Turning up the Profit
Enhancing Operational Efficiency in Kitchen Cabinet Manufacturing with Axalta’s Zenamel™
Introduction
While working with a leading kitchen cabinet manufacturer that specializes in producing semi-custom and stock cabinets, the Axalta team was asked to address challenges the company had been experiencing related to operational efficiency, specifically regarding their cabinet finishing process. This case study focuses on how Axalta’s self-priming kitchen cabinet enamel, Zenamel™ SP, offered a solution to these challenges, resulting in significant improvements across various aspects of their manufacturing operations.
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There were several critical issues facing our customer in the manufacturing process related to the application of conversion varnish on their cabinets. The primary problems were:
Lower Yield: The existing process led to lower yield due to inconsistencies in the application of the enamel, resulting in a higher percentage of scrapped cabinets.
Complex Process: The incumbent process required the application of two different products in three separate coats, making it complex and prone to errors.
Extended Processing Time: The multi-step process extended the overall processing time, impacting production efficiency.
Inventory Management: The requirement for two different products added complexity to inventory management.
Axalta’s Zenamel™ proved to be the solution to these pressing issues. Zenamel™ SP is a self-priming kitchen cabinet enamel designed for optimal performance and efficiency. Here’s how it addressed the challenges faced by Our Client:
Simplified Application: Zenamel™ SP can be applied in just two coats, as opposed to the previous three-coat process with two different products. This simplified the application process and reduced the likelihood of errors.
Enhanced Yield: The new product and application process improved yield with fewer scrapped cabinets, translating to cost savings for Our Client.
Reduced Processing Time: Zenamel™ SP two-coat application significantly reduced the processing time, allowing for quicker cabinet production and delivery to customers.
Operational Simplicity: The streamlined process made it easier to maintain Standard Operating Procedures (SOPs), reducing the complexity of training new employees and ensuring consistent quality.
Improved Working Conditions: The use of Zenamel™ improved working conditions in the factory by reducing exposure to potentially harmful chemicals and fumes.
Inventory Management: Our Client benefited from simplified inventory management, as they only needed to stock Zenamel™ instead of two separate products.
Implementing Axalta’s Zenamel™ resulted in a range of benefits:
Higher Yield: Reduced scrap and increased production efficiency led to a higher yield of quality cabinets.
Cost Savings: The improved yield and reduced processing time translated into cost savings.
Enhanced Quality: The simplified application process resulted in more consistent and high-quality cabinet finishes.
Improved Employee Satisfaction: Better working conditions and reduced complexity led to increased job satisfaction among employees.
Efficient Inventory Management: Managing a single product streamlined inventory operations.
