How Fabridor Embraced Robotics to Solve Quality Issues in Custom Cabinet Manufacturing

In Quebec, Canada, the custom kitchen cabinet manufacturer Fabridor faced a growing, albeit subtle, problem. Though customers rarely demanded refunds or returned products, the company’s general manager, Hubert Dubois, sensed a pattern: they were losing customers, and the reason was often hidden in the details of quality. Despite an efficient production process building around 300 doors a day, quality checks at Fabridor’s plant were sparse, pulling just one door per shift for testing. For doors made of medium-density fiberboard (MDF), quality issues could remain hidden until later in the finishing process, when painted surfaces revealed flaws.

When issues did arise, correcting them disrupted productivity. Operators had to sift through previous shifts’ work, repaint doors to identify where sanding errors originated, and, if found, re-sand entire batches. It became clear to Dubois that the solution was automation.

Embracing Robotics with a Leap of Faith

Dubois, experienced in manufacturing and a proponent of robotics, faced a challenge in gaining approval from one of Cabcor Industries’ CEOs, Fabridor’s parent company. This CEO was hesitant, preferring tried-and-tested machinery over the unfamiliar territory of custom robotics. But Dubois emphasized that automation would save labor costs by eliminating one manual sanding position per shift.

The investment was substantial: two sanding robots would cost nearly $288,000. Given Fabridor’s annual profit margins of around 5% on $5 million in revenue, this was a risky move. However, faith in Dubois’s judgment, backed by his past experience, helped seal the deal.

The Quest for the Right Automation Partner

Implementing an effective robotic sanding solution was no small feat. Unlike simple automation tasks, the robots needed to emulate the precise, oscillating patterns human operators used to avoid marks on MDF surfaces. Dubois’s search led him through multiple integrators. He eventually found the right partner, an automation integrator with the capability and willingness to develop the necessary sanding patterns.

Three weeks after their initial visit to Fabridor, the partner presented a working demo. Dubois signed the purchase order, and in early 2024, Fabridor’s automated sanding system went live. The result? Productivity increased by 25%, raising production speed from 17.5 doors per hour to 22, though Dubois believes that figure will climb higher as the operation returns to full capacity.

Automation’s Broader Potential: The Role of Cobots

Fabridor’s story isn’t unique in today’s manufacturing environment. Collaborative robots, which work alongside humans, are finding widespread use in industrial settings. According to SkyQuest research, the global cobot market is projected to grow significantly, from $914.88 million in 2023 to $2.3 billion by 2031.

Cobots offer an adaptable solution to various manufacturing needs, including quality control, packing, machine tending, and sanding. Unlike traditional robots that require fenced-off areas, cobots’ safety features allow them to work directly with humans. Various types of cobots offer unique interaction levels, from safety monitored stop cobots that halt if a human enters the workspace, to hand guiding cobots that follow operator commands.

A Look at Cobots in Practice

Other manufacturers have tapped cobots to tackle labor shortages and streamline repetitive tasks. For example, Roechling Industrial North America employed CNC machine-tending cobots to address labor shortages, while SEAT Componentes in Spain used cobots to unload 18,000 machined gears per day without external integration support.

Cobots are not only relieving operators of monotonous tasks but also improving safety. It is widely noted that cobots reduce injury risks in tasks like palletizing or machine tending. Furthermore, as cobots become increasingly mobile and modular, manufacturers can deploy them flexibly across multiple jobs or workstations without extensive setup.

The Upsides and Challenges of Cobots

Cobots offer significant benefits: they excel in repetitive tasks, operate in tight spaces, and empower human workers to focus on complex, value-added activities. However, cobots have limitations. Their safety and ease of use can lead to a false sense of simplicity—many tasks require expert integration and may even necessitate safety barriers for high-speed operations.

For Fabridor, the journey to automation has been transformative. Though still early in evaluating the financial impact, Dubois is encouraged by the initial improvements in productivity and quality. The success of Fabridor’s robotic sanding solution exemplifies how automation, particularly cobots, can be harnessed to meet the unique demands of custom manufacturing, offering lessons for other industries seeking to improve efficiency, maintain quality, and ultimately retain customers.

Ready to take your manufacturing process to the next level? Discover how automation and robotics can streamline production, enhance quality, and boost your bottom line. Contact us today to explore customized solutions that fit your unique needs and set you up for long-term success in a competitive industry. Let’s build the future of manufacturing together!