QTK Fine Cabinetry rebranded to reflect its sole focus on cabinets.
QTK Fine Cabinetry aims to satisfy its customers one kitchen at a time.
“Your kitchen, your taste, that’s our slogan and we employ this methodology to build every single project,” says Daniel Toto, general manager. ”We don’t stock parts, we cut everything we need for one job. Everything is processed in a batch size of one and our Schelling and IMA machine’s speed and reliability allow this. We not only build the kitchen for each customer, we design it for how each particular user uses their kitchen.”
The company rebranded from Quality Tops & Kitchens to QTK Fine Cabinetry because of its focus only on cabinets. QTK purchased a Schelling FH6 with Duplus and automatic label printing in May 2009 at Ligna. Shortly after that and before the Schelling was delivered to QTK, the company moved from two buildings comprising 31,000 square feet to one building with 45,000 square feet in size in Vaughan, Ont., near Toronto.
“Before we moved we were forced to place new machinery where it fit as opposed to where it belonged in the manufacturing process,” Toto says. “By moving we were able to plan the production work flow and install the machines in the most efficient location possible. This allowed us to capture lost efficiencies from being separated into two plants.
QTK has been in business manufacturing quality custom-made residential cabinetry since 1974. “Our customers are new home builders, designers, contractors and private home owners,” Toto says.
Everything is made in one location. “We order sheet stock, cut on our Schelling FH6, edgeband on our IMA Novimat Concept with 24-color automatic selector, then parts get drilled on three point-to-point CNC machines. From there boxes are assembled using dowels,” Toto says.
“We employ a just-in-time system for all material and hardware inventory as well as work in progress inventory. We don’t cut, edgeband and build cabinets until just a few days before they are to ship. The reliability of our European machinery allows us to do this.
Increasing speed
Toto says that one of the biggest upgrades has been in the speed of the process. “We replaced our front-load panel saw with a rear load, automatic labeling Schelling FH6, replaced an edgebander with one tape color with an IMA Novimat Concept with 24 tape coil. And we employed just-in-time ordering of all hardware and sheet goods. Assembled cabinets take up a lot of space, so we try to minimize how many kitchens we warehouse waiting to be shipped.”
Improved production systems have helped the company make one kitchen at a time more efficiently.
The company uses a lot of colored melamines for their interiors. They offer the customer the option of using a color matched melamine as the interior as opposed to white. Last year more than 90 different colors were used for their cabinet interiors.
QTK employs Microvellum software for engineering and creating automatic g-code for the three CNC machines in the factory, and Ardis optimizer and automatic part labeling on the Schelling FH 6 panel saw.
The company also uses the MicroManager ERP system to track projects in production, assign employees to projects, to scan items being shipped and to gather data recording the number of man hours spent on each project.
The Ardis Inventory Management System (AIMS) allows them to keep, catalog and re-use offcut pieces.
Handling offcuts
“This makes keeping offcuts easier, more organized and is environmentally friendly,” Toto says. “Each time an offcut is generated that is bigger than a certain size, an offcut label is automatically printed.
“The saw operator places the offcuts in a section that is also labeled and scans the part label and the area label so the system knows where the parts are located. Next time we optimize all the offcut parts scanned into the system will try to be re-used – if any of the parts are to be re-used the system tells the saw operator which part to get and where it is located.
QTK doesn’t use bubble wrap and cardboard to transport cabinets because of they are not environmentally friendly. Instead, QTK wraps cabinets in re-usable blankets that are transported back to the factory upon completion of the project.
“We are constantly innovating and pushing forward in design and process improvements,” Toto says.
Doors made in house.
Finished doors then exit the dust-free paint room to have hinges installed, placed on the cabinets and loaded directly into the delivery truck.