How Tharp Cabinets Overcomes Supply Chain Challenges to Meet 5 Week Delivery Times

In a FORBES Magazine article written by Ethan Karp on February 12, 2022, Ethan stated:  “After decades of roller-coaster dips and upturns, American manufacturing is at a pivotal point. Can 2022 be the year the industry reclaims global leadership status, despite all the curves the pandemic has thrown at us?”  His answer:  “Yes. If manufacturers make bold investments in talent, technology, and innovation.”

I recently sat down with Mark Kyner, Tharp Custom Cabinetry’s Operations Manager to discuss Tharp’s 5-weeks manufacturing turnaround and the increased demand for kitchen and bathroom cabinetry.  Here is what we discussed:  

With all of the challenges of manufacturing timelines these days (for example, many kitchen appliances are backordered for up to 12 months) how can Tharp be so efficient (purchasing lumber, drawer slides, stains, paints, etc.) to be able to handle 5-weeks production turnaround? 

We utilize Lean methodologies to keep the “right” amounts of materials (Called Kanban system), keep a sharp eye out on the horizon for potential upsets in the supply chain, and have increased our safety stock or Kanban level to ensure our supply. We are also proud of our vendor relations and how we work together to overcome challenges.

All of Tharp’s cabinets have been manufactured in Loveland, Colorado since 1971.  How does this help? 

Local Manufacturing takes away one of the biggest bottlenecks in our current world situation – transportation of goods. By utilizing local sources for our materials, local skilled craftsmen, and our own delivery trucks and staff and install crew, we take the mystery out of getting products in homes.  

What are some of the processes, tools and software that keeps Tharp on track? 

We’re structured and organized, and Tharp uses proprietary order tracking MRP (Materials Requirements Planning) system, which we fondly named Alice, as well as hands-on management by dedicated Project Managers.

Does Tharp have automation to speed up the process…things that smaller shops may not have? 

About three years ago, Tharp moved into a new 100,000 sf manufacturing plant, which not only increased capacity, but gave us the opportunity to modernize our equipment and streamline processes.  We have a number of dedicated machines and highly trained operators that allow us to efficiently and accurately produce.  

It’s great to be quick but what quality checks does Tharp have to make sure everything is perfect? 

We have a number of checkpoints, from sales entry, drafting reviews, production checks from department to department, and a final quality walk from a Project Manager post install. We also utilize lean tools to determine when we miss, and this allows us to quickly correct mistakes. But we have installed the mantra that quality is everyone’s responsibility and all team members need to execute their part according to Tharp’s process to deliver quality products. 

Despite constant challenges in American manufacturing, Tharp Custom Cabinetry has continued to invest in our people, processes and innovation.  All of this focus has allowed Tharp to deliver quality cabinetry to our customers, faster than any other cabinet manufacturer in the region. Contact us to learn more about how we can help you solve your cabinetry needs or stop by our Denver or Loveland showroom to speak with one of our specialists today.