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Suppliers adjust to lean mfg., fewer factories

By Jeff Linville -- Furniture Today, February 26, 2006

Greensboro, N.C. — U.S. furniture makers are turning to lean manufacturing techniques to survive, causing suppliers to change their business models as well.

The trend was evident at the Carolinas Industrial Woodworking Expo here this month, where lumber and machinery exhibitors saw fewer furniture manufacturers than in past years.

So many factories have closed in recent years that many domestic producers have an excess of machinery and tools and aren't shopping for more, said some suppliers. On the other hand, suppliers say some U.S. manufacturers are turning to more sophisticated, computerized machinery as a way to create stylish, value-priced furniture with fewer workers.

One company offering new, high-tech equipment is saw maker TigerStop. One complaint the company has heard from saw operators is that it takes too much time to measure wood and readjust for each cut, said Tom Dole, marketing director. A new computerized system attached to a saw can automate many steps, saving time and using lumber more efficiently. Dole demonstrated with a three-foot board. The computer came up with two components that could be made, with only half an inch of waste.

Engineered wood source BlueLinx has found that as more U.S. companies look to cut costs, it has been easier to persuade upholstery manufacturers to try plywood frames rather than solid wood, said Donahue Bottoms Jr., territory manager.

Lumber giant Weyerhaeuser is using lean manufacturing techniques at its own facilities, said Gary Janelle, market development manager. In some cases, Weyerhaeuser's team has trained its clients on reducing costs, he said.

Because domestic producers have downsized, warehouse space is at a premium for many. Suppliers of lumber and other components are looking for ways to offer smaller shipments at a greater frequency.

With downsizing, furniture has become less important to the U.S. woodworking industry, and that was evident at the show. Several exhibitors said they were at the event to see cabinetmakers.

That could change soon, as a few companies said they heard complaints from attendees about Chinese companies getting into the cabinet business. A spray booth supplier said the move to imports was hastened by U.S. regulations, which hurt domestic factories with tighter rules on spray chemicals, emissions and safety.

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Suppliers adjust to lean mfg., fewer factories

Mar 2, 2006

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