Originally, the goal was 100 doors a day. Now, they can do
close to 200 on certain days.
Employees agree that the current system is less stressful,
and there is no feeling of having to rush to complete work.
More of the planning and work is done in the office before
the process starts on the shop floor.
Miller said that everyone’s ideas matter, and everyone at
the company is part of the lean process.
“I never thought it would be this stress-free,” Martin said.
“Part of it is breaking habits, getting people to think. Once
they started seeing improvement they bought into it.”
One of the challenges to start was to get people to believe
in the process before results started to show up.
Recently, Martin offered employees an incentive if they
could reduce the turnaround time to produce a cabinet door
by 10 percent.
“We asked if they were working harder now,” Martin said.
“They said no, they aren’t working as hard as before.
“Guys on the shop floor are great. They’ve bought into
this lean journey. They’re working hard and are engaged. I
couldn’t ask for a better crew.”
Customers have also benefitted from the improvement in
the shop. Mullet can often offer shorter lead times on orders
for cabinet doors.
“Nothing appears to be going on,” Martin said of the shop.
“If you look at a computer you can see something is happening.”
But Martin said that reminding people how things used to
be and how they are better now is a continuing challenge at
Today, they have much more room, and are producing
more cabinet doors, with seemingly less effort and even fewer
“I never envisioned we would be doing what we’re doing
now,” he said. ✚
Mullet reduced its lumber inventory sharply by making smaller orders
and working with its lumber suppliers, ordering only what was needed.
Added recently was a Holz-Her Kundig finish sander with polishing
heads. Only a few new machines have been added recently.
✚ ✚ Accu-Systems, Miter machine
✚ ✚ Cantek America Inc., Cutoff saw
✚ ✚ Doucet Machineries Inc., Cabinet door clamp
✚ ✚ Extrema Machinery Co., Ripsaw, planer, widebelt sander
✚ ✚ Holz-Her US Inc., Div. of Weinig Group Kundig finish sander
✚ ✚ Larick Machinery Inc., Shaper
✚ ✚ Razorgag,e Optimizer pusher system
✚ ✚ Voorwood Co., Shaper
For more info:
Or go to woodworkingnetwork.com