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Overview

Masco Cabinetry was an international manufacturer of custom kitchen and bath cabinetry. By sales volume its was the largest custom and semi-custom cabinet maker in North America. The company was based initially in Middlefield, Ohio before merging with other Masco entities where it resided in Ann Arbor, Michigan.

The Problem

At the time, Masco Cabinetry was one of the highest cost products on the market. Several years of finishing at the top of the JD Power rankings was the driving force in the manufacturing strategy. After the Great Recession in 2009, the leadership wanted to look for a nimbler way to manufacture while keeping its world class materials, customer service and quality intact.

The Solution

A leader in the cabinet production space, produces premium semi-custom wooden cabinets. One of their operations is a finishing operation that manufactures and finishes cabinet doors and drawer fronts. Approximately one third of this plants volume is sourced through a sister plant in Pennsylvania.

Although the PA plant represented a purchase price variance savings, the corporation was reluctant to shift more volume to the PA facility because of quality issues. The number one quality issue being hardwood cracks. As an organic material, wood is naturally subject to drying defects such as hardwood cracks. However, the corporations external vendors had achieved substantially lower defect rates.

The PA operation had been struggling with drying defects since opening its doors. During the years leading up to our engagement, internal charter teams sought to reduce these defects with little to no success. As a result, we were contracted to assemble a team to address these long standing problems.

The aggressive 50% targeted reduction in drying defects required a full-scale Lean Six Sigma problem solving approach. Working with the client’s onsite team, we utilized the DMAIC, Define-Measure-Analyze-Improve-Control, approach to determine the critical inputs to the process output. We recommended and implemented four critical changes:

  • Adopt OEM tools and techniques to reduce split boards.

  • Recalibrate the kiln drying process to reflect the industry standard.

  • Develop a measure and control system for the plant humidification system.

  • Enhance the dimension inspection process.

The implementation reduced drying defects throughout the operations by over 50% in less than six months. Savings consisted of reduction in material, labor and overhead cost for the Pennsylvania site.. Additional benefits included purchase price variance savings from insourcing. In summary, the engagement resulted in $3.8MM annual savings, a 300% return on investment.

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Typography is the art and technique

Typography is the art and technique of arranging type to make written language legible, readable and appealing when displayed.

Typography is the art and technique

Typography is the art and technique of arranging type to make written language legible, readable and appealing when displayed.

Typography is the art and technique

Typography is the art and technique of arranging type to make written language legible, readable and appealing when displayed.

Typography is the art and technique

Typography is the art and technique of arranging type to make written language legible, readable and appealing when displayed.