|In addition to producing kitchens for Merillatâs Classic and Essential lines, the Adrian, MI, plant manufactures the white and bisque cabinet doors for all of Merillatâs plants.|
Since its founding in 1946, Merillat Industries has grown to become one of the largest manufacturer of residential cabinetry. A subsidiary of Masco Corp. since 1985, Merillat has manufacturing plants in seven states and employs more than 4,200 people. The Adrian, MI, facility is 485,000 square feet and serves as the corporate headquarters. The company is ISO 1401 and KCMA ESP certified.
1. Corporate-wide, the company utilizes the concepts of Six Sigma and lean manufacturing to improve production and consistently reduce defects in all areas by half.
2. Merillatâs production is based on âkitchen-at-a-timeâ manufacturing, with a five-day turnaround. The companyâs supply chain is also on a just-in-time basis.
3. Employees are empowered to participate in the Six Sigma process and get their ideas heard and implemented. It offers certification for Black, Green and Orange Belts.
âAt these cross-functional meetings, we'll also go through metrics with each leader, in a roundtable discussion, to allow everyone to communicate without constraints and to share information,â explains Green. âThis process is a continual one.â
Streamlining the Production Process
Although Merillat tracks its transition to lean manufacturing to the late 1990s, the basic techniques have been implemented in the company since founder Orville Merillat's days, says Wittig. âOrville was doing a lot of things we now consider lean manufacturing, even back in 1946.â
Along with its transition to lean manuf
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