Merritt, a specialist in high-end luxury millwork, recently finished a traditional style project in East Hampton, New York, that included their woodworking in his-and-her offices, bathrooms and dressing rooms, as well a theater and library.
Merritt, based in Mentor, Ohio, focuses on the art and science of woodworking and joinery for residential estates and superyachts.
The company oversees the operations including consulting, engineering, carpentry, hardware, architectural metalwork and specialty materials.
“This collection of services enables Merritt to manage the entire process from design concept to project delivery, ensuring an exacting and finished product delivered anywhere in the world, on time and within budget,” said Michael Merritt, CEO of Merritt.
“Merritt’s consulting group is effective with the developing process and leveraging software to reduce overall construction time line for all trades. The company’s clients want to move as fast as possible – perfect detail in record time – it is never fast enough.”
On the East Hampton project, this was a repeat client. Merritt previously worked with the homeowner and interior designer.
All projects are managed by a project team, led by a project principal. One or two project managers are deployed depending on size and complexity as well as one or two lead project engineers.
From this, Merritt has project coordinators, administration, engineering, production management, plant fabrication, logistics and installation. In all disciplines Merritt uses their own equipment and employees.
The company uses various software: Visual manufacturing for ERP and plant scheduling; Microsoft Projects for project management customized to their needs; Microsoft Office Suite; and AutoCAD, Revit, Solid Works, Solid Manufacturing Ultimate, Rhino, Alpha CAM, and Inventor.
Solid wood construction
The first step on this project was to buy veneer logs for the cherry and pine rooms and have them custom sawn and dried. The client prefers solid wood construction, so Merritt purchased the highest quality veneer logs and custom sliced them. The flat-cut panels went to panel, door and drawer insets and the quarter grain was used for the casings, cornice, base and trims. The women’s bath is in Birdseye Maple veneer.
Merritt is automated in all aspects with most machines using CNC programing, including ripsaws, moulders, mortise and tenoners, along with drilling, sawing and veneering. Being a traditional project, there was a lot of moulding and radius milling on the CNC machines.
This traditional style project featured finishes including Birdseye Maple, American black cherry, Rift white oak, Baltic pine, as well as custom glass and mirrors. Specific to this project, the American black cherry lumber was sourced from premier veneer logs and custom sawn into lumber.
“Merritt has a focused lean plan, we run the business based on hours for all work, all is billable and all is tracked and reviewed,” said Michael Merritt. “Merritt is in a custom business, it is always different but we need to find the common threads and improve.
“Automation is our strongest suit. We must produce pieces and parts quickly, effectively and accurately. Although the assembly, sanding and finish is still an art and is mainly by hand. We are strong schedulers and client committed. It keeps the company focused and on task.
Merritt has a lot of experience in creating the look of luxury. “Creating more luxurious interiors in a residential space can be simple, whether it’s the lighting and decor, or architecture and design, there are various ways to update a space to an inviting, comforting atmosphere,” Merritt said.
“Similar to statement walls, adding a statement room can make an impact to a home’s overall space. Finding a few statement pieces can be one way of creating such a space, but simply adding wooded panels, book shelves and crown moulding can provide that wow factor you are looking for.
“Add a sense of warmth to your home in an unexpected place, by adding wood panels to your ceilings. Incorporating elements of natural wood, creates an authentic and decorative focal point for your living space,” Merritt said. “By using lighter color woods and creating patterns, your room will visually look larger.”
Mentor, Ohio, Lodi, California
High-end woodwork and millwork
Total employees: 300
Plant size: 150,000 square feet
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