for more than 50 percent of overall work.
The process starts with an Extrema ripsaw. Ripped lumber
then goes through an Extrema planer and a Cantek cutoff
saw with Razorgage optimizer pusher system.
A Larick shaper cuts tenons on the pieces, and an Accu-Systems 1045 miter machine makes miter cuts. A Powermatic
rip saw is also used.
Another change to create a more efficient flow was the
replacement of a large clamp carrier with an RF gluer for
glued-up door panels. Glued door panels go through a Larick
410 shaper for raised panel doors, then directly to sanding.
Also in the Abbeville shop is a Ritter shaper, Doucet cabinet door clamp and an Extrema three-head widebelt sander.
The next step is a Voorwood shaper that is used for outside
edges. Added recently was a Holz-Her Kundig finish sander
with polishing heads. Two people can also do hand sanding,
if needed. Mullet Door doesn’t do finishing.
Since the lean transformation began, Mullet Door has
added only three new machines: the new RF gluer, Kundig
sander and Voorwood shaper.
Previously, Mullet Door produced 75 to 100 doors a day in
its shop. Today, the shop has increased production 30 to 35
percent, and with fewer people.
There are six employees in the shop. The company focuses
on a single day of work. On Tuesday afternoon, for example,
John Miller, office manager, draws up the work plan for
Mullet now focuses on smaller lot sizes. Even a larger order of 100 doors is broken up into smaller lots.