FURNITURE MANUFACTURING
The efficiency gained by optimising and consolidating the separate production halls into one new facility enabled employees to be at their creative best
Together with Schuler Consulting, the company addressed the optimisation of its production processes. The goal was to make the processes “smarter” to increase production output and remain competitive. During an on-site visit, the consultants from Schuler analysed the current process situation and identified the short-, medium-, and long-term optimisation potential. The result was an individual roadmap for Performance Display & Millwork, showing how the improvement measures can be implemented. The roadmap also included an individual process comparison for the “nesting
The furniture manufacturer from Keene, New England, US, has a mission: To bring innovative, sustainable, and high-quality furniture to schools, kindergartens, and care facilities. For Whitney Brothers, this mission also entails innovation and sustainability within its production. As a certified lean company, Whitney Brothers strives for the digitisation of all production processes from the point of sale to production, with the goal of achieving “paperless manufacturing”. “We have been working with Schuler since 2016. Over the years, we have built deep trust and a productive partnership and conducted many successful projects. In early projects, we worked together to standardise our product designs and align our production with the demand for smaller batch sizes,” recalled Mike Jablonski, president of Whitney Brothers. Standardising the design principles of the extensive product range was the most efficient method to achieve shorter lead times. Designs, materials, and construction principles of all products were analysed and simplified. Uniform standards and design principles minimised part variety and construction variants and create common machining features for the products. The result — shorter setup times on the machine and faster production times.
A highlight was the last joint project where Schuler standardised Whitney Brothers’ assembly process, yielding an efficiency increase of 35-47% on the packaging. The company is already looking forward to implementing the next optimisation project, said Jablonski. “The Schuler team always makes sure that the project work is fun. We appreciate the collaboration in the joint workshops. We gain new inspirations and direct results every time.” PRODUCE SMART TODAY AND TOMORROW From children’s furniture to store construction, this last project example is about store builder Performance Display & Millwork from Grimes, Iowa, US. For about 30 years, the company has been engaged in classic store construction for retail. The manufacturer supports its customers in both custom-made designs that need to be integrated into existing concepts and in the “reconception” and implementation of complete store construction solutions. In the early 2000s, the manufacturer expanded its portfolio and has since offered individual carpentry services for new and rebuilt commercial buildings and public facilities. The manufacturer works closely with general contractors, architects, and engineering firms. Production and storage of Performance Display & Millwork cover around 80,000m 2 .
vs cutting” scenario as well as possible machine concepts.
Specifically for cutting, the Schuler team uncovered a lot of improvement potential. Through a new concept for batch formation, a lot of raw material can be saved during cutting. Optimisation of surrounding processes further contributes to material savings. Moreover, the stated project goal was not only to increase production efficiency but also — with a view to the competitive situation in the labour market — to ensure knowledge retention in the company. The standardisation of work processes ensures that manufacturers retain knowledge amid labour shortages
46 PANELS & FURNITURE ASIA | SEPTEMBER / OCTOBER 2024
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