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 Page 1 Page 2 Page 3 Page 4 Page 5 Next > Last >>

Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
July/Aug
GAMS preview, 2018 Mid-Year Report, EAM and Safety
June 2018
2018 Lubrication Guide, Motor and maintenance management, Control system migration
May 2018
Electrical standards, robots and Lean manufacturing, and how an aluminum packaging plant is helping community growth.
April 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
August 2018
SCADA standardization, capital expenditures, data-driven drilling and execution
June 2018
Machine learning, produced water benefits, programming cavity pumps
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
August 2018
Choosing an automation controller, Lean manufacturing
February 2018
Setting internal automation standards

Annual Salary Survey

After two years of economic concerns, manufacturing leaders once again have homed in on the single biggest issue facing their operations:

It's the workers—or more specifically, the lack of workers.

The 2017 Plant Engineering Salary Survey looks at not just what plant managers make, but what they think. As they look across their plants today, plant managers say they don’t have the operational depth to take on the new technologies and new challenges of global manufacturing.

Read more: 2017 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
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 Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Material Handling
This digital report explains how everything from conveyors and robots to automatic picking systems and digital orders have evolved to keep pace with the speed of change in the supply chain.
Electrical Safety Update
This digital report explains how plant engineers need to take greater care when it comes to electrical safety incidents on the plant floor.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me