The Exact 7 Step Process We Use To Manufacture Your WorkSpace Garage Cabinets In The U.S.
Yep, we’re still manufacturing right here in the U.S. I know it may come as a shock to you seeing as most other cabinet brands are manufactured outside the country and shipped via container ship to a giant warehouse out on one of the coasts. Yet, here we are in Middle America producing world class storage solutions for your garage, home, and business!
I know what you’re thinking…
How do they do it?! How’s it possible to custom manufacture in the 3-5 business days after I place an order, employ hardworking Americans, and still compete with all those other brands using cheap labor and inferior materials?
Well, let me tell you a bit about the 7 step process we use to manufacture your WorkSpace cabinets…
Step 1 – Order Entered Into Our System
Like just about everything else these days, our manufacturing process has gone high tech. So, the first thing we need to do after your order is placed is enter it into our computer system. We send your order through a computer program that nests the cabinet parts together in patterns.
Step 2 – Cabinet Doors, Drawer Fronts, and Box Parts Machined On CNC Routers
And this is where the magic starts to happen! We use precision, computer drive CNC routers to cut out the doors, drawer fronts, and all of the cabinet box parts for any storage cabinets on your order.
At this point, the cabinet box parts and the doors and drawer fronts will part ways.
Compressed air is used to blow dust off the cabinet box parts and a label with your job name and the part information is attached. Those parts are then stacked on a skeleton cart and moved to the edgebanding machine.
The doors and drawer fronts have their edges sanded before a label with your job name and the part information is attached to each one. From there, those parts are stacked on a separate skeleton cart and moved to the powder coating station.
Step 3a – Edgebanding Cabinet Box Parts
The edgebander is used to glue a finished edge to the cabinet box parts. But don’t the simplicity of its task full you! This is a very complex machine with lots of intricate moving parts. The cabinet box parts are added at one end of the machine and it has a built-in roller return system that allows the operator to continuously load parts.
After banding is added to all necessary edges, the cabinet box parts are again stacked on a skeleton cart and this time moved on down the line.
Step 3b – Powder Coating Doors & Drawer Fronts
When the doors and drawer fronts are ready to be powder coated we hang those parts on the powder coating line and use compressed air to blow off any dust. Read our blog post Why Powder Coating is the Perfect Finish for Garage Cabinets for more information!
The parts first go through a pre-heat oven before being sprayed with a dry, negative electro-statically charged powder. The board is positively grounded, so the powder sticks to the board. The line moves the parts into another oven where the powder melts into a gel, flows a bit, and begins the curing process.
When the parts are done curing, they are removed from the line, stacked on a pallet, and moved to the next CNC router.
Step 4 – Cleaning and Palletizing Cabinet Box Parts
At their next stop, cabinet box parts are cleaned of any glue left by the edgebander. They are also cleared of dust and inspected for damage here. Once the parts have passed our stringent quality control inspection, they are stacked on a pallet between layers of foam, cardboard and filler panels.
When all parts are cleaned, inspected, and accounted for the pallet is moved over next to the CNC router; where it will meet up with the powder coated doors.
Step 5 – Drilling, Cleaning, and Palletizing Doors
After being coated, the doors are sent through another CNC router to drill the hinge holes. Compressed air is used to clear off any remaining dust before stacking the parts on the pallet. The doors are stacked on top of the already palletized cabinet box parts between layers of foam filler panels.
The entire load is then strapped to the pallet and shrink wrapped to ensure none of the parts move during transit.
Step 6 – Building and Palletizing Drawers
We send all your drawer boxes assembled to make installation easier for you. In addition to assembling the drawer box, we also attach the powder coated drawer fronts and the drawer slides for you as well.
A piece of foam is shrink wrapped to all visible parts of drawer fronts to provide additional protection during shipping. The back of the drawer box and slides are shrink wrapped as well to prevent the slides from moving. The drawers are then stacked on the pallet with the doors and cabinet box parts.
Step 7 – Building the Crate
This final step oftentimes proves to be the difference maker when it comes to getting all your cabinet parts to you damage free.
After any countertops and / or other accessories you ordered are stacked on the pallet we nail sheets of OSB to all four sides of the pallet and put a top on it to create an imposing and formidable crate. These are affectionately known around here as “tank crates” and boy can they take a beating!
So, that’s how it’s done! You now know exactly how we go from an order placed through our online store to actual product ready to ship to your door. We can do all that in (3) days.
Pretty cool, huh?