Furniture Design Process

INTER OFFICE PROCEEDURES

  • All orders are emailed to our office: info@aprjoinery.com.au. Once received the orders are printed as 5 x copies for disbursement: 1 x for the Main Office file, 1 x for David the Operations Manager (Factory File), 1 x for Robert the director, 1 x for the Veneer Layer and 1 x for the Cutting Section.
  • The Main office staff ensure that the order is complete & contains constant information throughout, that Drawings, completed Specification Sheets & a copy of the original quote are also present (these components help expedite the order & are vital to ensuring that the client receives exactly what they ordered, leaving nothing open to interpretation).
  • The order in then entered into our computer system & work schedule, which is on a network (for all departments to access for verification). A delivery docket, configuration stickers & quality check labels are all printed up & attached to the Factory File copy (ready for use when the order is dispatched).
  • An order confirmation is then sent through to the client.
  • David, the Operations Manager then makes up a cutting list for the Veneer Layer & the Cutting Section with exact sizes, edge detail and type of veneer to be used on both the top and bottom of the specified table tops. These lists are then attached to the production sheets along with all to the specification sheets and the cad drawings (which show: sizing, edge detail, cable management, pilot holes, etc) enabling the production crew to know exactly what is needed for the job.
  • David then produces a program on Cut Rite for the Beam Saw cutting section and the Router CNC profiling section which is downloaded straight into the machines so as the operators can start machining immediately.

    WRITING MATERIAL LISTS

    PROGRAMMING
  • David then calculates the material quantities needed and places any order with the suppliers: namely for board, veneer, solid timber, as well as adhesives and sundry items to maintain our standard running stock levels (all stocks are checked before orders are placed, as we hold a base stock level of most commonly used goods as standard. These stock levels are tallied and a sheet is produced each month of running stock levels). If additional specialized stock items are required, a request is given to the orders department who places an order with the applicable job number and purchase order number so that all paperwork can be traced the job and the client’s order

    VENEER ROOM

    VENEER LEAF

    RAW BOARD STOCK
  • The cutting lists are dispersed to the relative sections: cutting (beam saw), profiling (CNC router) and the veneer department (veneer layer). These departments are all briefed with what needs to be done and what may need special attention also.

FACTORY PROCEEDURES

  • The board required for the specific job is lifted onto the Beam Saw from stock via a vacuum lift by an operator, which is placed onto the machine and pushed into position. The PO# for the job is called up on the beam saw’s computer program & the cutting for the board is initiated.

    VACUUM LIFT

    BEAM SAW

    CONTROL PANEL
  • Once cut, the board is then placed onto a trolley via the vacuum lift and wheeled to the router for profiling. The board is placed onto the machine by the operator and sucked down into position. The PO# for the job is called up on the CNC’s computer program & the router cutting for the board is initiated.

    CNC ROUTER

    EDGE BEING ROUTERED

    CURVED SOLID EDGING
  • While this is happening the edging, normally solid timber, is cut up and planned for the job to the specified thickness and length required.
  • The board, after CNC profiling, will be then taken to a bench for edging. This is done via edge clamps for the profiles are curved. The glue left on the edge material to dry.

    EDGE CLAMPING

    GUILOTINING VENEER

    STITCHED VENEER

    VENEER LAYONS
  • In the meantime, the veneer is stitched for the top and bottom surfaces. The bottom being a balancing veneer of same thickness and similar structure to the top veneer and the top veneer is calculated for even leaf width and length for the custom job required (so as to provide a uniform, pleasing to the eye pattern). It is taken to the guillotine and cut to the desired length and width and then taken to the stitcher for assembly.
  • Once glue has dried, the board is de-clamped and edge planned for preparation for the calibrating sanding. This is done in preparation for adhering the prepared veneer layons to the board surfaces, to ensure a smooth base surface.

    CROSS BAND SANDER

    CONTROL PANEL
  • The board is taken to the calibrating sander which is set to the required thickness via the numeric touch screen control. Both the vacuum extraction for the sand particles & the sander itself is turned on. The board is placed on the conveyor table and pushed into the machine for sanding. The board/panel is taken from the out feed end side of the machine and the process is repeated once again for the top surface. The board is checked for any raised excess of the edging may be left above the surface and if needed it is passed one more time for final finishing before it is taken to the press.

    APPLYING GLUE

    PRESSING

    TRIMMING EXCESS
  • Whilst the board and veneer are taken to the press, the glue is mixed to the correct proportions and left for a minute so as it can activate. The board and veneer are placed into position and the adhesive is rolled onto the board, between 80 to 100 microns thick. The veneer is placed onto the board and hand applied onto the glue film (to ensure it is straight & symmetrical) and then placed into the press. The press is raised to sandwich the panel and set at 100kg/square centimeter pressure and left for about between 2 to 4 minutes (dependent upon the current environmental temperature) via a set timer. After this time, the board is then taken out and any excess veneer is trimmed off the edges.
  • • The panel is then taken to the router/profiler for edge profiling and the profile edge is put on it with a diamonded tipped profile cutter. The PO# is called up again on the machine’s computer to obtain the information regarding which profile has been specified.

    CNC DIAMOND TIPPED CUTTERS

    ROUTERED EDGE

    CABLE BOX CUT OUT
  • Once the machine has finished cutting the profile, the panel is then taken off the machine and taken to the bench for edge sanding. The edge is sanded with 180 grit and then again with a final fine sanding of 240 grit. When this is complete the panel/top is taken to the drum sander for surface sanding. The machine is set to the desired thickness and the sanding belts are set. The first of the belts in the machine is set with a 120 grit belt (this initial sanding is to take any coarse veneer from the surface) and this is followed down in grit to finishing 180 grit belt so that the surface is smooth for polishing. Once this is complete, the top is inspected for any minor scratches and minor dents (this is done using a quick drying liquid that highlights any imperfections). If there is something visible then the item is steamed or hand sanded then passed through the sander again for final finishing.
  • The table top is then taken to the polishing section where it is sanded with a disc sander with 240 grit sandpaper for final finishing before a sealer coat is applied.
  • Once the head polisher is satisfied that the product is ready for sealing, the sealer is mixed in the right proportion with the correct thinners for the required drying time (once again, this will vary dependent upon what the current environmental – temperature & humidity). The sealer is applied inside a temperature controlled environment (booth) which is between regulated 21 and 25 degrees for the sealer to be applied. The sealer is applied at a level of 80 to 100 microns. Both the top and bottom are sealed with the bottom receiving up to 120 microns of paint for balancing. With the sealer dry, the table tops are prepare with 240, 320 & 400 grit sand paper and edges sanded with a profile pad sander by hand. The table top receives a finally inspection of readiness for the finish coats and inserted in the spray booth. The same process of mixing and booth temperature control that was used for the sealer is again used to apply the finish coat.

    TABLE TOPS BEING SPRAYED

    CHECKED OFF BETWEEN COATS

  • The finish coat is applied in a cross hatch fashion with a total of 4 passes minimum (dependent upon species of veneer & if it is an open grain or closed grain finish). The top is inspected for any tiny impurities that may have applied themselves to the surface then a final cross hatch pass is applied and the top before it is put into a drying rack.
  • The table top is left for the required 8 to 10 hours drying time and then taken out again for inspection. By this time the surface has a total of approximately 120 to 150 grams of paint per square meter for an open grain finish. Additional coats are applied if it is a closed grain finish.
  • The top is brought up to the sander and the bottom is sanded with a 180g Scotch Brite belt to smooth the bottom.
  • The top is moved for final inspection to the dispatch area where it is inspected in natural light. We then applied with a description sticker showing the PO# as well as the finish type and dimensions and a quality check sticker with the date of inspection and the who the inspector was to the underside of the table

    QUALITY CHECKED BEFORE DISPATCH

    EDGE PROTECTION TO SUIT VARIOUS PROFILES

  • The table is then wrapped for transport. If going somewhere local or is scheduled for dispatch to a Sydney warehouse, it will be wrapped in Polyfoam and paper backed bubble wrap. If it is interstate dispatch, an edge foam is applied and an inter layer of cardboard is also on the top for extra added protection.
  • The delivery docket/dispatch sheets are taken out of the orders folder with one copy left in the folder for reference of what the whole order contained.
  • Once the client or warehouse has received goods & signed off the deliver docket, 1 x copy is left for the recipient & 2 x copies are then returned to our office for invoicing & job finalization purposes.
WE ARE LOCATED AT
52 Allingham Street, Condell Park
NSW, 2200, Australia
p (61) 2 9791 0717