1. Production Decisions Chapter 6 Mr. Higgins

2. Objectives Identify the need for a plan of procedure Identify the need for a plan of procedure List the steps in making production decisions List the steps in making production decisions Describe alternative tools for completing cabinet-making process Describe alternative tools for completing cabinet-making process –Preparing to build cabinetry involves research and planning. –This Chapter deals with the HOW TO DO IT and WHY TO DO IT THIS WAY

3. Production Decisions Production Decisions – Production Decisions – –Guide you in the HOW TO DO IT and WHY TO DO IT THIS WAY –They relate very closely to design decision –Sometimes you make your own design decisions, or use someone else's –The drawling specify shapes, dimensions, and joinery for the product –Decisions include how to do the following Cutting Cutting Surfacing Surfacing Forming Forming Assembling Assembling Finishing Finishing

4. Planning your Work Planning – essential so you do not waste time and materials. Planning – essential so you do not waste time and materials. Each steps builds on previous task and goes to the next. Each steps builds on previous task and goes to the next. –Example Squaring a board. –Must have a written Plan of Procedure –Fig 6-2 Sketch – Specify size – Production Decisions – Perform Operations – Control Quality – Evaluate Former Products Sketch – Specify size – Production Decisions – Perform Operations – Control Quality – Evaluate Former Products

5. Plan of Procedure Plan and Procedure – the What to do Steps Plan and Procedure – the What to do Steps –Identify the appropriate tools –Obtain materials and supplies –Lay out and rough cut standard stock –Square work pieces and components accurately to size –Prepare joints –Create holes and other openings –Shape components –Assemble components –Apply finish –Install Hardware Stock – Materials in unprocessed form Stock – Materials in unprocessed form Workpices – rough cut stock being sized Workpices – rough cut stock being sized Component – one or more pieces being processed into a bill of materials Component – one or more pieces being processed into a bill of materials

6. Sample Plan of Procedure save a great deal of uninteresting labor, secure the following pieces of stock, surfaced on four sides and cut to length: save a great deal of uninteresting labor, secure the following pieces of stock, surfaced on four sides and cut to length: 4 legs, 1-1/2 by 1-1/2 by 36 in., S-4-S. 4 legs, 1-1/2 by 1-1/2 by 36 in., S-4-S. 4 rails, 7/8 by 4 by 10 in., S-4-S. 4 rails, 7/8 by 4 by 10 in., S-4-S. 2 rails, 7/8 by 3 by 10 in., S-4-S. 2 rails, 7/8 by 3 by 10 in., S-4-S. 2 panels, 3/8 by 9-3/8 by 9-1/2 in., S-4-S. 2 panels, 3/8 by 9-3/8 by 9-1/2 in., S-4-S. 1 panel, 3/8 by 6-1/2 by 9-1/2 in., S-4-S. 1 panel, 3/8 by 6-1/2 by 9-1/2 in., S-4-S. 2 shelves, 7/8 by 12 by 19 in., S-4-S. 2 shelves, 7/8 by 12 by 19 in., S-4-S. 1 top, 7/8 by 16 by 20 in., S-4-S. 1 top, 7/8 by 16 by 20 in., S-4-S. 2 stiles for door, 7/8 by 2 by 12 in., S-4-S. 2 stiles for door, 7/8 by 2 by 12 in., S-4-S. 2 rails for door, 7/8 by 3 by 10 in., S-4-S. 2 rails for door, 7/8 by 3 by 10 in., S-4-S. 1 back, 7/8 by 12 by 13 in., S-4-S. 1 back, 7/8 by 12 by 13 in., S-4-S. 8 slats, 3/8 by 1 by 8 in., S-4-S. 8 slats, 3/8 by 1 by 8 in., S-4-S. Begin the work on the rails for the sides of the stand. Have them all squared up to exactly the same length and to the correct width and thickness. Mark the tenons on the ends of each and cut them with a saw and chisel. Begin the work on the rails for the sides of the stand. Have them all squared up to exactly the same length and to the correct width and thickness. Mark the tenons on the ends of each and cut them with a saw and chisel. When this is finished, try the legs to see that they are all the same length and that their surfaces are square with each other. Next mark the mortises in the legs for the tenons of the rails. To make the mortises, first bore to depth with a bit 1/8 in, smaller than the width of the mortise and cut to the line with a chisel. When this is finished, try the legs to see that they are all the same length and that their surfaces are square with each other. Next mark the mortises in the legs for the tenons of the rails. To make the mortises, first bore to depth with a bit 1/8 in, smaller than the width of the mortise and cut to the line with a chisel.

8. Identifying Tools More tools in this shop then most. More tools in this shop then most. Must know how to use them and the safety associated with each and every machine. Must know how to use them and the safety associated with each and every machine.

9. Identify Proper Tooling Correct saw blades Correct saw blades –Crosscut –Rip –Combination Correct bits Correct bits –Hundreds of different bits Jig Jig –Holds the workpiece and guides the tool Fixture Fixture –Holds the workpiece while the operator guides the tool

10. Lay out and rough cutting stock Stock – machine surfaced, measured, laid out, and rough cut larger then the worpiece dimensions shown on the working drawling Stock – machine surfaced, measured, laid out, and rough cut larger then the worpiece dimensions shown on the working drawling –You need the extra wood to square the stock Plane the stock to the surface you are desiring Plane the stock to the surface you are desiring Lay out materials being aware or grain direction and wood defects Lay out materials being aware or grain direction and wood defects –Cabinet sides have vertical grain –Work around visual defects of Knots, cracks, After laying out material make cuts from After laying out material make cuts from 1/32 to 1/16 oversize. You can cut it to desired length on the second cut. desired length on the second cut.

11. Squaring Workpices to Size Surface one face on the Planer Surface one face on the Planer Smooth one edge with the jointer Smooth one edge with the jointer Surface the second Face using the planer Surface the second Face using the planer Rip the lumber to width on a table saw Rip the lumber to width on a table saw Square one end on the radial arm saw Square one end on the radial arm saw Crosscut the Work piece to length Crosscut the Work piece to length –Check machines setups regularly for square-ness and accuracy

12. Preparing Joints Joinery is an important part of cabinetmaking Joinery is an important part of cabinetmaking More then 30 types of joints More then 30 types of joints On some joints you have to follow certain steps to make them work. On some joints you have to follow certain steps to make them work. –Make the mortise first

13. Creating Holes and other Opening Drilled after the stock is squared Drilled after the stock is squared Usually before cutting curves because you need square edges to find the location Usually before cutting curves because you need square edges to find the location You can make holes with many different tools You can make holes with many different tools –Router –Portable power drill –Drill press –Saber Saw

14. Shaping Components Shaping – means creating a Shaping – means creating a curved face, edge, or end on a workpiece. Shaping before joints could Shaping before joints could result in poor joints Edge shaping is done with Edge shaping is done with a shaper or router Carving is a special means of shaping. Carving is a special means of shaping.

15. Smoothing Components Smoothing a surface often is the most time consuming part of the cabinetmaking process. Smoothing a surface often is the most time consuming part of the cabinetmaking process. Once each work piece is cut and shaped Once each work piece is cut and shaped Hand planes, Hand Scrappers and jointers Hand planes, Hand Scrappers and jointers Abrasive, sanding – many different types Abrasive, sanding – many different types –Machine Sanders, Hand sanders –Start with a 80-100 grid sand paper –Then use 150 grit sand paper –Smooth with a 150-220 grit paper

16. Assembling Components Assembly – usually occurs after all components have been cut to size and smoothed Assembly – usually occurs after all components have been cut to size and smoothed Assemble with Mechanical fasteners, hardware, or adhesives Assemble with Mechanical fasteners, hardware, or adhesives –Fasteners, screws nails and stables… RTA –Adhesives – glues, cements, Prevent the clamps from marking Prevent the clamps from marking the wood with blocks and pads

17. Applying Finish Build up finishes form a film on the surface Build up finishes form a film on the surface –Film resists scratches Penetrating Finishes are absorbed into the surface Penetrating Finishes are absorbed into the surface –Oil-Resin, linseed oil, and tung oil Application Procedure Application Procedure –Remove any glue with scrapper. Dried glue does not accept glue –Raise dents by using a wet rag and warm iron over it –Make repairs with wood putty, filler –Remove dust with a fine bristle brush or vacuum cleaner or dry rag –Brush or wipe the finish on the wood. Wiping stain is done with a lint less cloth pad. Wiping stain is done with a lint less cloth pad.

18. Heath considerations Finish must have a dust collection system, air ventilation system and open area Finish must have a dust collection system, air ventilation system and open area Place rags in a Approved metal container Place rags in a Approved metal container Install hardware when everything is done Install hardware when everything is done