Process

Every product that Monarch manufactures goes through systematic processes of estimating, engineering, procurement, milling, assembly, and finishing before it is finally delivered and installed at the site. This ensures that all controls are met, and each area of the company is able to add their expertise to producing a quality product, on time and to specification.

Nothing compares to a tour of our facilities to see the process at work. Should you wish to visit Monarch, please call 1-800-669-WOOD and we will schedule a tour.

Our Sales Team works with the Estimating Teams to schedule projects to bid. Once a project is received for pricing, a team specific estimator is assigned to the project and the process begins.

• Each job is classified as Millwork, Retail Fixtures, Foodservice/Casework or Graphics.
• The team’s leadership assigns a project estimator who reads through the documentation to get a full understanding of the required scope and specifications.
• A thorough take-off is done to identify all components of the job and its site requirements.
• With the help of our vendor network, we estimate all costs and then generate a formal proposal for our client’s review.

Once Monarch is awarded the job, the architectural prints are brought to Project Management. The Project Manager is responsible for seeing the project through to completion. Their first task is to get manufacturing drawings submitted to the client for approval.

• Engineered drawings are used exclusively in manufacturing to ensure quality and precision.
• Drafts people draw each component of the project with detailed shop instructions.
• Monarch can value engineer job components to increase durability and lower costs.
• After architectural approval, drawings are stock–billed to provide final instructions to the shop floor or our supply chain.
• Project Managers facilitate communication between the many departments and contractors.

As the job is engineered, the material bills are sent to Purchasing for procurement. To ensure the quality of materials and efficiency in purchasing, the following steps are taken:

• The Supervisor of Purchasing, Jay Bloom, reviews all requisitions.
• The purchasing information system tracks all orders.
• Monarch sustains long-term vendor partnerships to achieve the best terms available.
• Fast delivery times allow for rush jobs and quick changes.
• Purchasing agents regularly meet with suppliers to preview the newest products and materials.

As materials are received, they are logged into the inventory system and noted in the production reports. Once production is scheduled, materials are put into the mill.

• Our Machining Cells are groups of state of the art CNC manufacturing equipment that are programmed seamlessly through downloads from the CAM department.
• Computerized machine programming allows for exact milling reproductions and material efficiency reporting.
• Monarch has invested millions of dollars to increase cutting capacity and accuracy.
• Optimization software is utilized to determine the maximum yield of each piece of material.
• The finish cut department matches veneers and panels to produce the highest quality appearance.

The craftsmen and artisans of New England have been renown throughout the nation and the world. Monarch’s cabinetmakers embody the Old World craftsmen ideals with their experience, expertise and knowledge of quality craftsmanship.

• Monarch’s staff is made up of men and women from a wide variety of ethnicities and backgrounds, which lends to a diverse workplace and a variety of resources.
• Many of Monarch’s cabinetmakers have over twenty five years experience.
• The assembly department is made up of five to six person teams, each guided by an experienced lead man.
• Assembly is a crucial part of the manufacturing process which requires the utmost skill from both the cabinetmakers and the supervisors.
• In high production environments, teams are cross trained to increase productivity through lean efforts, reducing errors and increasing opportunities for value engineering.

For as long as Monarch has been a wood manufacturer, finishing has been one of its greatest assets. A combination of Old World artisans, modern equipment and techniques, and a constant demand for the highest quality finish has driven this department to success.

• Our Finishing Departments have been matching the most difficult color combinations with a steady hand and an eye that outlasts the most modern equipment.
• The staff of sprayers and toners reach for perfection with each pass of the spray gun. After each layer of paint or lacquer has dried and cured, the finish is hand–sanded to ensure the quality of the subsequent coats.
• New high volume, low-pressure spray equipment is used to create a smoother cover with less raw material and lower VOC’s.
• Monarch’s mechanized Rhodes® spray line with flash tunnels and curing ovens brings the unfinished product to the sprayer, increasing efficiency and finish quality.

While maximizing the utilization of its own fleet of trucks, Monarch also uses a wide range of transportation companies and freight forwarders. These relationships allow Monarch to complete jobs throughout the nation and around the world.

• Monarch work can be seen as far away as Saudi Arabia and Guam.
• As jobs become due to ship, the Shipping Supervisors oversees the hand blanket wrapping of each component.
• Project Managers oversee the final steps of the job, including installation and maintain constant communication with customers.
• A punch list is completed and the job is finished for another satisfied customer.

After the job is completed, and each stage of the schedule has been met, accounting and administration begin the process of final billing and vendor payments.

• Our Cost Accountants and Project Managers use the mountains of data collected during the manufacturing process to estimate percent of completion for proper billings.
• Accounts Payable collects all invoices from the legion of suppliers and sub-contractors who also contributed to the production effort.
• Credit Management follows up all accounts receivable, monitors payments, and acts as a liaison for all customer requests.