New York Custom Interior Millwork Corp., a high-end architectural woodworking company in Queens, New York, was hit with a five-alarm fire that started August 3 and continued burning August, fueled by the wood, lacquers, thinners and paint at the business.

New York's WABC reports that the fire destroyed the facility used by a commercial and residential interior woodworking design and building company, despite efforts of more than 150 firefighters.

The New York City Health Department is advising people in the area avoid smoke exposure from structural fires by closing windows while indoors and reducing outdoor activity where smoke is present. A video of the fire by Richard York is show at the New York City Firewire Facebook page.

Among New York Custom Interior Millwork's many high-profle jobs was the renovation of the famed Tavern on the Green in New York's Central Park. A member of the Architectural Woodwork Institute, New York Custom Interior Millwork is a family run business, established in 1966.

As a result of Brennan's efforts, Taylor Studios reached the Inc. 500 list of the fastest growing companies in 2000, and the Inc. 5000 lists in 2007 and 2009.  

Baxter's American Grille, Champaign IL - Bar islands and wine lockers fabricated by Taylor Studios, Inc

• Full upholstery and seat foam replacements
• Leather repair and/or replacement; seat re-dye and leather color restoration
• Headliner and baggage panel refurbishment
• MX runner and protective cover fabrication
• Custom fabrication, repair, modification, re-veneering, repairing and refinishing for cabinetry and fixtures
• Carpet extraction and replacement
• Cleaning services, stain/ink removal

The 2016 annual Architectural Woodwork Institute (AWI) convention taking place Sunday, October 23 until Tuesday, October 25 in Kansas City, Missouri will visit veneer firm C.S. Humphrey & Co. and RCS Millwork's 60,000 sq. ft. plant. The convention will also feature educational sessions, industry professional speakers, team building, networking, and over 50 industry-leading exhibitors.

Activities will actually begin Saturday, October 22 - a day before the show officially begins - with a case study from restaurant chain Benihana. Harvard MBA graduate and architectural woodworking businessman Marc Sanderson will focus on the restaurant's management style, operational and marketing strategies, production, and design choices. The rest of the day and Sunday will feature tours, networking, and a reception dinner.

Activities truly kick off Monday with a keynote speech from Ross Shafer, author of eight business books, 14 human resources training films, and winner of six Emmy Awards for his work as a television host and producer. The day will continue with a presentation about global economics from Alan Beaulieu, a financial management presentation from Sebastien DesMarais of Hollywood Woodwork, a sales and marketing lecture from Hafele America's Scott Markwood, succession and estate planning with Husch Blackwell's Christine DeMarea, and efficiently communicating through technology with Innergy Discover's Jonathon Adams.

Tuesday will continue with another keynote from Ross Shafer - this time regarding what customers will expect by the year 2020. AWI members will then head out on manufacturing plant tours, with visits to veneer firm C.S. Humphrey & Co. and RCS Millwork, who runs a 60,000 square foot manufacturing facility.

Advanced Cabinet Systems has integrated design and estimating applications at its Marion, Indiana, operation to its production machinery. A labeling scheme keeps project components organized as material flows through the plant.  

Advanced Cabinet developed its Division 12 cabinet specification as part of a strategic plan to grow its business in the segment, and to be able to  handle fabrication and fulfillment with great speed and precision. It was built in coordination with adoption of  LEAN manufacturing processes, and an automated, integrated Enterprise Resource Planning System.

Much of the software was developed internally by a team including plant engineering manager Tim Hanson, programmer Aaron Hanson, and Kyle Rennaker, marketing manager.

Incorporating parametric modeling of hundreds of cabinet designs, the Division 12 specification for Arcom MasterSpec represents Advanced Cabinet Systems own automation of its estimating and production workflow systems.

Rick Thaler, president, OGB Architectural Millwork

Have fun, make money and build business. It’s been a winning mantra for Rick Thaler, president of OGB Architectural Millwork, as he brings the New Mexico-based firm to new levels of success.

Thaler was introduced to woodworking as a teenager, doing framing and general construction work. He later learned cabinetry, and made his own custom furniture and cabinetry. “I wandered into the Bradbury Stamm woodshop to use the widebelt sander. They were building a spiral staircase on one side of the shop and a big bank teller line on the other side and I knew right away that was the kind of work I wanted to do. I got a job there as an apprentice cabinetmaker and learned how to run a lot of machines, do layouts and cutting lists, and how to plan a project from start to finish.”

A bump in the road, “I got laid off the week before my first child was born,” gave Thaler insight into another side of the industry – machinery sales. However, he soon returned to woodworking, and honed his business and crafting skills.

Thaler rejoined Bradbury in 1990 and became general manager in 1999. “In 2000 I was able to buy the woodworking business and renamed it OGB Architectural Millwork, the initials of the founder Orville Grant Bradbury.”

READ MORE 2016 Wood Industry Market Leaders revealed Meet all the 2016 Wood Industry Market Leaders: Farooq Kathwari, Ethan Allen Interiors; Paul Wellborn, Wellborn Cabinet; Todd Wegman, Stevens Industries; Sylvain Garneau, Groupe Lacasse; Jack Lansford Jr., Decore-ative Specialties; Bob Lewis, Closet & Storage Concepts/More Space Place; Rick Thaler, OGB Architectural Millwork; and Brian Preston, Lamon Luther.

Under Thaler’s leadership, the 28,000-square-foot shop has produced a variety of award-winning commercial and residential projects.

“My proudest achievement is simply my business itself – the beautiful work we do, and the opportunity to give long term, gainful employment to so many people in the trade I love,” Thaler said.

“My goals are to maintain our current trend of steady growth and increasing profitability, maintain our level of quality and service, and become completely unnecessary to the running of the company within two years,” he added.

In his free time, Thaler enjoys hiking, biking, shooting pool and “hanging with my 9-month old grandson.”

Also playing a large role in Thaler’s – and OGB’s – profile, “I target 10 percent of my net for community giving,” he said, citing the Kiwanis, Fraternal Order of Police, Tour for the Cure, The Susan B. Komen Foundation and other national groups, as well as local agencies like New Day, Fathers Building Futures, La Familia and The Children’s Grief Center. Event sponsorships also include the Outpost Performance Space, AMP Concerts and Southwest Roots Music, three non-profit music organizations.

Quick Glimpse:

Education: Three years of college at different institutions

Number of years at the company: 26 years —10 years as an employee, 16 as an owner.

Number of years in the industry: 35 years

Word that describes you: Optimistic

Business mantra: Have fun, make money, build business

Best advice ever received: The best advice was from my Dad, who said, “Do unto others as you would have them do unto you.”

Who have you tried to emulate in business and why? I’ve tried to emulate my father, who was a physician and knew nothing about business or manufacturing, but who was an honest, kind person who valued his family, his friendships and his integrity most of all, and who lived well.

Todd Wegman, president, Stevens Industries Inc.

Teamwork: It’s what drives not only Stevens Industries President Todd Wegman, but is the very essence of the employee-owned, multi-million dollar panel laminator, commercial casework and millwork manufacturer, and private label manufacturer.

Wegman helped spearhead the transition to an ESOP, initiated by then owner Chuck Stevens, to ensure the Teutopolis, Illinois-based company remained with local ownership. Having worked there in high school and college, Wegman left his Chicago-based financial consulting firm and “rejoined” Stevens in 1998,  putting the ESOP plan in place. Working in purchasing and sales, he would later serve as vice president before becoming president.

“Knowing many different aspects of the business – the products and our efficiencies – has been one of my strengths,” he said. “New product designs, coupled with efficiencies in innovation, have been the driving force of our success.”

Another strength has been “having good people and letting them do their jobs.” Stevens Advantage Casework and Millwork is among the largest commercial casework and millwork operations in North America. The firm employs about 500 people and under Wegman’s leadership, continues to grow. Stevenswood Laminated Panels are used in office furniture, store fixtures, closet systems, education and healthcare environments.

READ MORE 2016 Wood Industry Market Leaders revealed Meet all the 2016 Wood Industry Market Leaders: Farooq Kathwari, Ethan Allen Interiors; Paul Wellborn, Wellborn Cabinet; Todd Wegman, Stevens Industries; Sylvain Garneau, Groupe Lacasse; Jack Lansford Jr., Decore-ative Specialties; Bob Lewis, Closet & Storage Concepts/More Space Place; Rick Thaler, OGB Architectural Millwork; and Brian Preston, Lamon Luther.

“We’re helping push new products and innovation in efficiency,” he said. Using a strategy of being “a first follower,” Wegman added, “We may not be the company that dreams up the idea, but we are the one that refines it for the better.”

Refining ideas for the betterment of Stevens – and the industry – is a role that comes naturally to Wegman. “I want to continue to innovate with our products and grow all facets of the business: supply and casework,” he said.

Employee development also is critical, and, Stevens has started a Certified Training Operations Program (CTOP). It will soon host its first graduation.

Community service is important, too. In addition to the United Way, Stevens has given its talents to local projects. “We like to be able to use our skills and resources to create more value than just writing a check,” Wegman added.

It’s that passion that has helped drive Stevens’ – and Wegman’s – success. “Being honest in dealings and having true passion for what you do – those are two of the most important aspects of being successful.”

Outside of work, Wegman enjoys time spent with his wife, Carrie, and their four children, Mary Claire, Ava, Ellie, and Charlie, in a variety of activities.

Quick Glimpse

Education: BS Economics, University of Illinois; MBA Wake Forest

Number of years at the company: 18 years

Number of years in the industry: 18 years

Words that describe you: Team player, with a passion for doing the right thing, for the right reason.

Best advice ever received: Be honest in your dealings and have a true passion for what you do.

Strategy: Put together a team with complementary skill sets to extend your strengths. Rather than micromanaging, hiring good, passionate people and trusting their abilities will lead to growth. Create a culture that drives entrepreneurialism. Entrepreneurialism can be a power tool at all levels of an organization. If we prepare to make decisions, make the decision and own the outcome, we can do great things.

At Timber Products Company, sustainability isn’t just a buzzword, it’s a commitment woven through every step of our manufacturing process. From seed to finish, each product is the result of thoughtful operations and experienced craftsmanship.

Reforestation 
We plant approximately 350,000 trees every year on our 114,800 acres of company-owned and managed timberlands.

Growth
We believe that active management of timberlands is critical. We tend our forests to maximize timber growth over the long term and carefully monitor our inventory to ensure that we are growing more timber each year than we are harvesting. We use a comprehensive Environmental Management System to ensure that our practices protect soil and water quality and promote the viability of the wildlife communities that inhabit our forestland.

Harvest
Our annual timber harvests are dispersed across our lands in order to maintain a mosaic of diverse timber types and ages within each watershed.

Manufacturing
Each of our mills operate on the principle of sustainability. We use virtually 100% of the tree: cutting lumber, peeling veneers and using chips and sawdust to create composite panels. The bark is sold for landscape material and peeler cores are used to manufacture pallet stock. Any by-product left over is burned in our boilers to produce steam for our operations. Nothing goes to waste at Timber Products Company.

Finishing
We use no-added formaldehyde (NAF) and ultra-low-emitting formaldehyde (ULEF) resins to reduce emissions, and meet the strictest regulations in the world.

To find out more about who we are, head over to our new website to learn more about our sustainable forestry and manufacturing practices!

Who are the largest cabinet manufacturers in North America? The biggest producers of furniture? The millwork and store fixture companies with the largest sales?

This information is part of the FDMC 300, an annual report that FDMC and Woodworking Network produce each year. The top 10 lists here are based on 2015 data, the most recent completed year we’ve researched.

The FDMC 300 is a group of the 300 largest cabinet, furniture, millwork, store fixture, office/contract and component producers in North America.

As we reported earlier this year, sales for the FDMC 300 group of companies grew 7 percent in 2015 to $46.404 billion, by our estimate. For this important group of 300 companies it was the fourth consecutive year of sales growth, and it came after five years of declines from 2007 to 2011.

Once again, cabinet companies of different sizes did especially well in 2015. Many of the larger, publicly traded companies and privately held firms we were able to document had a positive year.

We won’t have final figures for 2016 for several months, but indications that we’re seeing point to another year of sales growth.

Wood products companies in our industry have continued to become more efficient by using technology and new management techniques. They have done more with fewer people, and with fewer resources.

You don’t hear “we’ve always done it that way” from people who are always on the lookout for a better way. These companies are leaders both in their market and in the overall wood products industry. Additional information can be found at fdmcdigital.com by clicking on the Knowledge Center tab and selecting FDMC 300 in the dropdown menu.
Should your company be listed next year?  Did you have about $10 million or more in sales?  Contact me at karl.forth@woodworkingnetwork.com.

Cabinet industry

1. MasterBrand Cabinets
Main location: Jasper, IN Divisions: Aristokraft, Decora, Diamond, Dynasty, HomeCrest, Kemper, KitchenCraft, Norcraft, Omega, Schrock, WoodCrafters Annual sales: $2.085 billion* (‘15) Manufacturing plants: 16 – Auburn, Talladega, AL; Waterloo, IA; Arthur, IL; Ferdinand, Goshen, Huntingburg, Jasper (2), Kinston, NC; Grants Pass, OR; Weslaco, TX; Winnipeg, MB; Valle Hermoso, Rio Bravo, Gomez Palacio, Mexico; and six Norcraft locations. Total square footage: 6 million Total Employees: 12,000

2. Masco Corp.
Main location: Taylor, MI Divisions: Domestic cabinet companies include KraftMaid Cabinetry, Merillat Industries, Masco Retail Cabinet, Quality Cabinets Annual sales: $1.025 billion* (‘15) Domestic manufacturing plants: 8 –  Middlefield, Orwell, OH; Los Lunas, NM; Culpeper, Mt. Jackson, VA, Wilson, PA, Mt. Sterling, KY; Duncanville, TX. Total square footage: 5 million Total Employees: 12,000

3. American Woodmark Corp.
Main location: Winchester, VA Divisions: Timberlake, Shenandoah Cabinetry, Potomac Annual sales: $825.5 million (‘15) Manufacturing plants: 9 – Kingman, AZ; Jackson, Toccoa, GA; Gas City, IN; Monticello, KY; Allegany County, MD; Humboldt, TN; Berryville, Orange, VA Total square footage: 3 million Total Employees: 3,700

4. RSI Home Products
Main location: Anaheim, CA Divisions: Prestige Cabinets, RSI Professional Cabinet Solutions Annual sales: $300 million* (‘15) Manufacturing plants: 9 – Anaheim, Mira Loma, CA; Springfield, MO; Neodesha, Columbus, KS; Lincolnton, NC; Tijuana, Mexico Total square footage: 3 million Total Employees: 3500

5. Elkay Wood Products Co.
Main location: Waconia, MN Divisions: Mastercraft, Medallion, Yorktowne, Design-Craft, Schuler, InnerMost, Woodbridge, American Cabinetry Collection Annual sales: $250 million* (‘15) Manufacturing plants: 7 – Aurora, CO; Culver, IN; New Ulm, Waconia, MN; Independence, OR; Mifflinburg, PA; Danville, VA Total square footage: 2 million+ Total Employees: 250

6. ACProducts, Inc.
Main location: The Colony, TX Divisions: Advanta, Echelon Annual sales: $180 million* (‘15) Manufacturing plants: 1 – Thompsontown, PA Total Employees: 900

7. Foremost Groups Inc.
Main location: East Hanover, NJ Divisions: Kitchen & Bath Div., Home Div., OEM Div., Canada Div. Annual sales: $175 million (‘15) Manufacturing plants: 6 – Woodland, CA; East Hanover, NJ; Hobart, IN; Rizhao, Shenzen, Shandong, China Total Employees: 200

8. Wood-Mode Inc.
Main location: Kreamer, PA Divisions: Wood-Mode, Brookhaven Annual sales: $130 million* (‘15) Manufacturing plants: 1 – Kreamer, PA Total square footage: 1.2 million Total Employees: 1,200

9. Wellborn Cabinet Inc.
Main location: Ashland, AL Divisions: Cabinetry by Karman, Rutt HandCrafted Cabinetry, Heritage Custom Cabinetry .Annual sales: $125 million (‘15) Manufacturing plants: 4 – Ashland, Lineville, AL; Salt Lake City, UT; New Holland, PA Total square footage: 1.4 million Total Employees: 1150

10. Leedo Mfg.
Main location: Stafford, TX Divisions: Leedo Cabinetry Annual sales: $97 million (‘14) Manufacturing plants: 3 – East Bernard, El Campo, TX. Square footage: 265,000 Employees: 570

Photo: Teknion

Contract furniture

1. Steelcase Inc.
Main location: Grand Rapids, MI Divisions: Coalesse, Turnstone, Steelcase Health, Details, Vectra Annual sales: $3.059 billion (‘15) Manufacturing plants: 21 -- Grand Rapids, Kentwood, Gaines Township, MI; Atlanta, GA; Athens, AL; City of Industry, Corona, CA; High Point, NC; Clymer, Dixonville, PA; Okmulgee, OK; Tijuana, Mexico Total square footage: 11.8 million Total Employees: 10,700

2. Herman Miller Inc.
Main location: Zeeland, MI Divisions: Nemschoff, Geiger, Maharam, ELA Intl Annual sales: $2.142 billion (‘15) Manufacturing plants: 9 -- Atlanta, GA; Holland, Spring Lake, Zeeland, MI; Hildebran, NC; Sheboygan, WI; Melksham, England; Dongguan, Ningbo, China Total square footage: 4 million Total Employees: 7,510

3. Haworth Inc.
Main location: Holland, MI Annual sales: $1.8 billion (‘14) Manufacturing plants: 17 -- Big Rapids,  Holland, Kentwood, Ludington, MI; Bruce, MS; High Point, NC; Canada; China; France; Germany; India; Portugal; Spain Total square footage: 5.5 million Total Employees: 7,000

4. HNI Corp.
Main location: Muscatine, IA. Divisions: Allsteel, Gunlocke, HON, HNI Intl, Maxon, Paoli, Artcobell, HBF, Lamex, bpergo Annual sales: $1.775 billion* (‘15) Manufacturing plants: 10 -- Cedartown, GA; Mt. Pleasant, Muscatine, IA; Wayland, NY Total Employees: 8,500

5. Knoll Inc.
Main location: East Greenville, PA Divisions: KnollExtra, KnollStudio, KnollTextiles, Spinneybeck Annual sales: $1.065 billion* (‘15) Manufacturing plants: 6 -- Grand Rapids, Muskegon, MI; East Greenville, PA; Toronto, ON; Foligno, Graffignana, Italy Total square footage: 2.5 million (North America) Total Employees: 4,000

6. Global Group
Main location: Downsview, ON Divisions: Global Contract, Globalcare, Global Total Office, Global Salon, Offices to Go Annual sales: $1 billion* (‘15) Manufacturing plants: 50+ -- Downsview, ON; Marlton, NJ (U.S. headquarters) Total square footage: 4 million+ Total Employees: 4,500

7. KI
Main location: Green Bay, WI Divisions: KI Europe, Pallas, Spacesaver, Middle East, AFP, Sebel Annual sales: $650 million* (‘15) Manufacturing plants: 9 -- Pontotoc, Tupelo, MS; High Point, NC; Green Bay, Bonduel, Manitowoc, Fort Atkinson, Two Rivers, WI; Pembroke, ON Total square footage: 1.9 million Total Employees: 3,000

8. Kimball International Inc.
Main location: Jasper, IN Divisions: Kimball Hospitality, Kimball Office, National Office Furniture Annual sales: $600.8 million (‘15) Manufacturing plants: 10 -- Borden, Jasper, Salem, Santa Claus, IN; Danville, Fordsville, KY; Martinsville, VA Total square footage: 3.55 million Total Employees: 3,600

9. Teknion Corp.
Main location: Toronto, ON Divisions: Annual sales: $500 million* (‘15) Manufacturing plants: 21 -- Calgary, AB; Concord, Markham, Toronto, ON; Montmagny, St. Vallier; St. Romuald, QC; Clayton, NC, Malaysia Total square footage: 2.5 million Total Employees: 3,400

10. OFS Brands Inc.
Main location: Huntingburg, IN Divisions: OFS, First Office, Carolina, Loewenstein, Highmark Annual sales: $275 million (‘15) Manufacturing plants: 9 -- Huntingburg, IN; Huntington Beach, CA; Leitchfield, KY; Archdale, NC Total square footage: 1,200,000 Total Employees: 1650

Photo: Ethan Allen Interiors

Residential furniture

1. Ashley Furniture Industries Inc.
Main location: Arcadia, WI Divisions: Ashley Casegoods, Ashley Upholstery, Millennium  Annual sales: $4.08 billion (‘15) (excluding retail) Manufacturing plants: 9 -- Colton, CA; Ecru, Ripley, Verona, MS; Advance, NC; Leesport, PA; Arcadia, Independence, Whitehall, WI Total square footage: 13,043,245 Employees: 24,000

2. La-Z-Boy Inc.
Main location: Monroe, MI Divisions: Upholstery Group: England, Casegoods Group: American Drew, Hammary, Kincaid  Annual sales: $1.261 billion (‘15) Manufacturing plants: 8 -- Siloam Springs, AR; Redlands, CA; Newton, MS; Neosho, MO; Lenoir, Taylorsville, NC; Dayton, Morristown, TN Total square footage: 5 million Total Employees: 8,000

3. Heritage Home Group
Main location: High Point, NC Divisions: Broyhill, Drexel Heritage, Henredon, Hickory Chair, LaBarge, Lane, Maitland-Smith, Pearson, Thomasville Annual sales: $750 million* (‘14) Manufacturing plants: 15 -- Tupelo, MS; Conover, High Point, Mount Airy, Lenoir, Hickory, Thomasville, NC; Cebu, Philippines; Tambak Aji, Semarang, Indonesia Total square footage: 6 million Total Employees: 6,000

4. Dorel Industries, Inc.
Main location: Montreal, QC Divisions: Altra, Ameriwood, Cosco Home & Office, Dorel Asia, Dorel Home Products, Ridgewood, Carina, SystemBuild Annual sales: $640 million* (‘15) Manufacturing plants: 5 -- Columbus, IN; Tiffin, OH; Cornwall, ON; Montreal, QC; Helmond, Holland Total Employees: 4,600

5.  Sauder Woodworking
Main location: Archbold, OH Divisions: Sauder RTA, Progressive, Sauder Global Sourcing, Sauder Mfg., Wieland, Butler Woodcrafters Annual sales: $550 million (‘15) Manufacturing plants: 7 -- Archbold, Stryker, OH; Grabill, IN; Richmond, VA Total square footage: 4 million Total Employees: 2,500

6. Ethan Allen Interiors Inc.
Main location: Danbury, CT Divisions: Ethan Allen Global, Ethan Allen Retail, Ethan Allen Operations Annual sales: $469.4 million (‘15) Manufacturing plants: 6 -- Maiden, Old Fort, NC; Passaic, NJ; Orleans, VT, Silao, Mexico; Honduras Total square footage: 2 million Total Employees: 4,000

7. Flexsteel Industries Inc.
Main location: Dubuque, IA Divisions: DMI Furniture Annual sales: $467 million (‘15) Manufacturing plants: 6 -- Harrison, AR; Riverside, CA; Dublin, GA; Dubuque, IA; Starkville, MS; Juarez, Mexico Total square footage: 2,120,000 Total Employees: 1,400

8. Brown Jordan International
Main location: St. Augustine, FL Divisions: Brown Jordan, Tropitone, Winston, Casual Living, Charter, Wabash Valley Annual sales: $400 million* (‘15) Manufacturing plants: 8 -- El Monte, Irvine, CA; Sarasota, FL;  Silver Lake, IN; Juarez, Mexico  Total square footage: 1 million Total Employees: 1,500

9. Klaussner Furniture Industries
Main location: Asheboro, NC Divisions: Klaussner International, Enso, Candor Creek, Comfort Design, Klaussner Outdoor Annual sales: $350 million* (‘15) Manufacturing plants: 3 -- Asheboro, Candor, NC Total square footage: 1.8 million Total Employees: 1,800

10. Best Chairs, Inc.
Main location: Ferdinand, IN Divisions: County Line Annual sales: $261 million (‘15) Manufacturing plants: 6 -- Cannelton, Ferdinand, Jasper, Paoli, IN Total square footage: 1.1 million Total Employees: 980

Photo: Koetter Woodworking

Architectural woodwork

1. Moulure Alexandria Moulding
Main location: Alexandria, ON Divisions: Royal Woodworking Co. Annual sales: $150 million (‘15) Manufacturing plants: 5 -- Moxee, WA; Alexandria, Aurora, ON Total square footage: 846,000 Total Employees: 800

2. Fetzer Architectural Woodwork
Main location: Salt Lake City, UT Divisions: Retail, Architectural Annual sales: $65 million (‘15) Manufacturing plants: 2 – Salt Lake City, UT Total square footage: 220,000 Total Employees: 300

3. EMI Industries LLC
Main location: Tampa, FL Annual sales: $51 million (‘14) Manufacturing plants: 6 -Tampa, FL; Alpharetta, GA; Boonton, NJ; Cranston, RI; Arlington, TX Total square footage: 385,000    Total Employees: 300

4. Eggers Industries
Main location: Two Rivers, WI Annual sales: $50 million (‘15) Manufacturing plants: 3 -- Two Rivers, Neenah, WI; Smithfield, KY Total square footage: 550,000 Total Employees: 425

5. Koetter Woodworking Inc.    
Main location: Borden, IN Annual sales: $50 million* (‘15) Manufacturing plants: 1--Borden, IN Employees: 282

6. Mission Bell Manufacturing
Main location: Morgan Hill, CA. Annual sales: $45 million* (‘15).  Manufacturing plants:  1 -- Morgan Hill, CA Total square footage: : 80,000 Total Employees: 200

7. Merritt Woodwork
Main location: Mentor, Ohio Annual sales: $40 million* (‘15) Manufacturing plant: 2 -- Mentor, OH Total square footage: 105,000. Total Employees: 200

8. Imperial Woodworkin Co.    
Main location: Palatine, IL. Divisions: Calmar Manufacturing Co., Imperial Woodworking Enterprises, Imperial Architectural Finishing Annual sales: $40 million* (‘15) Manufacturing plants: 3 -- Palatine, IL; Colorado Springs, CO; Calmar, IA Total square footage: 240,000 Total Employees: 250

9. Goebel Fixture Co.   
Main location: Hutchinson, MN Annual sales: $35 million* (‘15) Manufacturing plants: 2 - Hutchinson, Minnetonka, MN Total square footage: 110,000 Total Employees: 150

10. Parenti & Raffaelli Ltd.    
Main location: Mt. Prospect, IL Annual sales: $25 million* (‘15) Manufacturing plants: 1 – Mt. Prospect, IL Total square footage: 56,000 Total Employees: 120

10. Mark Richey Woodworking
Main location: Newburyport, MA Annual sales: $25 million* (‘15)  Manufacturing plants: 1 – Newburyport, MA Total square footage: 130,000 Employees: 100

Photo: Stevens Industries

Store fixtures & casework

1. Lozier Corp.
Main location: Omaha, NE Annual sales: $500 million* (‘15) Manufacturing plants: 10 - Omaha, NE; Scottsboro, AL (2); Middlebury, IN; Joplin, MO; Union, MO; McClure, PA; Fort Worth, TX Total square footage: 3.5 million Total Employees: 2,500

2. idX (Universal Forest Products)
Main location: Earth City, MO Divisions: Baltimore, Chicago, China, Dallas, Dayton, India, London, Los Angeles, Louisville, Mexico City, New York, North Carolina, Seattle, SF Bay Area, St. Louis, Tokyo, Toronto Annual sales: $350 million* (‘15). Manufacturing plants: 9 - Ontario, CA; Jeffersonville, IN; Columbia, MD; Washington, NC; Dayton, OH; Cedar Hill, TX; Puyallup, WA; Leicestershire, UK; Wujiang City, China Total square footage: 3.1 million Total Employees: 1,400

3. L.A. Darling Co..
Main location: Paragould, AR. Divisions: L.A. Darling Wood, L.A. Darling Gondola, L.A. Darling Specialty Metal, L.A. Darling Sa de CV, L.A. Darling Ltd. Annual sales: $110 million* (‘14) Manufacturing plants: 4 -- Corning, Piggott, Paragould, AR; Mexico City Total square footage: 1.5 million Total Employees: 1,200

4. Stevens Industries
Main location: Teutopolis, IL Divisions: Techline, *acquired LSI Corp. in 2016 Annual sales: $95 million* (‘15)  Manufacturing plants: 1 – Teutopolis, IL Total square footage: 450,000 Total Employees: 450

5. Colony Inc.
Main location: Elgin, IL Annual sales: $85 million* (‘15) Manufacturing plants: 3 - St. Charles, Elgin, IL; Xiamen, China Total square footage: 550,00 Total Employees: 750

6. Fleetwood Fixtures
Main location: Leesport, PA. Divisions: High Country Millwork Annual sales: $70 million* (‘15) Manufacturing plants: 1 – Leesport, PA Total square footage: 287,000 Total Employees: 160

7. Panel Processing Inc.
Main location: Alpena, MI Divisions: Alabama Inter-Forest Inc., Holland Panel Products, Modular Wood Systems, Thermo Pressed Laminates Annual sales: $70 million* (‘15) Manufacturing plants: 11 -- Eufaula, AL; Merrillville, IN; Alpena, Coldwater, Holland, MI; Klamath Falls, OR; Jacksonville, TX; Claudville, VA Total square footage: 1.05 million Total Employees: 252

8. Artitalia Group
Main location: Montreal, QC Divisions: Artitalia, Hemsley Furniture, International Visual Corp. Annual sales: $60 million* (‘14) Manufacturing plants: 2 – Montreal, QC  Total square footage: 650,000 Total Employees: 350

9. Amstore Corp.
Main location: Grand Rapids, MI Annual sales: $50 million* (‘15) Manufacturing plants: 2 -- Grand Rapids, MI; Shanghai, China Total square footage: 900,000 Total Employees: 200

10. TJ Hale
Main location: Menomonee Falls, WI Annual sales: $40 million* (‘15) Manufacturing plants: 2 - Menomonee Falls, Milwaukee, WI
Total square footage: 250,000     Total Employees: 160

Photo: Closet & Storage Concepts/More Space Place

Closets & home organization(based on information from staff reports)

1. Newell Rubbermaid
Main location: Atlanta, GA Estimated annual sales: $5.92 billion

2. The Container Store
Main location: Coppell, TX Estimated annual sales: $794.63 million

3. California Closets
Main location: Berkeley, CA Estimated annual sales: $100 to $500 million

4. ClosetMaid
Main location: Ocala, FL Annual sales: $125 million

5. Closet & Storage Concepts/More Space Place
Main Location: West Berlin, NJ
Estimated sales: Over $40 million
 

Good customer service is key when it comes to retaining, as well as obtaining, customers. Today's wood products manufacturers must also work harder, smarter and faster than their competitors. What follows are some of the customer service strategies put in place by manufacturers of wood components, cabinetry, architectural woodwork and furniture.

Read all the 2016 WOOD 100: Strategies for Success

JB Cutting Inc., Mt. Clemens, MI —  “Our quick turnaround and excellent customer service have always been our number one priority” said Christina Relyea, sales & marketing manager of the component manufacturer’s success.

A  full-service manufacturer, JB Cutting specializes in custom doors, drawers and other finished components for cabinetry, store fixtures, healthcare furnishing and home organization.

“In the interest of making production run more smoothly and sales soar while increasing employee engagement and satisfaction, we’ve been working with a Certified Business Advisor,” she added.

“We also strengthened our partnerships with several TFL suppliers while promoting our new line of five-piece doors, the Artisan and Craftsman Series.”

Concepts in Millwork, Colorado Springs, CO —  A fixture in the architectural woodwork industry, Concepts in Millwork has been recognized throughout its history not only for the high-profile projects, such as Denver’s DU Academic Commons (pictured), but also for its capabilities and service.

The company’s skill set – including design, project management and the ability to combine unlike materials to create unique projects – has helped distinguish it from its competitors, said Scott Robinson, company president. That material mix could include acrylics, glass, wood, laminates and more. “We’re often providing much more than [traditional] architectural millwork” he said.

Concepts in Millwork is premium-grade certified for fabrication and installation through the Architectural Woodwork Institute. And because many of its projects require compliance for obtaining LEED certification, the company uses only NAUF (no-added urea formaldehyde) panels and sustainably certified woods for all its jobs. “It became easier for us to standardize and go to one type of material,” Robinson added.

Hudec Woodworking Corp., Griffith, IN —  Business is heating up for this architectural millwork firm, which specializes in high-end restaurant work.

“Serving the client is at the top of our agenda with any project, big or small,” said Gary Hulen, general manager. “Most of our business is repetitive and by referral, so keeping that client relationship is very important.

Developing the capabilities to be a one-stop source for the architects, designers and general contractor has also helped the company obtain and retain business throughout the nation. “They’re coming to only one place for a turnkey product, and we get control of the job and the ability to oversee the quality,” he added.
The company recently added a Biesse CNC router to upgrade in its capabilities.

Here are some more customer service strategies:

Meeting & exceeding deadlines

Interior & Exterior Designs Inc., La Habra, CA
Owner & designer Leon Williams attributes “Top 10” work and marketing for helping drive up 2015 sales 2.9% for the custom cabinet firm. “Just continuing to give our best, 100% effort, integrity, precision, meeting lead times, not playing games during or at the end of a job – we live for the referrals of each job,” he said.

Rynone Mfg. Corp., Sayre, PA
A manufacturer of casegoods, countertops and cabinets for the multi-family, housing, institutional, healthcare and commercial industries, the firm keeps a continued emphasis on quality, price and the timeliness of delivery, said Richard Rynone, president. “Rynone delivers these every day.”

Juan Pampanas Designs Inc., Miami, FL
“The key steps we took, that lead to our company’s overall success, were in assuring the delivery of our cabinetry in a timely fashion with the utmost quality,” said Daniel Pampanas, associate director at the contemporary cabinet and furniture firm. “In doing so we made sure our clients were always satisfied which continuously lead to referrals and repeat business.

Pleus Cabinets, Jefferson City, MO
“Timelines are the main reason for our success,” said Alan Pleus, president of the commercial and residential cabinet firm. Sales for the company grew 27.7% last year, and look to be even better for 2016, Pleus added.

Enhanced capabilities & offerings

High Country Cabinets, Banner Elk, NC
“Our company motto is ‘Exceeding Customer Expectation’ and we do that from the design, to our presentation, product, installation,” said President John Page. “Our whole company has bought into that philosophy.” A full-service firm, it designs and manufactures cabinetry and furniture. 2015 sales were up 6.7%, and look to be even stronger this year.

Monarch Custom Plywood Inc., Vaughan, ON
The architectural plywood and panel firm has increased its production capabilities to service its growing customer base, said Ted Turvey, sales, marketing & media. Among the new equipment is an automated trim line and double panel press.

Parenti & Rafaelli Ltd., Mt. Prospect, IL
The architectural woodwork firm is a full-service manufacturer, from estimating and project management, to manufacturing and finishing, through installation. It also offers touch-up and repair services to clients, as well as restoration work.

The personal touch

Amish Cabinet Doors, Appleton, WI
The cabinet door manufacturer offers online ordering. However, personal service is “just a phone call away,”  stressed Robert Cook, treasurer. “Since 2013 we have put great effort in having a live, knowledgeable voice answer the telephone. Many of our customers are first-time buyers and need help understanding terminology and how to measure correctly.” Sales have grown steadily since, including a 15.6% jump in 2015.

Boland Woodworking Inc., Philadelphia, PA
“Maintaining good solid relationships, and being more proactive rather than reactive,” while servicing customers in a timely matter are among the service strategies used by the custom furniture and casework firm to keep clients satisfied, said Brian Boland, president. The strategy is obviously working, with 2015 sales up 9.2%, and 2016 projected to be even better.

Red Star Cabinet Co., Farmingdale, NY
A family-owned cabinet manufacturer specializing in multi-family and luxury condos, the company pays special attention to the details. “Our quick turnaround and repeat customer base show we excel in customer satisfaction and loyalty,” said Robert Edelbach, president.  “We have also spent time researching and sourcing the proper suppliers who are willing to work with us and help offer our clients full customization  of products.” The firm recently expanded its product line to include LED mirror panels and medicine chests which it fabricates to customer specification. 2015 sales were up 3.0%.

Signature Custom Cabinetry Inc., Ephrata, PA
The custom residential cabinetry firm attributes good customer service for much of its success. “[We have] a keen focus on understanding customers in our niche and serving them,” said Kent Martin, president and CEO. 2015 sales at the multi-million dollar firm rose 7.3%, and should continue.

Closet America, Lanham, MD
The award-winning closets firm excels at customer service. In addition to having its company-trained installers and vans, it has provided designers with tablets and software to create 3-D renderings for clients.

Premium Woods LLC, Lincoln, NE
Bob Long, president of the wood and laminate casework and tops firm, said “Over communicating with our customers and responding to matters in a timely matter,” have helped the company maintain and obtain customers. “Delivering a quality product in a timely matter,” is another secret to the company’s success.

Cabinets 2000, Norwalk, CA
“We pride ourselves in giving the customer what they want” said Sherwood Prusso, president. He referenced the cabinet firm’s pigmented UV finish program, which has helped grow sales.

Read more 2016 WOOD 100: Strategies for Success

Marketing Initiatives
Go-to-Market Strategies
Business Strategies
Productivity Enhancements
Technology Integration
Product Innovations
Customer Service
Return to WOOD 100 Main Page
Read the special Leadership Edition of FDMC online
 

There's no lounging on the job for these top innovators. Check out the strategies these WOOD 100 companies have when it comes to new product development.

Steelcase, Grand Rapids, MI —  The contract furniture giant said its Brody WorkLounge is “the first and only microenvironment designed for the brain and the body” — enabling people to remain focused on what’s important.

The Brody WorkLounge, which debuted in 2015, was developed from research which showed that in a typical day workers and/or students will “switch tasks every 3 minutes, get interrupted every 11 minutes and take 23 minutes to get back on task,” thus making productivity hard to maintain, Steelcase said.

The furniture is part of the Intelligent Office concept of embedded technology. For example it could be adapted with a sensor, which would activate a red light around the chair’s perimeter, signaling that the unit is occupied, Steelcase said.

Arbor Mills, Lockport, IL —  The luxury kitchen, bath and other room cabinetry manufacturer has consolidated its interior cabinet organizing systems under the brand name BIN. "This is an extensive systematic coordination of related accessories for cabinetry," explained Daryl DelSasso, president.

The functional storage and workflow system optimizes a single drawer or group of drawers and cabinets into organized storage solutions, with the ability to adjust as a person's storage needs evolve. It includes 60 individual components for base, wall and tall cabinets, and drawers.

Arbor Mills also improved the finishing capabilities within the plant, including investments into a plural component finishing system. 2015 sales rose 8.3%.

Here's some more product ideas:

Wellborn Cabinet, Ashland, AL
The cabinet giant is also making a name for itself in the closets industry, with new products introduced regularly. "Wellborn Cabinet continued key product development to meet the demands of our customers and the continued delivery and support of our product," said Krislyn Wellborn, PR/social media specialist.

Premier EuroCase, Denver, CO
Success for the full-service panel processor “comes from our ability to maximize our manufacturing capabilities, and leverage our investments in technology that address emerging industry trends,” said Andy Wilzoch, founder & president. Capitalizing on the popularity of its Reflekt high-gloss product, the firm launched two lines – UltraMatte and Ion – without making another large investment in the technology. “This allowed us stay a step ahead of our customers’ expectations as well as our industry rivals by introducing the new materials as they are gaining popularity as the latest trends in interior design,” he said. 

The Maui Closet Co., Kahului, HI
President Debra Finkiewicz attributes new product development for helping spur sales grow 8.2% in 2015. As a manufacturer of closets, wall beds, shoji-style doors and more, Finkiewicz said the company is "always looking for new ways to design and manufacture. We refer to the new trends in products, and work to keep all in track with our clients needs." To raise market awareness, Maui Closet skinned its new installation van with photos of completed jobs. "It is great advertising."

TC Millwork Inc., Bensalem, PA
The store fixture manufacturer has developed Smartwall, a UL-listed display and perimeter wall system that incorporates thin wall standards and brackets to power shelves with low-voltage, LED lighting. "Those shelves are wireless to the end user, so there are no visible connections," said Jeff Kubach, creative director.

Carlisle Wide Plank Floors, Stoddard, NH
The Manhattan Collection is the firm's first luxury wood flooring in a herringbone pattern. “We’ve seen an increased demand for patterned floors among our clients, though many want to use patterned flooring as a way to accent a particular room or design element in their home versus using patterned flooring throughout,” said Dean Marcarelli, vice president & CMO.

A&A Millwork,  Minneapolis, MN
Sales grew 9.1% at the company, which specializes in historical wood mouldings, windows and doors. ”We increased our sales focus on our high demand and unique ability products,” said Nicole Aune, director of sales & marketing. The firm also reviewed those items which fit the category, “and put high focus with our sales team on these products, as well as increased our marketing efforts.”

A-dec, Newberg, OR
In launching its new line of dental furniture, A-dec said it consulted with dental professionals to optimize the furniture for improved workflow and efficiency, including integrated LED lighting and USB ports. "The furniture is an innovative fusion of technology and materials that will set the standard for the dental practice of the future," said Ciarán Hynes, director of Dental Furniture Project Management. "It is designed to grow with the practice, and evolve along with technology and work styles."

Willa-Hide, Greenville, TX
The company has become the fastest growing concealed cabinet manufacturer in the country, with products developed to hide firearms, jewelry and valuables, with many different options available.

 Bush Business Furniture, Jamestown, NY
The contract furniture manufacturer says its Easy Office concept is an open office solution for one to 100 people. It comes in seven pre-packaged configurations, with pre-installed connectors, and in straight or L-desk formats.

Stikwood, Sacramento, CA
The company continues to develop new styles and finishes for its peel-and-stick wood plank paneling, used in residential and commercial applications. Sales have been growing since the product debuted in 2012. They're so good that the firm is expanding into Michigan, with plans to invest $4.2 million in a distribution facility.

Read more 2016 WOOD 100: Strategies for Success

Marketing Initiatives
Go-to-Market Strategies
Business Strategies
Productivity Enhancements
Technology Integration
Product Innovations
Customer Service
Return to WOOD 100 Main Page
Read the special Leadership Edition of FDMC online

Millwork 360, Tampa, FL —  The architectural woodworker’s technology investment has reduced the manufacturing time of its products, while improving capacity and quality, spurring 2015 sales to a 39.9% jump.

Recently installed were three Weinig moulders – two Powermat 600 and a Powermat 1200 with PowerCom Link – to the Electronic Measuring System in the Tool Room. “This has dramatically reduced set-up times, thus reducing downtime and increasing output,” said Jamie Burge, CFO. “Since installing these machines, the learning curve for training new operators has decreased substantially, from three to six months down to one month.”

He added, “The software also allows us to access information such as lineal footage ran per order, production stoppages, as well as optimizing the order to decrease head changes and other manual adjustments. The average daily production of Architectural Grade Mouldings has steadily increased to 22,000 lineal foot per shift.”  
To be added is an Accord 40 FX CNC router for door components, “significantly reducing labor costs and lead times for our custom doors.”

Genesis Products, Elkhart, IN —  This full-service manufacturer of wood and laminate products has a reputation for driving sales and innovation. The wide range of industries served – residential furniture, contract furniture, hospitality, store fixture, cabinetry, manufactured housing and recreational vehicles – ensures the company is up on the latest trends and technology.

Recent investments include a Schelling panel saw, Weeke CNC machining center, CR Onsrud CNC routers and Harlan laminator. “We also just bought a new Wemhoner at IWF,” said Trent Evans, division director. “This gives us entry into the membrane pressing market.”

Genesis Products is solutions oriented, and will continue to expand its capabilities for customers, added Alysha Liljeqvist, director of marketing & communications.

Here's some more examples of technology investments:

Decore-ative Specialties, Monrovia, CA
The custom cabinetry component manufacturer helped develop a Challengers Award-winning CNC shaper sander with Bacci. The unique design significantly increased capacity, and improved consistency and productivity in the cabinet door making process. Decore won a 2016 WMIA Wooden Globe Award for Innovator of the Year.

Deano Hardwoods, Broussard, LA
The moulding manufacturer’s capacity grew following the addition of a Kentwood moulder from Stiles Machinery, said Francis Elder, sales manager.

EuroCabinet, Jonesboro, AR
The cabinet and fixtures firm “Worked smarter to maximize the use of CNC machining,” said Russ White, president. The strategy worked, as sales jumped 65.9% in 2015. New tech included: an Intellistore system, Holzma panel saw,  Weeke router and machining center,  and Homag and SNX edgebanders.

Ramsey Cabinets, Amherst, VA
The custom cabinetry manufacturer upgraded equipment, including a widebelt sander and Cabinet Vision software, said Gary Ramsey, owner. 2015 sales grew 12.5%

Bellmont Cabinet, Sumner, WA
After the cabinet company grew “at an unsustainable rate” between 2011-2014, “In 2015 we deliberately slowed down our sales growth to focus the company on quality and operational improvements,” said Casey Bell, COO. These included the purchase of two Biesse nested-based CNC routers, an Omal dowel inserter, Holzma panel saw, three Homag edgebanders, and an MB brush sander. 2015 sales grew 14.6%

Barnick Wood Design Inc., Grover Beach, CA
The custom cabinet company’s sales grew 5.2%, due in part to increased productivity and its quality employees. “Our panel sizing equipment increased productivity and decreased lead times, while high-quality finish equipment increased the quality of the product as well as our work environment” said Nicholas Barnick, president. 

WB Mfg., Thorp, WI
WB Manufacturing has taken Industry 4.0 to the next level with its fully integrated, lean workcell, including a new Biesse CNC router, material handling system and edgebander. The company manufactures cabinetry and casework for the educational, office, industrial and health markets.

Koch Cabinets, Seneca, KS
Investments in finishing, an optimized chop saw and nested based CNC routers helped improve productivity and quality, and has enabled the cabinet firm to stay price competitive, said Barry Koch, production manager. 2015 sales grew 18.4%

Lewis Wood Products, Grovetown, GA
The door manufacturer relocated to a larger, modern facility and added equipment, including a Butfering sander,  Quincy compressor and PMK end coper, said Kim Lewis, president. Sales grew 33.8%.

Cabinet Component Innovations, Bessemer, AL
“We invested in the development of a new facility, which added 20,000 feet of manufacturing space,” said Wayne Moore, president. The cabinet components maker also added two Thermwood CNC routers, Vorwood edge foilers, a Mecco laser marking system and a Taylor Quick Chop Optimizing Saw. Sales grew 8.2%.

Read more 2016 WOOD 100: Strategies for Success

Marketing Initiatives
Go-to-Market Strategies
Business Strategies
Productivity Enhancements
Technology Integration
Product Innovations
Customer Service
Return to WOOD 100 Main Page
Read the special Leadership Edition of FDMC online

These woodworking manufacturers are ahead of the curve when it comes to optimizing productivity. In addition to lean manufacturing, new technology and training methods, a successful strategy requires a commitment by all employees to the process. What follows are some of the methods put in place by the 2016 WOOD 100 class, which includes cabinet manufacturers, residential and office furniture producers, architectural woodworkers, wood component manufacturers, closet companies and more.

Yoder Lumber, Millersburg, OH —  Capacity has doubled at Yoder’s Hardwood Components division since investing in technology, lean manufacturing and Six Sigma program. Along with cross-training, older employees work alongside younger ones to assist with workflows.

“At Yoder Lumber we are committed to improving communication and integrated many new systems and visual cues to help provide quicker feedback,” said Dennis Hange, marketing manager.

“As a company we are proud to set many new milestones of growing our production figures, thanks to our wonderful workforce who saw this an opportunity to practice their new skills and lean manufacturing principles learned throughout the year,” he added.

An  optimizing line of  a WoodEye scanner and Talon Saw (Eagle Machinery), Cresswood grinder and Opti-Match were also added.

Inova LLC, Altamont, NY —  Sales jumped 44.0% in 2015 and look to be even better this year for Inova, a manufacturer of home organization and space-saving products, including Sofa-WallBeds, TableBeds, and WallBeds for  hotel, government and residential customers.

Continuous improvements in production helped spur the success, noted Sarah Bucey, financial manager. “We adopted a lean manufacturing philosophy, and started by doing a deep clean of the factory and offices, as well as our overall processes and procedures. We also switched to a one-piece flow and encourage our employees to focus on small, daily improvements and teamwork.”

The firm doubled its capacity in 2015 and also invested close to $750,000 in new equipment, which included a panel saw, edgebander, two CNC machines, a dovetailer and widebelt sander. “In 2016, we purchased a new Volvo L-90 Wheel Loader for our Sawmill and Kiln division,” she added.  “A state-of-the-art Friulmac double-end trimmer was added as an extension to our Kentwood moulding unit at our Hardwood Components division.”

ConceptWorks, Elkhart Lake, WI —  The display maker has grown sales in part through market diversification. "We used to be only in the point-of-purchase sector, but we moved into healthcare, architectural, retail, restaurant and trade show displays," said President Adam Schneider. Today, about half of the business is in retail displays, 20 percent in trade show displays, 10 to 15 percent in speciality architectural projects and the rest in other types of jobs.

Lean manufacturing techniques are also evident throughout the 20,000-square-foot plant, including Kanban tags and production status boards.

ConceptWorks also uses vendor-managed inventory to fulfill its supply needs. "We don't have to tell them," Schneider said. "[Fastenal likes] it because they have a strong hold on our business. We love it because we never have stock outs."

Here's more productivity enhancements.

Lean manufacturing

Elias Woodwork, Winkler, MB
Sales for the wood, thermofoil and DLV cabinet components manufacturer grew 15.3%, due in part to improved technology and processes at the 285,000 square-foot facilities. “We have detailed quality tracking at each manufacturing step,” said Jeremy Funk, sales & marketing manager. Elias also performs a “careful analysis of each metric with decisive action taken to remedy any issues.” Along with investments in machinery, the company has state-of-the art finishing systems.

North American Plywood Corp., Parsippany, NJ
The plywood and components maker grew 10.7% in 2015. “We constantly increase productivity through employee training and purchasing state-of-the-art machinery,” said Donald Kuser, general manager. “We work directly with panel product manufacturers to increase quality and value pricing.” Boasting the largest UV coater in the U.S., the firm purchased a Superfici UV edge coater as well as a custom automated drawer side machine and another twin-table Northwood C axis router.

Pacific Crest Cabinetry, Ridgefield, WA
Sales grew 22.3%, and the custom cabinet manufacturer looks to do even better in 2016. “Through waste reduction in all aspects of our business, we have been able to make a product that is a leader in our market in quality, lead time, and price,” said  Brian Boggs, general manager.

Woodtronics Millwork Corp., Yorktown Heights, NY
The architectural millwork and cabinetry continues to streamline production, for improved productivity, safety and service, said President Jan E. Efraimsen.

Koetter Woodworking, Borden, IN
The architectural millwork firm reorganized its order processing and invested in technology. This enabled it to cut inventories, reduce labor and shorten lead times on orders. Koetter won the 2016 WMIA Wooden Globe Award for Excellence through Technology.

Diplomat Closet Design, West Chester, PA
The custom cabinet, closets and home organization firm’s sales grew 25.1%. “We’ve increased production with screen-to-machine capabilities and renovated our shop, added employees and updated our processes from sale to install,” said Ryan Lindstadt, president. Also purchased was a Biesse router and Brandt edgebander.

Architectural Arts, Des Moines, IA
The architectural millwork firm has improved its turnaround time since transitioning toward producing kits on the CNC that contain all the required pieces for the products.

Employee skills/training

Giffin Interior & Fixture Inc., Bridgeville, PA
Sales for the architectural woodwork firm grew a whopping 101.6%. According to Gordon Giffin, CEO, the company invested in training and software and also focused on improving employee skills and implementing lean initiatives.

Lancaster Cabinet Co., Leola, PA
Sales grew a whopping 72.3% as the custom cabinet and millwork manufacturer implemented lean principles in equipment and inventory arrangements, said David Allgyer, general manager. “We also focused on great customer service and faster turnaround times.”

Toddwood Mfg., High Point, NC
President Todd Fuentes attributes his success –  and 28.2% sales growth – to his skilled employees. An OEM producer of products and furniture from solid wood and veneer panels, he said, “We are adding customers as we add capacity.” The firm also invested in a tenoner and plans to buy a CNC router this year.

Custom Creative Furniture LLC, Lawrenceville, GA
Sales jumped 49.5% for the custom cabinetry firm, which focused on improving productivity, including an upgrade of its finish quality. “We also added skilled employees and developed new skills from within,” said Tom Floyd, owner. “At the end of 2015 we purchased a CNC, as well as a building to expand the shop.”

Bernhard Woodwork Ltd., Northbrook, IL
The architectural woodwork and store fixtures manufacturer invested “in both human and physical capital – training and new machinery – to be more productive,” said Mark Bernhard, president. 2016 sales are expected to be even better, he added, and include plans for an integrated manufacturing system and automated inventory processing.

California Woodworking Inc., Oxnard, CA
Sales for the cabinetry and countertops manufacturer rose 4.4%. “Our ability to retain an extremely lean and highly skilled team contributed to our overall success in 2015,” said Luke Vickery, vice president. The firm also purchased a system that allows materials and labor to be tracked for job costing. “Using this system has allowed our company to adjust our figures for labor and materials so that they are in line with actual amounts required to effectively complete each project.”

American Millwork & Cabinetry, Emmaus, PA
“AMC has taken significant steps to increase productivity, hence becoming more competitive while increasing customer service, cross training and bringing value-added alternatives to our customer,” said George Reitz, president & CEO of the architectural woodwork and commercial casework firm, which grew 38.5% in 2015.

Read more 2016 WOOD 100: Strategies for Success

Marketing Initiatives
Go-to-Market Strategies
Business Strategies
Productivity Enhancements
Technology Integration
Product Innovations
Customer Service
Return to WOOD 100 Main Page
Read the special Leadership Edition of FDMC online
 

Product diversification, networking and acquisitions are just a few of the ways in which these WOOD 100 firms grew their profits. Offering advanced training and empowering employees in the business helps keep a stable, and happy, workforce.

Northland Woodworks, Blaine, MN —  The cabinetry and architectural millwork shop “Focused on a tactical approach by engaging our team 100 percent through successful CRM and project management software implementation, restructuring, creating job titles and duties, and creating and executing a strategic growth plan,” said Matt Krig, vice president.

Aiding the success of the business has been the opportunities gained through Cabinet Makers Association involvement: networking, plant tours and learning from others best practices. 

“We’ve tied increased productivity and proactive thinking into being able to better provide for our people, with a great healthcare, profit sharing and benefits package to make it a career rather than a job.”

Indiana Dimension Inc., Logansport, IN — “It’s the people that make the company,” said Jeremy Rentschler, sales manager at the diversified components manufacturer.  “Drives” is another way to phrase it.

A term used throughout the plant, “DRIVES” stands for Dedicated, Responsive (to customers and each other), Integrity, Value (by innovation), Enterprising and Safety. It’s posted on placards and T-shirts, providing a visual reminder to workers of their importance, and role, in the success of the IDI, he added. IDI also provides opportunities for employees to advance through skills training and other methods.

A lean manufacturer, IDI produces rough-milled panels through fully-machined components, including cabinet doors and drawers. Capabilities include moulding, edge gluing, edge profiling, sanding, CNC routing and finishing. Rentschler adds that the company also offers a seven-day turnaround and JIT delivery on orders.

The company was founded in 1990 by Milt Cole and Roy Rentschler as a sister company to Cole Hardwood.

D&L Wood Products, Crown Point, IN —  The architectural millwork and components manufacturer announced last year it would invest in a new facility, to be located adjacent to its current 30,000-square-foot plant. When completed, the two buildings will connect, for easy access.

President and founder Bob Ligda said the additional space will up the company’s total square footage to approximately 60,000, and will be used for offices, warehouse and manufacturing.

“We need more floor space to make things flow better from a production standpoint, so that there are no bottlenecks anywhere,” he said. “The new space will eliminate that.”

D&L specializes in commercial properties and hotel chains, including the lobbies, cafes and boutiques.

CCF Industries, Apollo, PA —  The cabinet drawer manufacturer overcame a devastating fire and, in doing so, rebuilt the company into something even bigger and better than before.

“We lost everything in the fire except for a few files,” said President Ken Clifton of the 2014 fire that destroyed the 16,000-square-foot plant.

Moving into the new building on Sept. 21, 2105, CCF took advantage of its “fresh start’ and to revamp the layout of the shop floor. The new plant layout offers an improved workflow, with added equipment for increased capacity of the company’s dovetailed drawers.

Manufactured to specification, the dovetailed drawers are available in a variety of wood species as well as decorative overlays. The drawers come finished or unfinished, assembled or unassembled, with a variety of options, including: laser engraving, edgebanding, undermount side notching, front and side scoops, and file slots. Specialty drawers are also available upon request.

Read more master plans:

Employee training & empowerment

Barbosa Cabinets, Tracy, CA
In addition to hiring key managers to “build a better team,” the cabinet manufacturer introduced a training program to educate inexperienced employees on becoming woodworkers. “The results are a more organized and experienced workforce,” said Ron Barbosa, owner. Sales figures reflect the company’s success, up 15.1% in 2015.

David’s Woodworking, Arcade, NY
Company president David Hamm attributes employees skills, product quality and flexibility in design and production for helping spur sales 46.5% at the custom furniture, cabinets and millwork shop.

Shaw Woodworking, Cotuit, MA
“Attaining key knowledgeable and talented personnel, going after more and bigger projects, a continuous and constant improvement philosophy, and a superior business culture,” helped spur 12.3% growth at the custom cabinet and millwork firm, said James Shaw, president.

Acquisitions & expansions

Osborne Wood Products, Toccoa, GA
The components manufacturer credits its success to customer service, increased productivity, and increased employee knowledge and skills. Osborne also acquired the assets of Bendix Architectural Products in 2015, increasing Osborne’s catalog by hundreds of products. “The acquisition also opened up opportunity for current and new customers of the Bendix collection to order the products online with Osborne customer service,” said Lane Taylor, marketing assistant. 2015 sales rose 9.2%.

Panel Processing, Alpena, MI
A specialist in panel fabrication and finishing, the company’s “expansion into new locations with new and redundant capabilities has contributed to our success in 2015,” said Tonya Spens, national marketing manager. She added the new strategic locations will help the company avoid undue shipping costs and transit time.

Stevens Industries, Teutopolis, IL
A number of factors contributed to the laminated wood products, casework and architectural millwork firm’s success, said Amanda Emmerich, marketing coordinator. They include: new product development, increased sales geography, acquisitions, and “organic growth due to customer satisfaction.” 2015 sales for the company rose 17.5%.

Milgard Windows & Doors, Tacoma, WA
A Masco company, the window and door manufacturer expanded its operations with the opening of new manufacturing facilities in Grand Prairie, Texas.

Networking advantages

Brown Wood Inc., Chicago, IL
The company boasts three  divisions - contract, Designs of Distinction and the Gavel Co. - and one manufacturing plant. Overall, 2015 sales rose 5.5%. “By maintaining an active presence in multiple trade associations, and attending several industry trade shows and events, we were able maintain relationships with key decision makers,” said Kathryn Constantine, vice president. “Additionally, our involvement gave us insight into trends within our various industries and allowed us to be at the forefront of our customers and prospects minds when it came time to send items out to bid.”

Production & profit margin improvements

Laminate Works, Lenexa, KS
Sales at the laminated panels and components manufacturer rose 9.1%. “We added levels of management/supervisors in each department, and put a new focus on responsible selling and profit margins” said Olivia Clothier, marketing.

Beahm & Son Ltd., Evans City, PA
The cabinet company focused on its organization and planning to optimize the production, said Cody Beahm, office manager. “In the past we had periods of too much work then not enough, forcing us to work consistent overtime then immediately go to laying people off as not enough work was available. We took steps last year to better estimate the amount of time it took to manufacture our cabinetry and because of the planning we were able to smooth our production, cut down significantly on overtime, and fill in any downtime between projects.” The strategy worked, with 2015 sales up 11.5%.

Custom Cabinets by Monty Augustine, Iowa, LA
The cabinet and countertop manufacturer attributes its success, and 30% sales growth, to its employees and good production flow. “We make sure that everything flows efficiently through the shop and out the door,” said Owner Monty Augustine. “I believe that when you treat people with respect, do what you say you’re going to do, and deliver a quality product at a fair price, all while serving the Lord our God, success is guaranteed.”

Lexington Manufacturing Inc., Coon Rapids, MN
An OEM supplier of components to the residential window and architectural door markets, Lexington put a “strategic focus on delivering what customers want, when they want it, at a price we both can afford,” said Bill DeWitt, sales account manager. The strategy worked, as 2015 sales at the multi-million dollar firm rose 4.5%.

HRT Installations, Reading, PA
The custom architectural millwork and laminate casework supplier considers quality control one of the key components to its success. “There’s no punch list to employees; we’re completing one room at time,” said Kevin Hartman, vice president. The result is repeat business, plus a 2015 sales growth of 14.3%.

Raleigh Murphy Beds by The Master’s Craftsman, Raleigh, NC
Owner Wayne Kulesza implemented a strategy of “Keep working and increased productivity,” to grow 2015 sales 16.7%.

Stock Woodwork, Laredo, TX
“We were successful because we are small enough to provide attention to details, yet big enough to get the work out on time,” said Shane Stock, owner of the architectural millwork and casework firm. Last year the majority of work was for three hotels.

Navy Island, West St. Paul, MN
A systems-driven, highly automated door firm, “All of our products are refined and standardized,” said Jeff Stone, president.

Corporate culture

Kimball International, Jasper, IN
The contract furniture maker earned a “Great Place to Work” designation  for its corporate culture. The review focused on five key areas: Credibility, Respect, Fairness, Pride and Camaraderie.

Palliser Furniture, Winnipeg, MB
The furniture maker was named one of Canada’s “Best Managed Companies” for its business performance, in the areas of strategy, capability and its commitment to achieve sustainable growth.

Read more 2016 WOOD 100: Strategies for Success

Marketing Initiatives
Go-to-Market Strategies
Business Strategies
Productivity Enhancements
Technology Integration
Product Innovations
Customer Service
Return to WOOD 100 Main Page
Read the special Leadership Edition of FDMC online