A firsthand look at the innovative technology and designs by European wood products manufacturers is being provided to 23 wood industry professionals from cabinet, furniture and store fixture companies as they join Biesse America on a technology tour of Italy.

Kicking off the plant tours on Monday were visits to furniture manufacturers Lago and Caccaro. The Tech Tour runs Oct. 11-17.

On the Tour Participating in the 2015 Biesse Tech Tour to Italy are (L-R): front row Lori Hamblin, Classy Closets; Stephanie Parmer, Closets by Design (GA); Steve Parmer, Closets by Design (GA); Bill Weaver, Canyon Creek Cabinet Co.; Randy Jamison, Biesse America; second row Casey Bell, Bellmont Cabinets; Jill Standage, Classy Closets; Duane Standage, Classy Closets; Sherwood Hamblin, Classy Closets; Steve Bell, Bellmont Cabinets; Jason Varelli, Biesse America; Jim Caldwell, Bridgewood Cabinets/Hi-Lo Industries; Chad Grimm, Load King;  David Shamir, OFGO; Cory Shamir, OFGO; Rick Lovorn, Canyon Creek Cabinet Co.; back row Jed Richards, Holland's Custom Cabinets; Clay Smith, Royal Cabinets; Stephane Fortier, North American Cabinets; Sebastien Madore, North American Cabinets; Charles Chupp, Load King; Bob Foote, Canyon Creek Cabinet Co.;  Ken Carella, Load King; Donnie Batten, Load King; and Jeff Caldwell, Bridgewood Cabinets/Hi-Lo Industries. (Not pictured, Karen Koenig, Woodworking Network)

Lago: Located near Cittadella, Italy, Lago is a lean manufacturer of modular designed furniture for the residential, hospitality and commercial industries. Living room, bedroom, storage systems, and cabinetry are all produced at the 8,000 square meter plant.  

Lago has a unique philosophy that goes beyond the products and encompasses promotion – via social media, press, and digital marketing – not only for itself, but for customers through its Interior Life Network. Also being rolled out are small “talking” chips on the furniture which, when scanned by the company’s free app, will provide, among other things, product and purchasing information.

The plant is divided into two buildings. Of key interest in one of the 4,000 square meter buildings was the assembly line featuring BreMa Vektor Vektors, capable of drilling on six sides and inserting hardware on five sides of the panel. The Vektors also offer fast processing speeds and tool changes in seconds.  In line with the Vektors is a Bonacin clamp.
 

In addition to the BreMa Vektors, other key equipment at Lago includes an Akron edgebander, Skipper router and RBO conveyors. Barcodes help the company track the component parts as they run through the shop, which has an average of one to two weeks turnaround, depending on the product produced.

Caccaro: Located in Villa del Conte (Padova), near Cittadella, Italy, the company produces furniture and home storage systems. What’s cool about the Caccaro is how it manufactures the parts, including the vertical drilling and automatic insertion on its panels.

To do this, Caccaro has a one-of-a-kind BreMa Vektor 3.0. Unlike traditional Vektor machines, this one uses grippers instead of a chain to move the panels. This allows for parts to be drilled on the bottom edge in a throughfeed process. The machine also allows for the trailing end of one part to be machined simultaneous to the leading edge of the next part in the line.

The Vektor 3.0 is in a section of the plant that also contains an older Vektor drilling and inserting machine, enabling Caccaro to process 200 parts per hour on the two machines, including parts incorporating multiple hinge sizes and hole selections. Also in use in the building is an Eko for drilling and routing of parts.

As well as innovative, Caccaro is also a sustainable manufacturer, and was one of the first in Italy to adopt water-based coating systems.

Kitchen cabinetry was cooking on Day 2 of the Biesse Tech Tour to Italy, with 23 North American woodworkers getting a closeup look at the high-speed processes in place at Aran Cucine and Lube.

Aran Cucine: Located in Teramo. Italy, Aran is among the largest kitchen cabinet producers in Italy and one of the top exporters of cabinetry.  The large volume producer’s "flexible squaring" edgebanding line is what drew particular notice on the Tech Tour.

Installed approximately six months ago, the Biesse Stream MDS CNC edgebander has 2 pre-milling stations and can edgeband and square all four sides of the panel.  The 15-meters-long Stream MDS cell is equipped with the AirForce System and integrated with the Winner W1 flow management system.

Aran is a large volume producer, but of small batches, so different size parts are continuously run through the machines. Formerly owned by Masco,  Aran produces more than 20,000 semi-finished parts every day at its seven plants, which total in size to 55,000-square-meters covered surface (180,446 square feet), according to its website. The company has approximately 350 employees and is FSC and ISO 14001 certified. In addition to cabinetry, Aran also manufactures office furniture, wardrobes and bedroom furniture.
 

Biesse Tech Tour Furniture Manufacturing in Italy: Talking Chips & More Kicking off the plant tours on Monday were visits to furniture manufacturers Lago and Caccaro.

Lube: located in Treia (MC) Italy, which is southwest of Ancona, Lube is a large volume cabinetry producer of large batch sizes: it has one primary product line, which it offers in 346 different laminate colors and textures. Lube produces 150-200 kitchens a day, with each kitchen comprised of 12-15 cabinets.

A lean manufacturer, components are cut, edgebanded and drilled one day and assembled the next. The company has highly automated production lines for cutting, edgebanding, and drilling. Here’s what one line alone looks like:

After cutting on the angular Selco saw, the panels go from an RBO material handling system to a Stream two-sided edgebander with softforming capabilities, which then feeds into a Selco WNCR saw. The strips travel on the RBO to another Biesse Stream edgebander, to another RBO conveyor, to Biesse Techno Logics for drilling and dowel insertion and then to the RBO Winner stacking system.  

Similar panel processing lines are located throughout the shop, as well as other automated processes and robotic equipment. According to its website, the factory is 100,000 square meters, of which 75,000 is covered, and has over 450 employees, including 350 in the production area.

Taking place Oct. 11-17 and sponsored by Biesse America, this technology tour of Italian woodworking manufacturers provides a firsthand look at the innovative technology and designs in use by six wood products firms, as well as a look at new technology offered by Biesse. Twenty-three North American wood industry professionals from cabinet, furniture and store fixture companies attended the week-long Biesse Tech Tour event to Italy.

Impressive doesn't begin to describe the assembly operation at Scavolini, an Italian cabinet producer that’s taken the task to new heights — literally. In an area where space is at a premium, the Pesaro-based Scavolini moves product through the shop hundreds of feet up, down and sideways, as it assembles and ships more than 40,000 kitchens a year.  The visit to Scavolini and the high-tech operations of Colombini Group in San Marino capped off a week-long technology tour of Italian wood products manufacturers, sponsored by Biesse America.

Twenty-three North American wood products manufacturers (see below) from the cabinet, closet, furniture and store fixture industries participated in the Oct. 11-17 tour. The technology tour concluded with hands-on machinery demonstrations and a walk through Biesse' headquarters and factories, part of the 2015 bInside (Biesse Inside) event in Pesaro, Italy. Click here to also read articles on the manufacturing operations at Italy's Lago and Caccaro, as well as Lube and Aran Cucine.

Cabinet assembly at Scavolini: Based in Pesaro, Scavolini produces approximately 40,000 kitchens a year. That's an average of 200 kitchens per day, assembled by the company's 300 shop employees (600 total company-wide) at the 80,000 square meter cabinet facility, one of three production plants owned by the company.

Cabinetry components are outsourced, then machined and assembled in-house on a just-in-time basis, said Giovanni Severl, general manager. The majority of cabinets are sold throughout Italy, with New York and Russia among the top markets for the company's exports.

As orders are entered, an automated material handling system moves throughout a 10-story-tall area, retrieving the panels and components for processing and assembly. Among the equipment used at Scavolini are 10 highly-automated, high-speed production lines composed by Biesse Insiders for drilling and hardware insertion. Additional processing of doors and cabinet fronts was performed on a BreMa Vektor 15 line composed of two machines working in tandem.

The typical turnaround time, from order to shipment, is approximately three weeks, said Severl. These shipments include not only the cabinets, but also corresponding appliances, such as refrigerators and dishwashers — and quite possibly the kitchen sink — giving new meaning to the term "one-stop shop."

Once cabinets are assembled and packaged on the CVM line, the barcoded items are scanned, loaded on conveyors and sent to a temporary holding area – no more than two days pass between product assembly and the shipping of the full order, said Severl. Using an elevator lift, the orders are placed on an extensive conveyor system located above the main floor, and into the queue for shipment.

Founded in 1961, Scavolini also produces the high-end Ernestomeda brand at a separate 20,000 square meter facility. In 2012 Scavolini entered the bathroom vanity market and today produces 2,000 to 3,000 cabinets annually from a 13,000-square-meter facility.

Colombini Group: Located in San Marino, the Colombini Group has been producing furniture and cabinetry for more than 50 years and according to its website, is the largest producer of "single room" furniture, including 4,000 to 5,000 cabinets per day.

The company has more than 1,000 employees, with its headquarters stretching over 250,000 square meters. Manufacturing and assembly of the products takes place among four plants.

At one of the cabinet assembly plants, North American woodworkers watched while the vertical and horizontal components were bored, drilled and assembled in a just-in-time production setting. The setup on one line, for example, is as follows: components are placed on the RBO which feeds them vertically into the Biesse Insider FT2 drilling and hardware insertion machine, then to another Insider, and on to a third one, before meeting up with the horizontal components in assembly. On a line like this, the company produces approximately 300 boxes per shift of semi-custom cabinetry.

Cabinet boxes are offered in five standard colors, while more than 100 colors, pattern and texture options are available on the end panels and doors, a spokesman for the company said. Thicknesses on the doors, which come in solid wood/painted or laminated, range from 18-25mm. Here, Colombini uses a CVM Silver Pack box closing line to protect products during shipping.

Also seen on the tour was the machining operation at another one of Colombini's plants. Among the cutting systems in place here is the NexStep, which is used in conjunction with the WinStore material handling system. Also of special interest here was the brand new line featuring a Biesse Insider FTT R8 heavy-duty feedthrough drilling machine. The top and edge are machined, and then the parts are "flipped" for the other sides, for a capability of 12 to 15 parts per minute with a minimum batch of two pieces.

Also new at the plant was the Biesse Techno Kernel drilling and dowel insertion line, connected to an RBO Winner W1 feeder, stacker both with a baseboard management system. According to the company, approximately 30,000 parts are cut, edgebanded and drilled a day here.

About the Biesse America Tech Tour of Italy

Held the week of Oct. 11, the Biesse America Tech Tour to Italy included visits to six wood products production facilities plus close-up looks at the Biesse factories and visit to the Biesse Inside Event being held at Biesse headquarters in Pesaro, Italy

Pictured in front of the Biesse building are: (front row, l-r) Federico Broccoli, Biesse; Randy Jamison, Biesse America; Jill Standage, Classy Closets; Lori Hamblin, Classy Closets; Stephanie Parmer, Closets by Design (GA); Karen Koenig, Woodworking Network; Bill Weaver, Canyon Creek Cabinet Co.; Casey Bell, Bellmont Cabinets; Steve Bell, Bellmont Cabinets; Chad Grimm, Load King; Donnie Batten, Load King; Jed Richards, Holland's Custom Cabinets. In the back row, ( l-r) are: David Shamir, OFGO; Cory Shamir, OFGO; Sherwood Hamblin, Classy Closets; Stephane Fortier, North American Cabinets; Clay Smith, Royal Cabinets; Duane Standage, Classy Closets; Sebastien Madore, North American Cabinets; Steve Parmer, Closets by Design (GA); Ken Carella, Load King; Jeff Caldwell, Bridgewood Cabinets/Hi-Lo Industries; Bob Foote, Canyon Creek Cabinet Co.; Charles Chupp, Load King; Jason Varelli, Biesse America; Jim Caldwell, Bridgewood Cabinets/Hi-Lo Industries; and Rick Lovorn, Canyon Creek Cabinet Co.

Since 2009, Woodworking Network has paid tribute to market leaders in the wood products industry that have made an impact — not only at their own companies, but also on the industry as a whole. Represented are persons from all segments of the secondary woodworking industry, including: residential furniture, contract/office furniture, cabinets, closets/home storage, store fixture, architectural woodwork, window and door, and wood components.

Listed below, in alphabetical order, is the compendium of Wood Industry Market Leader honorees (titles/jobs were at the time of recognition):

Keith Atherholt (2010)
President, Lewis Lumber Products
In addition to his work on behalf of the industry, under  Atherholt the millwork/components producer increased sales and products, while reducing operating costs.

Neil Balter (2013)
Founder, Organizers Direct
Prior to founding Organizers Direct in 1995, Balter founded California Closets, the nation’s largest home organization franchise.

Bill Barton (2012)
President & CEO, California Closets
Barton has helped home organization giant California Closets grow even larger and more innovative, often looking outside the industry for new ideas.

John Bassett III (2012)
Chairman, Vaughan-Bassett Furniture Co.
Under Bassett’s leadership, the company has become the largest domestic producer of wood adult bedroom furniture. Bassett is also recognized for his leadership role in the fight against low-cost imports.

Troy Bednarz (2014)
Owner, Lakeside Cabinets and Woodworking
Under Bednarz, the custom firm has not only improved its production capabilities, but also racked up impressive sales growth.

Debra Behring (2015)
President, JB Cutting
While expanding the component firm's capabilities, Behring was also instrumental in creating the order entry software, helped design the catalog/marketing strategy, and worked to instill a philosophy for customer service.

Mark Bernhard (2009)
President, Bernhard Woodwork Ltd.
With a lifetime of experience in the industry, Bernhard has guided the architectural woodwork giant to new levels.

Franco Bianchi(2011)
President & CEO, Haworth Inc.
Under Bianchi’s leadership, Haworth has grown in brand recognition, offering integrated and innovative products for the contract furniture market.

Tony Bour (2015)
CEO, Showplace Wood Products
No stranger to the cabinet industry, Tony Bour has started three highly successful firms during his 49 years in the marketplace: Decora Cabinets and Starmark Inc., now divisions of Fortune Brands, and Showplace Wood Products.

Steve Brewster (2010)
Director of Sustainability, Kimball Office
In addition to his work at Kimball, Brewster has gained recognition as a speaker on sustainable manufacturing.

Mike Carson(2009)
President, Closet Works Inc.
Carson was instrumental in launching The National Closet Group, the first association for the home storage and organization industry.

Mark Clemens(2011)
VP Product Development, idX Corp.
In addition to his efforts at idX, Clemens has worked to improve the industry and is active in the AWI.

Margaret Fisher (2010)
Director Market Development, Lange Bros. Woodwork
A business advocate and author, Fisher has been a speaker on behalf of the AWI on the topics of LEED, wood and carbon, and forest sustainability.

Kent Gilchrist (2013)
President, Fremont Interiors
Gilchrist’s dedication to both his firm and the architectural industry as a whole has resulted in significant growth for both.

Bob Gronlund (2012)
Chairman & CEO, Wood-Mode Inc.
Under Gronlund’s leadership, Wood-Mode has become one of the largest U.S. manufacturers of custom and semi-custom cabinetry.

Roger Jones (2011)
VP Global Logistics, Century Furniture
Jones helped increase international work and develop the infrastructure to support Century’s Lacey Act implementation.

Steve Kincaid (2010)
President, Kincaid Furniture
Under Kincaid’s direction, the company has become a leader in solid wood residential furniture.

Peter Kleinschmidt (2013)
President, CEO & Chairman, Stiles Machinery
One of the founders of the WMIA, Kleinschmidt’s ability to look at the big picture also helped Stiles grow into what’s perhaps the largest woodworking machinery distributor in the U.S.

Edmund ‘Bud’ Klipa (2012)
GM Wood Division, Steelcase Inc.
Klipa has helped steer Steelcase’s Wood division’s offerings to meet the changing work modes and trends, and building a stronger global product portfolio through sustainable manufacturing.

Kevin Kuske (2009)
General Wood Manager, Steelcase Inc.
Kuske helped Steelcase reinvent its Wood business and put in place sustainability initiatives at the office furniture giant.

Skip LaBella (2014)
President, Closet America
Under LaBella’s direction, Closet America has grown significantly and has distinguished itself through its technology innovations, products and service.

Bastien Larouche (2013)
President, CEO & Founder, Ro-Bois-Tic
Larouche’s innovative approach to manufacturing led to North America’s first lights-out woodworking plant.

Bill LePage (2009)
VP Operations, The Simple Furniture Co.
LePage helped direct the RTA company’s sustainability efforts, including an eco-friendly line of children’s furniture.

Joe Lonardo (2015)
Founder & CEO, Bella Systems
In the seven years since founding the closet company, Lonardo has already opened three franchises along the East Coast, with more in the works.

Pernille Lopez (2009)
President, IKEA North America
Lopez helped direct IKEA’s growth from a small retailer to a nationally recognized home furnishings and accessories chain.

Matt Lundahl (2012)
COO, Meyer & Lundahl Manufacturing Co.
A “crusader” for the architectural industry as well as his own firm, Lundahl has helped grow Meyer & Lundahl into a premier specialty contractor in the Southwest.

Christine Marvin (2012)
Dir. of Marketing, Marvin Windows & Doors
Marvin’s contributions have helped ensure the fenestration giant remains innovative, and continues its long history of industry-first achievements.

Don Mead (2015)
President, The Gunlocke Co.
Mead helped grow the contract furniture firm out of the recession and continue its legacy of quality, design and sustainable manufacturing. Founded in 1902, Gunlocke is renown for its Oval Office chairs.

Hank Menke Jr. (2013)
President & CEO, OFS Brands Inc.
Menke has helped the office furniture maker remain at the top level through product innovation, value and service. Menke is also a recognized leader for his industry and community efforts.

Gene Ponder (2013)
Founder, Master WoodCraft Cabinetry
A recognized entrepreneur, Ponder founded Republic Industries before launching the successful Master WoodCraft cabinet manufacturing firm.

Jeff Pray (2011)
President & CEO, PIN
Under his direction, the store fixture maker continues to grow and gain recognition. PIN has won numerous awards for its service, product designs as well as innovative use of technology.

Mark Richey (2009)
President, Mark Richey Woodworking
Richey’s success comes from his strong environmental initiatives, as well as empowering employees.

Kevin Sauder (2009)
President & CEO, Sauder Woodworking
As president & CEO, Sauder has helped drive the RTA giant’s strong environmental initiatives: the company produces almost 300 tons of wood waste daily, yet has not taken a load to the landfill in more than nine years.

Jim Sherbert (2010)
CEO, Bush Industries
Under Sherbert’s direction, Bush has diversified into new markets and developed new brands and product lines, while putting in place strategies to increase enterprise value through sustainability.

Eric Smith (2012)
President & CEO, Panel Processing Inc.
Under Smith’s leadership, Panel Processing has grown to be the largest panel fabricator in the nation, offering a variety of manufacturing capabilities.

Steve Stephens (2014)
VP, Marketing & Business Development, acpi Cabinets
Stephens dedication and research skills have helped the cabinet firm develop new markets and opportunities for its products.

Greg Stoner (2010)
President, MasterBrand Cabinets
Stoner parlayed his experience in large-scale manufacturing environments to help position MasterBrand in its leadership role in the cabinet industry.

Karen Strauss (2011)
President, Masco Cabinetry Group
Under her direction, Masco consolidated the retail and cabinet divisions into one streamlined organizational structure.

Bob Timberlake(2012)
Chairman, Bob Timberlake Inc.
Timberlake’s innovative approach to design and marketing a branded furniture line helped turn around the furniture industry.

Kent Untermann (2014)
Owner, The Art Source
A true entrepreneur, Untermann owns and is actively involved in number of diverse businesses, including wood products manufacturing firms and franchises.

Brian Walker (2010)
President and CEO, Herman Miller Inc.
Walker has led contract furniture giant Herman Miller to be one of the “100 Best Companies to Work For,” according to Fortune magazine.

Richard Walz (2014)
President, WalzCraft
Under Walz’s leadership, the wood components firm has grown from a small shop to more than 250 employees, and is positioned for even greater success in the future.

Ron Wanek (2011)
Chairman, Ashley Furniture Industries Inc.
A self-made millionaire and one of the richest Americans, Wanek has led the residential furniture company to becoming the largest in the nation, and be among the first to both source and sell around the world.

Chris Watson (2011)
COO, Conestoga Wood Specialties Corp.
In addition to his work on behalf of the industry, Watson has led the wood components firm in strategic initiatives, including resizing of operations and lean manufacturing.

Bill Weaver (2009)
President & CEO, Canyon Creek Cabinet Co.
Weaver took a small company on the verge of bankruptcy and built it into a major cabinet manufacturer, renowned for its sustainability initiatives.

Jennifer Q. Williams (2010)
Owner & President, St. Louis Closet Co.
In 1991 Williams launched the first locally-owned closet firm that installed custom organizing systems.

Andy Wilzoch(2009)
Owner & President, Premier EuroCase
With the goal of always moving forward and reinvesting in infrastructure, Wilzoch propelled the firm from a 1,000-square-foot shop into one of the largest panel processors, as well as a casegoods and components maker.

Eric Wolff (2011)
President & CEO, The Stow Co.
Under Wolff's direction, Stow has become one of the premier, sustainable manufacturers of home organization products.

Mel Yoder (2015)
CEO, Yoder Lumber
For more than 50 years, Yoder has worked tirelessly to grow and promote not only his own company, but the hardwood dimension and millwork industry as a whole.

Boe Young(2010)
VP of Manufacturing, Impressions Marketing Group
Young has helped lead Impressions in its winning ventures, including multiple awarding of the A.R.E.’s “Above and Beyond Award” for customer service and project execution.

MINNEAPOLIS, MN –  Iowa State University Design Instructor Amy Mikovec understands how important it is to give her students real-world design experience. 

For the second time in two years, Mikovec and her ISU design students have traveled from Ames, Iowa to Cubic Visual Systems, a retail interiors and store fixtures specialist based in Burnsville, Minnesota. 

Mikovec's class traveled to Cubic Visual Systems’ this fall as part of a curriculum-required field experience protocol stipulated by ISU’s academic requirements.

“It is extremely important that the kids get out and see and feel how a real design firm works,” Mikovec explains with zeal.  “I saw the expressions on these kids’ faces when they walked through Cubic Visual Systems’ showroom floor.  They were simply in awe.”

Scott Parizek, a Lead Industrial Engineer with Cubic Visual Systems, feels it is crucial to give back to the design community as both a former design student himself and a father of college-age children.  Cubic is a provider of customized visual display systems for commercial space - from floor to ceiling and everything in-between. Its flexible systems were designed from the core to connect the customer to the merchandise. Cubic employs the latest trends in manufacturing technology, to offer shopfitters, architects and interior designers the store fixtures and components necessary when creating retail, display merchandising, exhibition and commercial environments.

“There is something very satisfying about helping the next generation of designers get their feet wet and experience the real world for a while,” Parizek explains with satisfaction.  “I think we opened some eyes today and that was a very good thing.” Parizek is a graduate of the University of Minnesota Carlson School of Management.

The event included a tour of Cubic Visual System’s showroom floor and a brief presentation and Q & A with Parizek and his staff.

For more information: Cubic Visual Systems   s.parizek@cubic-us.com  www.cubic.co.

Low-voltage LED lighting and miter folding are key parts of a new store fixture design that is designed to deliver flexibility to retail customers.

T.C. Millwork, Inc., a Bensalem, Pennsylvania, retail store fixture manufacturer, is developing some new and innovative products. Smartwall is a UL-listed display and perimeter wall system that uses thin line wall standards and brackets to power shelves that incorporate low-voltage, high-quality LED lighting.

The shelves are not connected to the standards by wires, so the retailer has the opportunity to rearrange them anywhere along the wall without having to plug in or unplug them. This has been installed in major retail stores such as J.C. Penney and Macy’s as well as Whole Foods, Pier 1 Imports and Clarks.

“These shelves are wireless to the end user, so there are no visible connections,” said Jeff Kubach, creative director at T.C. Millwork. “The standards are powered, so the person that is merchandising can configure the shelves in many positions. It’s also very energy efficient. A 56-foot section can be powered by one standard duplex outlet

“Another key is our miter folding. Every shelf is seamless because we have the ability to laminate film onto any surface, even a lightweight aluminum composite, which is then folded as one piece instead of five separate pieces.

“Then our LED lighting is incorporated into the shelves, whether (they are) puck lights or our new light strip with an integrated reflector to maximize the beam spread at over 800 lumens per foot. Another advantage to our LEDs is that they are rated at a 93.5 color rendition on the black body curve. This brings out the true colors of the merchandise.

One of T.C. Millwork’s newest products is the OLED lit shelving system. The horizontal panel wall system incorporates light panels less than 1mm thick into transparent glass shelves. These shelves can also be arranged anywhere along the standards without having to be connected with wires. The OLEDs emit over 90 lumens per watt and produce virtually shadowless lighting.

Every shelf is seamless because we have the ability to laminate film onto any surface, even a lightweight aluminum composite.

Smartwall’s frame is shipped to the retailer prewired in increments of 4 feet wide. Included in the shipment are wall panels, shelf brackets and lit shelves. The frame, which includes the powered standards, is mounted onto the store’s existing walls and plugged into a nearby outlet. That is covered by wall panels. After that, brackets are placed in the grooves of the wall standards. The shelves are lit when they are placed onto the brackets

Kubach said that Smartwall is different from other displays not only because it is wireless to the end user, but because of the quality of the lighting. The shelves are manufactured from aluminum composite material.

T.C. Millwork is also using light fixtures that incorporate reflectors to maximize the beam spread of the lighting. Kubach said that the company is also the first and only manufacturer to incorporate OLED light panels into its shelves.

“The best application for Smartwall is any store that wants to bring the light directly to the product, as opposed to using overhead lights to showcase the products,” Kubach said.

Pier 1 Imports, for instance, is constantly rearranging their shelves to fit their products. With Smartwall there is no need to reset the overhead lighting when the items are moved. The only step is rearranging the lit shelves, with no wires to connect or disconnect. TC Millwork, 215-245-4210   www.tcmillwork.com

CHICAGO, Ill. — Retail fixture organization A.R.E. | POPAI has appointed Steven A. Weiss as its new CEO. The non-profit association was formed last year following the merger of the A.R.E. (the Association for Retail Environments) and POPAI (Point of Purchase Advertising International).

Weiss will be based in A.R.E. | POPAI's Chicago office. Prior to joining the association, Weiss was senior vice president of Membership, Brand & Business Development for the Institute of Management Accountants and was responsible for managing the global brand and integrated marketing efforts.

"Steven has a significant track record driving growth for IMA on a global scale," said A.R.E. | POPAI Chairman Bob Rosean. "He joins our association at a time of great opportunity following the recent merger of two prominent associations in the retail experience industry. We look forward to benefiting from his knowledge and experience. During his 10 years with IMA, membership rose by 45% in part due to his team's delivery of benefit packages that included continued education and certification solutions - two important areas of focus for A.R.E. | POPAI.

A Certified Association Executive (CAE), Weiss has a B.A. in English from Bucknell University and a Masters degree in Education Psychology and Statistics from the University of Albany.

SHEBOYGAN FALLS, Wi. – Wind Mill Slatwall Products has appointed Bob Sexton to the position of project manager for the company.

“We are excited to have Bob join the Wind Mill team to help with the many new and current customer projects. He brings to the position his thorough understanding of assisting customers with custom products along with his knowledge of construction,” states Mark Radtke, Wind Mill’s executive vice president.

Previous to Wind Mill, Sexton worked for a local large format printer and also as a home builder. Currently a student at Grace Bible College, Sexton is pursuing his associate degree in leadership and ministry.

Wind Mill has been manufacturing and marketing retail display panels and related products since 1980. Wind Mill markets to store fixture manufacturers and distributors in the retail, merchandising, and display industries. Wind Mill is an exclusive manufacturer of Anchor Core. GarageEscape is a division of Wind Mill serving consumers with home organizational products.

Chicago - A.R.E. - POPAI The New Association has expanded its marketing-at-retail certification program to offer more ways to earn credits. The program is also expanding globally - enabling member and nonmember retailers, brand agencies, producers and agencies around the world to earn accreditation in the MaRC program.

According to A.R.E. – POPAI, the MaRC (Marketing at Retail Certification) is recognized in the industry as an achievement of relevant and extensive education that gives participants a competitive edge. It also demonstrates a commitment to continued advancement and professionalism in the industry.

The Association merger in October has provided additional opportunities for members and industry professionals to enhance their industry knowledge and for those enlisted in MaRC to earn additional credits. In addition to the existing Master’s class, organization shows and events, and GlobalShop attendance, now participants can earn credits from Shoptalk city-based programs, the Association’s annual conference for members, and the annual Retail Design Collective conferences.

The New Association is also piloting a program to make the MaRC available globally through vetted instructors and approved materials. Chapters around the world have expressed interest in a certification program, including China, Australia, India and Brazil.

 “The world is shrinking at a rapid pace, and expanding certification globally is an important goal for our association,” said Steve Weiss, CEO for The New Association. “We are already involved in global education programs, so the next logical step is to expand certification.”

Other expansion plans for later in the year include certification programs for members with jobs in store design and visual merchandising. Also new this year is a PowerPoint study guide for candidates who have earned credits to sit for the exam. The 100-slide presentation complements the textbook and focuses on key points that are covered on the exam.“The changes we’re making to our certification program will go a long way to help elevate the profession worldwide, not just in our marketing-at-retail program,” Weiss added. “Through new store design and visual merchandising certification/education programs we can provide greater continuity in practices around the globe.”

LAS VEGAS— Under Armour Brand House, LEGO and Giorgio Borusso Design took home top honors at the A.R.E. Design Awards ceremony held at the Four Seasons Hotel Ballroom March 23.

The Chicago Under Armour flagship store, designed by Big Red Rooster and located on the Magnificent Mile – a prestigious retail destination in Chicago – prevailed with the Store of the Year Award over 21 Gold Award winners from around the globe.

The Chicago location is a showcase for the brand's newest and innovative products. A black entry turret sets the tone for 30,000 sq. ft. of retail space. Immersion begins in the two-level rotunda, while videos and graphics envelop customers with score updates and social media. A giant bust wearing a UA shirt, a soaring ceiling, and a 30 ft. diameter LED ring provide large-scale imagery.

LEGO Shopper Marketing Agency of Denmark won Visual Presentation of the Year for its display in the new Hamleys toy store in Moscow's Lubyanka Square. 1.9 million LEGO bricks and 8,000 hours were spent on the project.

The winning LEGO display celebrates culturally and historically significant figures and events like the invention of the wheel, Alexander the Great, an iconic Viking ship, Gutenberg, and Galileo and his telescope, through the classic style of Russian monuments. The centerpiece culminates in the age of mass communication and space exploration, acknowledging Russia's current and past efforts in the field.

The Store Fixture of the Year was awarded to Giorgio Borruso Design for their Shapelifter Pixel Wall in the Chicago installation of ShopWithMe, a mobile, interactive retail store.

The functionality of the wall goes far beyond providing a place for goods to sit or hang. It actually brings product to the shopper to show something new and interesting, providing details about products or suggesting accompanying items. Like the store in which it resides, the wall integrates technology, merchandise display, and brand building.

A record 75 awards were presented this year, honoring all aspects of retail store design, with winners representing eight countries, including Vietnam and South Korea. The A.R.E. Design Awards--the industry's largest and most prestigious retail store design awards program--is in its 45th year.

Gold Awards were presented in all categories last night, as well as the Visual Presentation of the Year, Fixture of the Year, Individual Element Awards, and the Merriman Above & Beyond Award.

Full coverage of award-winning projects along with previous winners can be found here. 

Keeping pace with your industry is crucial for success, and nowhere is that more apparent than for wood products distributors. In an ever-changing market, it’s not enough to rely on past success – to set themselves apart, distributors need to be on the cutting edge of trends and knowledgeable about new products and services in order to provide the best value for their customers.

That’s why Timber Products offers training and education programs to help our distributors take their businesses to the next level.

Education for the Entire Team

Timber Products' trainings are an opportunity for our distributors to get their entire sales team together. Whether it’s an outside rep, inside rep, support team member, or warehouse staff, all employees benefit. The ultimate goal of these sessions is to train teams to be more knowledgeable about our range of products and services. Armed with this knowledge, distributors can increase sales by offering their customers unique products and custom solutions from Timber Products.

Because we offer such a variety of services, our distributors aren’t always familiar with everything we do. During our customer trainings, it’s common for a distributor to encounter a need they didn’t realize we could fulfill.

Many Ways to Get Training

We know many of our customers have diverse training needs, which is why we offer a variety of options to work with our distributors’ schedules and requirements.

We offer in-person trainings in the form of customized, on-site classes held at your business. Each training session is customized to suit the needs of each client and accounts for the type of products they purchase and capabilities they provide to their customers. These personalized trainings are among the most beneficial services we provide to our distributors.

We also offer regional workshops designed to gather multiple distributors in the same room to address the specific needs of their region.

Along with our in-person training, we also offer online webinars through the Woodworking Network. We prepare them around a predefined topic, and our customers are encouraged to ask questions of the experts during the webinar. These online trainings help your business keep its competitive edge and stay well-informed on industry trends, new products, and best practices.

We complete 12 to 15 trainings every year to keep our distributors up-to-date. If you would like to schedule a training with Timber Products, get in touch today at 1-800-547-9520.

ConceptWorks lives up to its name. “We take a concept and turn it into reality,” said company president Adam Schneider. He said the company concentrates on five pillars: technology, materials, quality, time frame and budget.

“We provide a highly technical solution that integrates a plethora of materials, that may or may not be wood, and we do so with an affinity for quality, under a very tight timeline, with a sensitivity to budget,” he said.

“It boils down to service. We listen closely to what the customer wants, and then dictate that back to them. This is what we’re going to do, the time frame and dollar amount. As long as we deliver what the customer expects, they are happy all the time.”

About 50 percent of ConceptWorks’ business is in retail displays, and the trade show sector would be about 20 percent, including everything from a 10 x 10 booth to a 60 x 100 trade show display, with all the work and details. Specialty architectural and design-based jobs account for another 10 to 15 percent of what they do. The final area is to design something from the ground up, which may be beyond any category.

The company has become more diversified. “We used to be only in the point-of-purchase sector, but we moved into health care, agricultural, retail, restaurant, and trade show displays,” Schneider said. “We did product launches, product development, anything market-centric. We also can do residential, including custom kitchens and bars and specialty items, like wine cabinets.”

The company started in 1984 as Sheboygan County Woodworking, and made curio cabinets and smaller point of purchase displays. A portion of the company is located in a former dairy farm (the main barn structure dates from about 1891) out in the country, with an Elkhart Lake, Wisconsin, address. It’s also near the city of Sheboygan. The company has expanded here three times, the most recent being in October 2015, and has 20,000 feet of space here.

The old name suggested that they only worked with wood, and only in Sheboygan County. Both are not true, so the name was changed in 2006. ConceptWorks had only 12 people then, was down to 7 employees in 2009, and now is up to 42. How did they do this? Lean manufacturing, a focus on the customer, and offering many capabilities and diversification.

“There’s very little that we say no to on our own terms,” said Schneider, who can count how many jobs he’s turned down. “Since October 1, 2004, I’ve said no to nine jobs. The due date was not realistic, price point was unreasonable, or the job wasn’t physically possible.”

“Sometimes we say no by saying, ‘We can do that, but here’s your price.’  It’s time, quality and price-point.  Pick any two of those three, but you can’t have all three.”

What do customers want today? “Lately the theme has been bigger, more massive, more wow factor, more impressive, or ‘I can’t believe they did that,’” Schneider said. “We’re seeing more reclaimed lumber and pallets being used. Let’s apply something from an old life in a new context. That’s been a theme recently.”

Most jobs that come in are “blue sky” which can make it fun to design and fabricate. Some don’t fit in a category. In trade show displays, making something people can experience, like a test drive, is a goal.

ConceptWorks has also adopted technology, including a lot of work in LED lighting.

“It’s been a great catalyst,” Schneider said. “We’ve tended to embrace any new technology. The electrical, touchpad locks, pop-up outlets, any new cutting edge, new-to-the-market products. We try to integrate technology wherever we can. We try to be as current and as cutting edge in our application as we can.”

Prototypes and renderings

Jason Gudex is a partner in the business and responsible for a major portion of the design phase. He is focused on rapid prototyping, and creating renderings for the customer. He uses SolidWorks, and has two MakerBots to make prototypes.

Gudex can create designs for a 3D printer, produce a DXF file, or a photo-realistic rendering. He can also produce what amounts to a video, allowing the customer to virtually walk through a large trade show display. About half of the proposed jobs may include such a rendering.

“We’ve learned that the ability to render something is a great sales tool,” Schneider said. “No longer do we rely on which adjective or creative phrase we use. Now you can see it with your own eyes and make that visual connection yourself. It’s like putting a salesperson with the customer -- on their own time.”

Also, when customers see this, there aren’t as many changes during and later in the job.

SolidWorks is 3-D and easy to manipulate and change as details change. It is more common in machine design. Schneider said that Gudex is the best modeling individual, he can do it accurately and quickly, and knows the best way to approach a project.

All prints contain a template for material lengths and widths, including grain direction. The rendering and advanced design work can even help figure shipping weight.

One-piece flow in the shop

In the plant, a new Biesse Sektor 470 panel saw can cut 12 foot x 12 foot x 3-1/2 inches (thickness) of material. It has improved saw output by 240 percent. (Schneider has the exact figure.) It can cut a variety of materials with the proper tooling, such as acrylic, laminate, aluminum and even composites.

The large saw and dust collection system were divided from the rest of the plant floor to minimize dust elsewhere.

The shop emphasizes one-piece flow, from the panel saw to the new Laguna Smart Shop II CNC router, which is used for boring, slot cutting and profile routing, and the Biesse edgebander and Powermatic table saw. A large job board resembles a departure screen for a major airport.

They are using the Laguna CNC router more than Schneider anticipated. It is the first CNC router the company has owned. They were initially concerned about the cost, and also the space for the CNC machine.

“We were on the fence for a long time,” he said. “Do we or don’t we buy a CNC? And after we bought it, we were kicking ourselves. We should have had this years ago. There were so many projects we could use it for. It’s performed much better than we thought it would and has paid for itself in less than a year.

“Once we got our heads around the ROI, and saw the expansion of the building coming together, it made sense to pull that trigger.” 

The Biesse Spark 5.3 edgebander is also new here. “Edgebanders are finicky,” Schneider said. “My advice to anyone buying an edgebander is to stay away from the used models. You get what you pay for. We had a used one and we jokingly called it Cybill, because it had multi personalities. The new one has been a gem for us.”

In another area of the operation, experienced woodworkers concentrate on custom work. Custom projects during a recent visit included making a solid surface shell around a particleboard structure, and many small magnets mounted on a retail showroom display for removable products. Also, they were making a display with cedar on the outside of a post with a robust particleboard and metal interior, décor elements for a restaurant, and a large project for a VA hospital in Colorado including wardrobe lockers, counters, and nursing stations. Also coming are bamboo projects and concrete countertops here.

For finishing, they are using a Graco E-XP1 system to provide a very strong finish, using the same method for truck beds, outdoor projects, even a children’s museum. A large open booth can be used to apply lacquer, enamels and urethanes, including various stains and finishes to make items look rustic, weathered or worn. Finishing only involves about 10 to 20 percent of their business.

Schneider’s favorite phrase is: Improvise, adapt and overcome.

“We’re built to go fast,” he said. “We’re kind of like a racehorse, we’re always ready to go once that starting gate opens.”

ConceptWorks is working with large manufacturing firms that have a fine attention to detail, hard deadlines, and very little direction for how to get there.  “Take what you learned from the conversation with them, and then feed it back to them. ’This is what I heard you say, this is what I believe you’re after, and this is what we’re going to do.’ That will win 80 percent of the battle, by being proactive. Showcase what you’re about to do, so there’s no surprises.”

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

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

Targeted marketing, creative videos, expanded showrooms and of course, social media, are among the ways the 2016 WOOD 100 companies are spreading the word about their products and services.

Northern Contours, St. Paul, MN —  Founded in 1992, the cabinet components and commercial fixtures manufacturer has steadily grown in size, scope and of course, sales. “From intricate custom parts to consistent, high volume runs, we offer a vast and diverse set of products and styles that invoke the hottest European trends,” including high-gloss acrylics, textured TFL, 3D laminates and more, said Melissa Sjerven, director of Marketing Communications.

Sales for the company grew 5.7% last year, and 2016 looks to be even better. “Our success in 2015 was greatly due to focused channel management, particularly in the areas of multifamily refacing and home organization,” Sjerven said. “The growth of our newer products, like SuperMatte 3D Laminates and 5-piece doors, was also a contributing factor. Additionally, manufacturing leadership, reductions in labor costs, and better processes fostered our increased productivity in 2015.”

Northern Contours has more than 420,000 square feet of manufacturing space, spread throughout five production facilities located in three states. It employs more than 450 people.

C.F. Martin & Co., Nazareth, PA —  The longtime guitar manufacturer hit a high note when it created a 40-minute documentary commemorating the 100th anniversary of the Martin Dreadnought, and the influence it’s had on subsequent guitar bodies.

Released this year, the award-winning, “Ballad of the Dreadnaught,” is narrated by actor and musician Jeff Daniels and includes interviews with music icons such as David Crosby and Steve Miller.

“Martin guitars aren’t the fanciest. They certainly aren’t the gaudiest guitars ever made, but they serve a purpose: they work. And that’s why they appeal to so many guitar players,” said Martin CEO Chris Martin IV in the movie.

Continuing the legacy, the Dreadnought Junior was recently added to the lineup.

Pella Corp., Pella, IA —  Already well known for its windows, doors, blinds and shades, Pella recently expanded its market reach with the opening of Pella Crafted Luxury, a 7,000- square-foot showroom in LuxeHome at Chicago’s Merchandise Mart.

Pella Crafted Luxury is a combination of products by Pella Corp. and the recently acquired Grabill Windows & Doors. Pella described the showroom as featuring “six vignettes that allow guests to interact with the products, making it easy for them to imagine the windows and doors in their own home.”

“Our expanding capabilities, craftsmanship and brand are now on display for designers and architects to engage within a stunning, inspirational setting,” said Annette Bravard, vice president of sales and marketing.

“It’s a place for us to provide a unique customer experience focused on solving design challenges in imaginative ways and celebrating individual style. Pella and the solutions we offer are evolving, and Pella Crafted Luxury is part of this change.”

In addition to Grabill, Pella Corp. includes architectural window firm EFCO Corp.

Here are some more top marketing ideas:

Integrated Wood Components, Deposit, NY
Sales for the laminator and fabricator of custom furniture and fixture components grew slightly, due to great customer service and an increased web presence. “Last year was brutal with the economy struggling, but we increased our exposure to our customer base through internet saturation,” said John Kamp, president.

Earth Elements, Gallatin Gateway, MT
“Our design center customers are able to look at wood samples next to tile and stone samples, all under one roof,” said Mike Wolfe, cabinet shop manager at the custom woodworking firm. “That’s really unique.” 

Strasser Woodenworks, Woodinville, WA
An emphasis on marketing, including increased efforts in social media, plus improvements to the manufacturing processes, combined to grow sales 2.8% for the high-end residential cabinet firm, said Judy Hedreen, co-owner and Development Manager.

Flexsteel, Dubuque, IA
The residential furniture provider redesigned its logo and websites as part of a business-wide rebranding. 2015 sales grew 7.1%.

Smart Closet Solutions, Brooklyn, NY
“SCS closely guards the customer experience by sending designers into the field who are the lead installers, instilling comfort and consistency for the client,” said Ben Aviram, vp design & installation. Sales for the closet manufacturer grew 13% in 2015.

Taghkanic Woodworking, Pawling, NY
The custom cabinetmaker introduced Pawling Closet Co. which filled a niche and complemented “the fine cabinetry and dressing rooms that we are already providing,” said Leland Thomasset, president. “This venture proved to provide an entirely new customer demographic in addition to our existing client base. While our gross profits rose approximately 1%, our net profit was up by 16%, primarily propelled by the new venture.”

Heritage Home Group, High Point, NC
Community service efforts have kept this residential furnishings giant at the forefront of customer’s minds. Among its endeavors was the raising of thousands of dollars for cancer research by employees of Hickory Chair, Pearson and Drexel-Heritage.

Ultimate Cabinets, Vera, OK
In addition to manufacturing prefinished cabinets and casework, the firm markets its services to local cabinetmakers that don’t have CNC capabilities, said Jeff Finney, owner. He added, “We are aggressively moving into the component industry with a goal to get high-quality parts to cabinet shops in the central U.S. with short lead times.” He credits his employees in the success. “A better employee makes for a better company. That is the only way we have been able to not only complete jobs on schedule but have a schedule at all.” It’s a winning strategy, with 2015 sales up 11.1%.

Ethan Allen Interiors, Danbury, CT
2015 sales rose 3.5% for the furniture giant, which recently celebrated its 10th year as the primary source of furnishings for HGTV’s Dream Home. “This is a wonderful partnership for us, and the home is a beautifully designed showcase for our furniture, accessories and art,” said Farooq Kathwari, chairman, president and CEO.

Conestoga Wood Specialties, East Earl, PA
The cabinet components maker touts its sustainability to customers, including its renewal of certification in the  KCMA Environmental Stewardship Program. In addition to being the first associate member to receive ESP certification, Conestoga is a past winner of the PA Governor’s Award for Environmental Excellence.

Bassett Furniture, Bassett, VA
HGTV continues to be a prime advertising vehicle for the furniture provider, which extended its partnership through 2019. “The HGTV HOME Design Studio is an important point of differentiation for our stores and is playing a key role in our improved comparable store sales,” said Robert Spilman Jr., Bassett president and CEO. 2015 sales rose 13.7%.

Stanley Furniture, High Point, NC
The furniture maker inked a licensing agreement with world-renowned fashion brand, Oscar de la Renta, set for introduction this fall. Stanley will design, manufacture and sell domestically and outside the United States the whole home collection. The firm said it expects the same success that it has with its Coastal Living licensed line, which is one of its best-selling.

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Recent controversy over the U.S. presidential election aside, consumer spending is not expected to diminish over the next few years, a fact which bodes well for the retail environments sector.

With that in mind, an October report in design:retail found 46.5% of  surveyed retail CEOs, store planners, designers and visual merchandisers, planned to increase their capital spending over the next year, including a number of renovations and new store openings in addition to those completed in 2016.  

Why the growth in brick and mortar stores? Despite the convenience of online shopping, research shows consumers still enjoy the in-person experience. Even Google has amped up its retail presence with a pop-up store in New York, and a recently announced partnering with Best Buy for Google shops in the electronics giant’s stores.

(Click on the infographic to enlarge.)

Information Sources: Shop!,design:retail, Statista, Conlumino USA, MarketResearch.com, National Retail Federation, Kurt Salmon, King Retail Solutions (Consumer Insights), Visual Merchandising + Store Design, and Mann, Armistead & Epperson Ltd.

Category: Store fixtures & interiors includes: display cabinets & cashwraps, POP & full store interiors, kiosks, endcaps, slatwall & systems