Mass Customization Strategy for Cabinets, Furniture and Millwork Using Edge Glued Panels

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1 Mass Customization Strategy for Cabinets, Furniture and Millwork Using Edge Glued Panels Wood Education and Resource Center Princeton, West Virginia Thursday, June 3rd, 2010 Sponsored by: US Forest Service s Wood Education and Resource Center, NC State University Wood Products Extension Workshop Leaders: Harry Watt

2 Discrimination Policy The work upon which this project is based was funded in whole or in part through a grant awarded by the Wood Education and Resource Center, Northeastern Area State and Private Forestry, U.S. Forest Service. In accordance with Federal Law and U.S. Department of Agriculture policy, this institution is prohibited from discriminating on the basis of race, color, national origin, sex, age, or disability. (Not all prohibited bases apply to all programs.) To file a complaint of discrimination, write USDA, Director, Office of Civil Rights, Room 326-W, Whitten Building, 1400 Independence Avenue, SW, Washington, DC or call (202) (voice and TDD). USDA is an equal opportunity provider and employer.

3 Workshop Sponsors-Under Utilized Eastern Hardwood Species Project US Forest Service s Wood Education and Resource Center of Princeton, WV North Carolina State University s Wood Products Extension of Raleigh, NC

4 Edge Glued Panels for Wood Products Lumber Glued on Edge to Create Blanks Process in Quantity Lower Cost Due to Economy of Scale

5 Equipment to Produce Edge Glued Panels Radio Frequency Batch Glue Press Cures in a Cycle From Five to Ten Minutes

6 Equipment to Produce Edge Glued Panels Feed Through Continuous Flow Edge Glue Press Pressure Applied by Feed Chain

7 Equipment to Produce Edge Glued Panels Wall Rack of Manual Clamps

8 Typical Processes to Make Glued Panels 1. Kiln Drying of Green Lumber 2. Rough Planing 3. Rip First to Width and Cross Cut to Width or First Cross Cut to Length and Rip to Width to Create Staves 4. Glue Into Panels and Cure 12 to 36 Hours 5. Plane Faces to Clean Off Glue 6. Trim to Blank Width and Length Dimensions 7. Wide Belt Sand to Final Blank Thickness

9 Businesses Involved in the Making of Glued Panels Dimension Plant-Producer of Glued Panels But Not a Manufacturer of a Secondary Wood Product Cabinet, Furniture and Millwork Operations

10 Businesses Involved in Using Glued Panels to Make Value-Added Wood Products Cabinet, Furniture and Millwork Operations

11 Designing Cabinets and Furniture Using Edge Glued Panels Works Well With Box Styles Use Glued Panels for- Tops End Panels Shelves Doors and Drawer Fronts

12 Concepts of Mass Customization Consumers Today Want Products That Meets Their Needs and Not Just Products That Just Come Close Consumers Want to Purchase Products That Have the Options They Want But Not Additional Options They Don t Want Factories Using a Mass Customization Business Strategy Will Configure Its Workforce From Marketing Through Design, Engineering, Inventory Management, Production and Distribution So It is Profitable to Produce Wood Products in Small Lot Sizes at a Low Inventory $ Investment and With Quick Delivery

13 Current Examples of Mass Customization The Window and Door Industry-No Finished Goods Inventory and Typical Delivery for Standard Sizes in Two to Three Weeks Kitchen Cabinets-No Finished Goods Inventory and Typical Delivery for Standard Sizes in Two to Three Weeks In a Number of Standard Wood Finishes

14 Twelve Elements for a Mass Customization Wood Products Business Strategy 1. Have Multiple Design Elements 2. Low Inventory $ From Raw Materials to Finished Goods 3. Quick Processing of Orders As Everything is Available When the Order Arrives = Raw Materials, Design, Production Lines, Etc.

15 Twelve Elements for a Mass Customization Wood Products Business Strategy 4. Good Information System 5. Focus on What is Important to the Customer-Materials, Design, Function, Delivery 6. Affordable and Satisfactory Delivery

16 Twelve Elements for a Mass Customization Wood Products Business Strategy 7. Linkage of Manufacturing Capabilities to Customer Needs 8. Reduction/Simplification of the Intermediaries Between the Factory and the Customer 9. Pleasant Buying Experience to Build Loyalty

17 Twelve Elements for a Mass Customization Wood Products Business Strategy 10. Deliver When Promised 11. Control of Costs-Materials, Direct Labor and Overhead 12. Elimination of the Customer Having to Special Order

18 Adjusting Sales and Marketing for Mass Customization of Wood Products Basic Configurations Should Meet Most Needs Embellishment Options Are Easy to Understand / Order Preplanning of Product Lines So Little Confusion Can Occur

19 Adjusting Design and Engineering for Mass Customization of Wood Products Must Be Able to Instantly Create Bills of Materials/Parts Lists Cases Can Be Boxes With Embellishments Good Designs Support High Material Yields

20 Adjusting Design and Engineering for Mass Customization of Wood Products Must Be Able to Instantly Create Bills of Materials/Parts Lists Cases Can Be Boxes With Embellishments Good Designs Support High Material Yields Reduce the Number of Parts Per Item

21 Adjusting Inventory Management for Mass Customization of Wood Products Work to Stock a Small Amount of Raw Materials to Support a Wide Product Line Develop Dimensional Standards That Effectively Use Raw Materials and Support High Yields A Limited Parts or Components Stocking Program Can Support Lower Costs

22 Adjusting Production and Factory Efforts for Mass Customization of Wood Products Good Buildings + Good Layout + Short Production Lines = Lower Manufacturing Costs and Fast Order Cycles Must Be Able to Handle Lots of Finishes in Small Lots Must Reduce Set Up Times to Five to Ten Minutes

23 Adjusting Distribution and Delivery for Mass Customization of Wood Products Must Raise Product Quality Levels to Reduce Need for Service at Retailer Must Construct an Affordable Delivery Method for Small Quantities

24 Summary Wood Products Manufacturers Can Still Support a Profitable National Mass Market Business Strategy By Adding Customization Features That Customers Value and Want to Buy. The Entire Business Must Be Configured to Serve the Customer and Find Economies of Scale

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