How Coastal Millworks Boosted Profitability While Decreasing Production & Installation Manhours by 14.8%
“INNERGY is not just software; it’s a mindset.
It has taught us to think differently about our business."
About Coastal Millworks
Founded in 1990 by John and Mary Maffett, Coastal Millworks began as a small, family-run shop with a passion for fine craftsmanship. Over the years, the company has grown into a premier provider of ultra-high-end residential architectural millwork, specializing in custom windows, doors, cabinetry, trim, and decorative elements. Headquartered in West Palm Beach, Florida, Coastal Millworks now boasts a team of 47 employees and generates $8.5 million in annual revenue.
The current CEO, Rick Maffett, literally grew up in the business—catching boards from a planer at the age of seven. After earning a finance degree and initially working in the company from 2006 to 2011, Rick returned in 2022 with a renewed vision. His leadership has been pivotal in modernizing the company’s operations, including the implementation of INNERGY’s ERP software to streamline processes and enhance productivity. Under his guidance, Coastal Millworks continues to honor its legacy of craftsmanship while embracing innovation and operational excellence.
The Challenge:
- Disconnected Processes: Estimating, production, and scheduling ran in silos, creating data gaps.
- Manual Inefficiencies: Paper-based workflows slowed production and increased errors.
- No Inventory Visibility: Lack of material tracking led to waste and poor planning.
- Limited Insight: Leadership lacked the real-time data needed for proactive decisions.
The Solution:
INNERGY’s Integrated ERP and Business Education
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- Streamlined Workflow: Transformed estimates into work orders, speeding up production.
- Centralized Data: Replaced spreadsheets with a unified system for better coordination.
- Improved Visibility: Identified bottlenecks and inefficiencies through real-time reporting.
- Ongoing Support: Provided training and resources to sustain growth and improvement.
Key Results:
- Revenue Growth: Increased from $5–6M to $7.0M in 2024, with a target of $8.0M in 2025.
- Greater Efficiency: Boosted throughput from $5.5M (2022) to $7.9M (2024) using 14.8% fewer manhours.
- Record Profitability: Achieved highest margins through smarter pricing and project focus.
- Stronger Team Alignment: Improved collaboration and accountability with INNERGY as the central platform.