On-time, Every Time: Lean Manufacturing

A standard project is a typical custom cabinetry job with a predictable scope, such as a residential kitchen or bathroom, where the client provides specifications within the shop’s usual offerings (e.g., common door styles, finishes, or wood species). It follows a standard production timeline without urgent deadlines.

Timeline: Typically 4-6 weeks, depending on complexity, material availability, and shop capacity. This includes design consultation, material sourcing, fabrication, finishing, and being ready for delivery to customer.

Lean Manufacturing Application:

• Value Stream Mapping: Focus on minimizing waste and being efficient with our time and resources, including understanding your deadlines to appropriately schedule for production.  

• Just-In-Time (JIT): Materials are ordered and prepped as needed to avoid overstocking, aligning with the project’s timeline.

• Standardized Work: Employees follow established procedures for common designs, ensuring consistency and reducing errors.

• Impact: The predictable timeline allows for efficient resource allocation, and minimal disruptions, optimizing shop throughput.

A rush project is a custom cabinetry job with an accelerated timeline, often due to client urgency (e.g., a tight move-in date or event-driven deadline). It may involve standard or custom designs but requires prioritization over other projects.

Timeline: 2–6 weeks, depending on scope and shop capacity. Expedited material sourcing, overtime work, or reallocation of resources may be required.

Lean Manufacturing Application:

• Prioritization and Flow: Rush projects disrupt the standard production queue, requiring dynamic scheduling to maintain flow. Lean principles help prioritize tasks without overloading our cabinetry manufacturing team.

• Waste Reduction Challenges: Expedited shipping or last-minute material changes can increase costs. We lean on negotiating with suppliers for faster delivery.

• Impact: Rush projects test lean efficiency, requiring tight coordination to avoid bottlenecks while maintaining quality. Owners’ hands-on involvement ensures any potential defects are caught early.

A commercial space project involves cabinetry for businesses, such as medical offices, restaurants, or retail spaces. These projects often require larger quantities, specialized designs (e.g., durable materials for high-traffic areas), or compliance with commercial regulations.

Timeline: 4-8 weeks, depending on scale and complexity. Coordination with other contractors (e.g., electricians, plumbers) and regulatory approvals can extend timelines.

Lean Manufacturing Application:

• Batch Production: Commercial projects often involve repetitive elements (e.g., multiple identical cabinets). Lean’s batch optimization reduces setup times by grouping similar tasks.

• Supplier Collaboration: Lean emphasizes strong supplier relationships to ensure timely delivery of large material quantities, reducing waiting times.

• Error Prevention: Commercial projects require precision to meet regulatory standards. 

• Impact: The longer timeline allows for lean planning, but coordination with external parties can introduce delays. Owners’ involvement in every step ensures alignment with our customer value focus.

A new construction project involves cabinetry for a newly built home or building, typically integrated into the broader construction schedule. Designs are often planned early, with fewer site constraints than renovations.

Timeline: Aligned with the construction schedule. Delays in other construction phases (e.g., framing, drywall) can push back cabinetry installation.

Lean Manufacturing Application:

• Pull System: Production is triggered by construction milestones (e.g., drywall completion), aligning with lean’s demand-driven approach to avoid overproduction.

• Standardized Components: New construction often allows for standardized cabinet modules, reducing design variability and enabling lean’s continuous flow in production.

• Collaboration: Owners work closely with builders to align timelines, minimizing idle time (waste) for installers.

• Impact: The extended timeline supports lean planning, but external delays can disrupt flow. Owners’ dedication ensures quick adjustments, maintaining lean efficiency.

A renovation project involves replacing or upgrading cabinetry in an existing space, often requiring custom measurements to fit irregular dimensions or match existing aesthetics. Site constraints (e.g., occupied homes, limited access) add complexity.

Timeline: 4-8 weeks, depending on site conditions and customization. Delays may arise from demolition, site prep, or unexpected structural issues.

Custom Flexibility: Our focus on customer value shines here, as owners tailor solutions to unique spaces. 

Waste Reduction: Precise measurements during site visits reduce errors and increased wait-times. Using technology like laser measurements.