Domestic makers, smaller brands and local artisans are key players in the battle of sourcing and supply. By Dianne M. Pogoda
Lingering supply-chain disruptions continue to impact every industry and every type of manufactured product — kitchen and bath included. The still-robust market for housing and remodeling means the supply-demand equation remains an enormous source of frustration, severe delays in completing jobs and loss of business.
Astute kitchen and bath designers and remodelers have come up with some solutions to product scarcities and increased timelines that can work in many markets. The secret is often taking a chance on lesser-known brands, developing relationships with new suppliers, and opting for smaller manufacturers with limited production. While this might cost more in the short term, it can save headaches and time in the long run, result in happier customers, and expose designers and consumers to new makers.
Why It’s Happening
In a podcast explaining supply-chain woes, Trey Northrup, CEO of LIXIL Americas (parent of American Standard, Grohe and DXV), said everything from logistics to raw-materials inflation to third-party suppliers has been impacted. He said demand has outstripped capacity — and demand keeps rising. And while the company ramped up production at domestic and international plants, there’s still a “hangover” effect. The primary issue is labor — the ability to produce enough with the labor that’s available in the plants, a shortage of workers to unload cargo ships and truckers to deliver the goods throughout the pipeline. Overseas, the chain is also impacted by long-lead components, because a lot of those come from around the world.
The shipping delays have played a big role not only in scarcity of items, but in the record inflation currently draining the economy — and there’s little to no price protection for products in the pipeline. Numerous industry advocates have implored the federal government to ease the bottlenecks in the supply chain and tariffs causing price spikes on many building materials, including lumber, steel and aluminum. Last year, the Ports of Long Beach and Los Angeles initiated 24-7 operations, easing West Coast delays. Those two ports handle about 40 percent of the shipping containers entering the U.S. And on Jan. 31, the Commerce Department reduced duties on softwood lumber shipments from Canada to the U.S., to 11.64 percent from 17.99 percent, in an effort to ease price swings in the lumber market that have jacked up the price of new houses as well as remodeling.
How K&B Is Coping
K&B designers, often the primary specifiers on remodeling projects, are exploring creative ways to work around the shortages.
Some designers said they are turning to domestic suppliers more frequently, but sometimes international brands that aren’t as well-known here have adequate inventory and can fill a need faster. This is particularly true for higher-end niche brands that have warehousing and distribution in the U.S. and therefore have inventory available and already in the country.
“We’ve begun to use products from lesser-known manufacturers, higher-end brands and local artisans,” said Kimberly Kerl, principal and designer at Kustom Home Design in Greer, S.C. “I’ve been able to find more products available through online channels than I can source through local showrooms, which saddens me. I prefer to work with my trusted suppliers that hire people in my community, but even they are telling me that if I can find an item in stock online to buy it.”
Vicky Serany, principal and designer for Southern Studio Interior Design, Cary, N.C., said her company has been developing relationships with more local showrooms. It’s a time-consuming process, but “the innovation will make us better in the long run.”
Among the ideas that have proved fruitful, she has asked her granite/stone manufacturers to fabricate sinks to integrate with the countertops, instead of ordering specialty sinks separately. “It’s an expensive, labor-intensive option, but looks beautiful,” she said.
To overcome the challenge of long lead times on custom ordered tiles, designer Vicky Serany creates unique tile installations using in-stock, readily available tiles.
For tile installations, Serany is using in-stock, readily available tile and creating unique installation patterns. This, she said, is an alternative to long lead times on custom ordered tiles.
Kerrie Kelly, FASID, CAPS, creative director of Kerrie Kelly Design Lab in Sacramento, Calif., said that for tile, local companies, including Fireclay Tile and Heath Ceramics, both out of Northern California, have stepped up to the plate with supply.
Some designers are turning to local, domestic manufacturers like Fireclay Tile, which produces tile out of its California factory. Shown: Fireclay Specialty Kite Tile used as a backsplash in a kitchen designed by Ideaspace A&D. Photo by Raquel Langworthy.
“We have also found that reclaimed wood products for flooring have provided a sustainable, unique aesthetic with wood shortages,” Kelly added.
Appliance delays, frequently stretching to several months, have led many designers to choose and order even before plans are finalized — and clients aren’t getting rid of the old appliances until the new ones are in hand.
Kerl said when pandemic-induced disruptions began, clients and contractors were side-swiped with the sudden product delays. “Projects were already under construction and contractors assumed product lead times based on the norms of the past several years,” she explained. “Those projects incurred massive delays due to the interruption in the supply chain. To help out some of these clients, for example, I saw appliance showrooms scrambling to provide clients with temporary appliances or ones off the showroom floor. Clients were buying used appliances to help them get by because theirs were discarded or donated at the demo stage. Substitutes were selected based on availability above function or aesthetics.”
Supply-chain backups also caused designers to change their typical ordering and scheduling processes.
“We’re ordering appliances when permits are pulled on a new construction project,” said Serany. It’s hard on homeowners, since they’re forced to decide before they’re really ready. So far, we’ve been able to make this approach work. For the most part, we’re checking stock and availability as we design — it’s the only way we can stay in business.”
Serany cited Lacanche Ranges, ultra-premium appliances from France. Although they’re not for all clients, the company delivered ahead of schedule — even from overseas, she said. She’s also searching resources like Chairish for vintage furnishings from which to create unique vanities, and even found an antique vessel sink for a special project.
Designer are turning to new brands, including Kimberly Kerl who said: “A supplier told me recently in a hushed voice that they have Fulgor Milano appliances in stock. I’ve never specified Fulgor Milano appliances, but you better believe I checked them out.” Shown: A Fulgor Milano 36-inch Sofia professional dual fuel range in palladio white.
As for cabinetry, designers are having better luck with small local cabinet makers. The prices for some fully custom orders are coming in at a lower cost than big brands, which are suffering because their product is stuck in cargo containers at ports.
“Cabinetry has been one of our biggest challenges and the timelines have delayed many projects,” Serany noted. “We’ve started using local custom shops, but they’re overloaded, too. Still, they are faster than the [big] manufacturers.”
Today, Kerl said, all parties — designer, contractor, supplier and homeowner — go into a project knowing the severity of supply-chain disruptions.
“In some cases, actual demo is being delayed until long-lead items are ordered and delivered,” she said. “This can include appliances, cabinets, tile and plumbing fixtures. But the game keeps changing. For a while, anything with glass was suddenly unavailable.”
Often, solutions lie in discovering new brands.
“A supplier told me recently in a hushed voice that they have Fulgor Milano appliances in stock,” Kerl said. “I’ve never specified Fulgor Milano appliances, but you better believe I checked them out. So, yes, we are using brands we never considered in the past — and I think in a way, it’s refreshing. I like discovering the smaller brands, the local artisans and the start-ups. I rely heavily on local dealers to help me find a good fit for my projects and they are doing the best they can to help. As a designer, I’m required to be creative. This disruption has just required me to apply that creativity in new ways.”
This article has been updated and was originally published on December 7, 2021.
