Take the Tour Millwork: ripping

Millwork: chopping
Millwork: glueing
Join us for a stroll through our factory
Design Phase  It all begins here, often from a rough sketch.
Computer-aided-design software brings shape and final dimension to Raw Lumber: storing
each component part of a collection piece. A Bill of Materials (BOM) A state-of-the-art computer-
is created that serves to describe in minute detail specifications for all ized chop saw automates cut-
Production Planning Manufacturing begins in Mill- ting parts in the right lengths Panels—drawer fronts, cabinet
materials and parts for every stage of the manufacturing process. work, where the first process is and quantities as dictated by the sides, etc.—are created by glue-
“ripping” (cutting boards into BOM.
Goal: New lines that can be efficiently crafted to meet market demand. desired widths). Here the com-
ing staves edge to edge on the
puter-programmed Opti-rip is
glue wheel. Millwork: planing
Production Planning  Production Product Design fed boards from a unit of lumber.
“packages” are scheduled to maximize fac- Lumber arrives in units of approx-
tory capacity. Units of lumber specific to a imately 1000 board feet. It is kept
dry in our lumber warehouse.
BOM are ordered. Current collection pack-
ages cycle every four to six weeks. Each production package begins
with scheduling and generating
Goal: Optimize factory production capac- the Bill of Materials (BOM).
ity. A planer-sander trims and sands
parts to their final pre-assembly
Millwork  Raw lumber is inspected, cut, No matter the item—dresser,
mirror, table, etc.—the process
thickness.
planed, and sanded to the rough lengths, begins with and back-of-a-nap-
widths and thicknesses mandated by the kin idea, which then is given form
through a design application. Parts: edge profiling
BOM. Ripping and chopping are followed
by the glue wheel (as necessary) and planer. Shipping: labeling
Visual inspection during rip and chop help cull blemishes. Warehouse: final
Goal: Achieve best balance of raw material yield and quality. inspection
Parts Production  Production departments each have a “custom-
er” for whom they produce. Millwork’s is Parts. Virtually all millwork Drawers: special
The “Fletcher” shapes (profiiles)
pieces need to be molded, edge profiled and/or shaped, among other assembly the edges of larger parts such as
processes, to define the collection style. As well, dadoes, dovetails and tops.
For timely and accurate shipping,
pocket holes ready parts for assembly. Sanding removes machine marks. all boxes are labeled with prod-
Goal: Maintain ±0.01-inch tolerance to ensure precise assembly. uct, destination and purchase Parts: large panel
As drawers are installed prior to order information. sawing
Assembly  Assembly is comprised of sub-assembly and final assembly boxing, a final inspection occurs
to assure customer-ready quality.
workflows. One critical sub-assembly is the internal skeletal frame that
provides for precise drawer position and function, as well as overall case Drawers are assembled separate-
strength. Final assembly merges sub-assemblies and all other compo- ly from their respective cases.
Precisely crafted, they are inter-
nents. Caster bases are added under heavier case goods to provide ease of changeable with any other same-
movement. size drawer in a collection.
Goal: Handcraft defect-free assemblies for Finishing. Ready for the home The beam saw cuts large panels
to precise dimensions.
Finishing  After a light sanding, if required, a sealing coat (including Finishing:
a stain, if specified) is applied, followed by a top-coat durable lacquer. lacquer coat
Parts: precision
Sanding between sealer and lacquer assures maximum adhesion and Sub-assembly:
smoothness. internal frame
Goal: Apply even coatings for maximum beauty and protection. Finishing: Assembly: case top
stain/sealer coat
Drawers  A special assembly process, drawers are assembled after the
drawer front has advanced through Finishing.
Goal: Assemble true and precise drawers to assure interchangeability. A durable top-coat lacquer is ap-
plied as the final manufacturing Frequent measurement assures
Warehouse/Shipping  Finished items come to the warehouse for step. The product is dry enough parts are within tolerances. Parts
for handling in about 24 hours; production processes and tech-
final inspection, foam-wrapping, boxing, labeling and storage. Drawers it is completely cured in about
A critical sub-assembly is the in-
nologies are critical to fit, finish
ternal frame. Precision-crafted
are inserted prior to boxing. Boxed items are rolled onto waiting trucks 30 days. Tops are carefully aligned and of hardwood, it is the supporting and strength.
After assembly, items are lightly secured to the case frame with
and trailers for shipping. sanded and then sprayed with a screws and a glue bead, assuring
structure for drawers as well as
all other outside components.
Goals: Protect and manage finished-product inventories; perform error- sealer or sealer-stain to prepare a case that is structurally rigid.
the surface for a final lacquer
free load-outs; and make safe and timely deliveries. coat.

4  Wood Castle Times Wood Castle Times  5