Greyloch Cabinets Achieves Full-Scale Automation at New Facility Through ROMS-6 Horizontal Strapping Solution
Background
Greyloch Cabinets is a premier cabinetry company that is family-owned and dedicated to crafting custom, handcrafted cabinets of exceptionally high quality. The manufacturer produces a variety of high-quality products, all made to order, including European Frameless Cabinets and modern slab panel cabinets with matte, gloss, and wood grain finishes.
Challenge
Greyloch opened a new $44 million state-of-the-art facility on September 6, 2023. The nearly 97,000-square-foot structure already employed 50 workers on the floor at the ribbon cutting and is expected to double that workforce by 2026. One emphasis of the new facility is automation.
Greyloch leadership wanted every possible activity equipped with the latest manufacturing technology. The objective of this push for comprehensive automation of their manufacturing process was to maintain the highest quality standards while reducing product lead times. Minimizing waste was also a goal. The result was an end-to-end system capable of cutting, edgebanding, drilling, and gluing custom cabinetry as the team shepherded each piece from sheet good materials to assembled products.
The last step in that process was the need to box and secure each load for delivery. This was an area outside of Greyloch’s specialization. Before the move to the new facility, their production team had been hand-strapping each cabinet off-line. The push for automating the entire system led them to seek a similar end-of-line packaging solution, and their German partner and integrator suggested EAM-Mosca.
Solution
An EAM-Mosca representative helped assess Greyloch’s situation and suggested the ROMS-6H SoniXs® horizontal strapping systems as the solution fully capable of keeping up with their desired manufacturing flow.
The ROMS-6H is an effective choice for furniture and larger appliance strapping. Critically for Greyloch’s goals, the machine is fully automatic, making it an ideal addition to the manufacturer’s new facility. In addition, its adjustable track width (with four-track sizes) and a large product height range of up to 90 inches make it capable of handling most cabinet strapping requirements. Despite the maximum size of each product, it can safely secure up to 120 triple-strapped loads per hour.
In addition, the ROMS-6H is equipped with indexing strapping heads, which utilize EAM-Mosca’s industry-leading SoniXs® technology. The ultrasonic sealing solution provides consistent, high-strength seals without the need for warmup or the risk of smoke. Greyloch’s German integrator partner installed the strapping solution, and its straightforward setup and easy user interface meant there was no need to adjust or alter the machine after installation.
Results
The ROMS-6H has successfully contributed to Greyloch’s superior manufacturing output at its new facility (which has increased the output per employee ten times over of leading competitors at a rate of 300 cabinets per eight-hour shift). In addition to improved output, EAM-Mosca’s automated strapping solution has allowed Greyloch to reduce the end-of-line strapping team from three employees to one.
The machine is enabling Greyloch Cabinets to set the gold standard for the cabinet industry by contributing to their ability to deliver exceptional customer service and safe and speedy delivery. Greyloch Cabinets has other areas of its facility where EAM-Mosca’s strapping and wrapping products could improve efficiencies, and both partners look forward to future collaborations.
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