CUSTOM KITCHEN PLANT - FRAME & FRAMELESS CABINETS

Background: Heritage Custom Kitchens (HCK) has developed a successful business supplying high-end custom kitchens for remodeling and new home construction. In addition to their original frame models in traditional designs, a new line of frameless cabinets with transitional and contemporary door styles was introduced. The plant had been expanded in three phases since its opening to accommodate new equipment for higher volume and for the new product line.

Situation: The addition of the new product line plus expansion of distribution to a larger geographic area produced substantial sales. This demand outstripped existing production capacity. The pressure on the plant was resulting in lengthened delivery times and higher labor costs.

To capitalize on this demand HCK envisioned a major expansion with four major objectives:

1. Increased Capacity - Expansion of the existing cabinet production plant to add volume.
2. Increased Scope - Addition of equipment to enable manufacture of components previously purchased from outside suppliers.
3. Reduced Labor Content - Installation of labor-saving process machinery and handling equipment.
4. Reduced Lead Time - Production of cabinet orders in five days while reducing in-process inventory.

HCK employed A. G. Raymond & Company to produce a master plan and detailed plant layout for this project. Following evaluation of various alternative facilities arrangements, a 90,000 ft² building was added to the existing factory. The new building was dedicated for cabinet production of both face frame and frameless boxes. The original facility (not shown on the attached drawing) was restructured for production of highly custom cabinets plus wood doors, laminated doors, and wood trim (mouldings).

The cabinet making process was designed to minimize order processing time. A new order begins production at the panel saw. Parts for daily production are downloaded to optimization software for creation of cutting patterns. As parts are produced from the various types of panels (wood veneered or paper laminated), labels are printed and affixed to each part. Parts are then sorted by order on special racks which are transferred on roller conveyor to subsequent operations.

Frameless parts proceed down the right hand wall through drilling and edge banding in preparation for assembly. Assembled laminated cabinets move directly onto hardware and trim lines for completion. Veneered units are moved to the left for finishing.

Cabinet parts for face frame units proceed through a U-shaped flow moving first to the left for machining and then back to the right for assembly. Following assembly face frame cabinets move through whitewood sanding and are readied for finishing.

As a cabinet order is being processed to the assembly stage, doors and other trim parts are produced for that order in buildings located to the left of the new plant. These parts are attached to the cabinet for finishing or are finished individually.

The finishing department consists of (i) a towline system for finishing fully-assembled cabinets and (ii) a flatline system with reciprocating sprayer and vertical oven. The flatline is used primarily for doors, panels, and other solid wood/plywood trim parts.

Following finishing doors and other trim are attached to the cabinets. After inspection and packing the units are moved into the shipping department - five days after the first cabinet part is sawn.

A. G. Raymond & Company Inc.  1033 Wade Ave. Suite 102 Raleigh, NC  27605
Phone: (919) 831-0070  Fax: (919) 831-0072  Email: info@raymondnet.com