buildings: Greener, cleaner, leaner; New building designs for industry; Take a new look at absorption cooling; Offshored jobs start to come back

Annual Salary Survey

After almost a decade of uncertainty, the confidence of plant floor managers is soaring. Even with a number of challenges and while implementing new technologies, there is a renewed sense of optimism among plant managers about their business and their future.

The respondents to the 2014 Plant Engineering Salary Survey come from throughout the U.S. and serve a variety of industries, but they are uniform in their optimism about manufacturing. This year’s survey found 79% consider manufacturing a secure career. That’s up from 75% in 2013 and significantly higher than the 63% figure when Plant Engineering first started asking that question a decade ago.

Read more: 2014 Salary Survey: Confidence rises amid the challenges

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.