August 22 - 25, 2018

Georgia World Congress Center | Atlanta, GA| USA

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A Fine Finishing Fable

by Editor 18. June 2018 15:59

By: Jim Larin, Fuji Spray

In the suburbs of Madison, WI lies a high end fine furniture production shop run by a 3rd generation woodworker named Tom. Tom learned everything he knows from his father, who was taught by his grandfather. Over the past 30 years, Tom was able to build his father’s two man shop into a ten-person operation servicing Madison and the greater Milwaukee area. They are well known for their ability to make something out of nothing.

              One of Tom’s greatest resources outside of his company was Bill, a wise, 40 year old veteran of the local lumber yard, and Tom’s fathers first contact when building his shop. Tom and his father always seemed to joke at family reunions, “Bill’s invite must have gotten lost in the mail again”.  Despite the family’s admiration of Bill and his decades of wisdom, Tom would soon have a new-found appreciation for their family friend.

              It was the start of the busy season for Tom when he stopped by the lumber yard to speak with Bill about getting some slabs for an upcoming project, a high-end board room table for the top law firm in Milwaukee. As they spoke, Tom went over his workflow and how he planned to build & finish the table. After taking in the impressively elaborate plan of attack, Bill asked suspiciously “The plan sounds great, but what happens if something goes wrong?”. Without fully processing Bill’s concern, Tom confidently responded “Bill, you know me, and you know my father – our process is so calculated and carefully thought of, nothing can go wrong”. Together they both chuckled while reminiscing about Tom Sr. After the lightheartedness subsided, Bill couldn’t help but say, “I don’t want to be the one to say I told you so but remember what your Dad would say – “when it rains it pours”. Tom nodded, thanked Bill for his input, loaded the remaining slabs into his truck, and started the thirty-five minute drive back to his shop.

              Over the next three weeks Tom worked in his shop on perfecting every angle and profile of the table to meet the specifications of the designer. Tom was so confident in his ability to meet his deadline that he included his new apprentice, Mark, during the build to show him the ropes of what it takes to build for high end clients with premium materials. As week four approached, Tom began preparing for the delivery of the finished piece. The law firm was on the 37th floor of a tall corporate building so Tom knew he had to plan ahead to make sure everything ran smoothly on delivery day. First, he arranged for a large rental truck as the table was far too large for Tom to transport in his truck. Since this was a corporate office, Tom was unable to secure a freight elevator during working hours and was told he must deliver on the weekend. For this reason, Tom had to pay overtime for two of his employees to come with him during transportation and installation.

Despite all the preparation, delivery days were always stressful. This particular delivery would prove to be the biggest test Tom would encounter since taking control over the shop thirty years ago. To start things off, heavy traffic caused Tom to miss the drop off time. Because of this, the team had to wait for security to get off break to gain access to the building. Then came the install. While moving the table through the tight boardroom doorway they scuffed one whole side of the table’s live edge and damaged two of the legs. Despite this, Tom was confident that they could buff out the scuffs. The table leg damage was only a minor aesthetic issue, would not affect the tables structural integrity, and was hard to see unless you really looked for it. That was before Mark, carefully removing the packaging straps, lost hold of his end of the strap and let the metal claw gouge the centermost part of the table. Tom was devasted, but before he could react, one of the firm’s partners walked in and said jokingly “you had better fix that or else we’ll sue”. Tom was too upset to find the humor in the comment and immediately began moving the table back to the elevator and down to the truck. During a moment of perceived levity, Mark joked “I guess Bill was right again, eh?”.

Tom delivered the rental vehicle without gas and had to spend the rest of his weekend in the shop reworking the problem to prepare for a second delivery. Due to his frustration and anger, he felt it was necessary to let Mark go. Next, the employee time cards and the rental invoice from the weekend came in – already Tom knew he would be losing a lot of money on this job. Luckily, the firm was understanding and reserved a freight elevator during working hours. Tom was grateful until he saw the $350.00 parking ticket on his rental vehicle for parking in a fire escape. At the end of the day, the table was delivered and the client was happy, but Tom was not.

A few days passed, and Tom learned how important it is to repair and refinish on site. He decided he would purchase a portable spray finishing system. His local retailer, the lumber yard, had just what he was looking for. So, Tom went on the thirty-five minute drive to the lumber yard to pick up his new investment. As Tom arrived he noticed that Bill’s son, Jeff, was holding down the fort on that day – Tom was relieved he didn’t have to speak with Bill, tail between his legs. Tom spoke with Jeff sharing the nightmare he encountered. After finishing his lumber yard therapy session, Tom shook Jeff’s hand and thanked him for his time. Before closing the door of his truck he said to Jeff “so what are the odds this stays between you and me?” Jeff smiled and waved as Tom pulled out of the yard.

After the final payment came in from the law firm, Tom decided he deserved a long weekend and took Monday off to spend time with his children. Around noon Tom heard a knock at the door and saw that a delivery woman was waiting out front with a long and slender parcel. Tom wasn’t expecting anything and was excited to see what was inside. Upon opening the package, to his dismay, he found a large umbrella and a small hand-written note from Bill. It read:

“Hi Tom,

I spoke with Jeff. I hope this umbrella serves you well.

Sincerely Bill.

PS: I told you so…”  

 

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Lean Manufacturing is More Than Just Tools

by Editor 18. June 2018 15:57

By: Larry O'Keefe, LJ Okeefe Inc.

Too often we hear Lean Manufacturing (or Toyota Production System) referred to by one or more of its many technical tools. Some call it ‘kaizen’, ‘JIT’, 5S and so on, leading one to perhaps believe these tools or elements are the essence of Lean. In fact, nothing could be more incorrect.
 
The Toyota Production System, upon which Lean Manufacturing is based, is a balance of three elements. Those elements are the Philosophy, True North (perfection is the goal) and the Technical Tools. Obviously, when a company begins its lean journey applying technical tools is one part of the response to the problems being attacked. Unfortunately, the efforts that simply apply tools without also embracing the other elements will fall far short of achieving sustained results or perhaps never achieve any real improvement.
 
Some companies even go so far as to decide to avoid implementing key parts of the system and then will explain that Lean Manufacturing does not work, or does not work for their business reality.
 
For example, some efforts may attempt to implement the concepts of JIT, such as takt time, continuous flow or pull systems while deliberately avoiding the foundation tools like production leveling. Implementation of these tools is not sequential; there is not a defined step by step process of when to implement each piece. Many will be implemented simultaneously, where simply leveling by volume within some time frame is used in order to balance a line to takt time and create standardized work. Too often I have clients tell me that they cannot level production because customer demand varies daily, even though lead time for the product is weeks or even months!
 
One role of top management in leading a lean transformation is to challenge current paradigms and conventional thinking. As my first Sensei explained to me when our plant was struggling with the concepts, “TPS is a revolution against current practices”.
 
Learn more about this topic during Larry's session, Leading Change, Top Management's Role in a Lean Manufacturing Transformation at the IWF 2018 Education Conference.
 

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Visual Format

by Editor 14. June 2018 11:32

By: Bobbo Buckley, Software Developer: Cabinotch Innovative Solutions

Effective Estimating that leads to Bullet Proof Proposals - BMG10

When it comes to effective estimating, the words every contractor and sub-contractor dreads to hear is "can you give me a ballpark estimate". If you guess low, it's the only number they remember. If you guess high, you may never see or hear from them again.
 
Ballpark
"baseball stadium," 1899, from (baseball + park (n.). Figurative sense of "acceptable range of approximation" first recorded 1960, originally referring to area within which a spacecraft was expected to return to earth; the reference is to broad but reasonably predictable dimensions.
 
My response to this inquiry always started with the statement, the average cost of a ballpark is $750 million, which never failed to produce a laugh, and to open the door to a more serious conversation, mission accomplished.
 
Don't get me wrong here, I'm not opposed to Ballpark estimates, they are great pre-qualifiers (they get rid of the tire kickers), but I'm not a FAN (see what I did there? Ballpark - Fan) of a single number. I always provided a RANGE like this:
 
1. The least expensive project we produced last year ran $400.00 per cabinet, and you have approximately 20 cabinets, so the best case scenario is your project will cost $8,000.00.
 
2. The average cost for all our projects, taking everything from the least to the most expensive projects into consideration was $750.00 per cabinet, you have approximately 20 cabinets, so your project will probably fall somewhere close to $15,000.00.
 
3. The average cost per cabinet for the most expensive project we produced this past year was $1,500.00 per cabinet, so if your selections align with that project, your project could cost as much as $30,000.00.
 
This broad range of prices is based on the selections customers made over the previous year (doors, drawer fronts, drawer box type, functional hardware type, wood specie, finish, accessories, etc.), so it's a good number. This is just a small example of the kinds of things we will cover in this session. Sign up now.
 
 
 

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How to travel lighter, smarter, farther in business

by Editor 14. June 2018 11:20

By: Monique MacKinnon, Energetic Evolution

Have you noticed progressively more businesspeople are packing lighter and flying only with a carry-on? Doing so saves time, money and effort.

Lighter is also better in business. The successful woodworking professional’s carry-on is the Eagle Soaring ToolTM. Once you use it, your workload, and possibly even yourself (smile) will lighten up. With clearer thinking, you will fulfill your responsibilities with more ease and enjoyment.

What areas of your work do you enjoy doing? Which ones weigh heavily on you? Reflect on and note them now. In the How to be Visionary, Create BOLD Results in Uncertainty session, you will learn how to soar, regardless of what you are doing or facing.

My promise to you: I won’t charge you for the Eagle Soaring ToolTM carry on that you will walk with!

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Background Matters

by Editor 14. June 2018 11:17

By: Ralph Bagnall, Woodworking Consultant, Author and TV Host: ConsultingWoodworker.com

We have all seen photos or video where something unusual or unexpected shows up in the background. These “photobombs” can be funny when they happen to other people, but can be distracting or even disruptive to your business marketing video. It is important that even as you insure that your video is properly lit and in focus, there are no distractions in the back ground that will take attention away from your message.
 
Your background should be well lit without being brighter than the subject. It should be neat and clean unless your video is about cleaning or organizing. When I began shooting video, I had a neutral blue sheet that I could hang behind the shot to hide the mess that usually existed in my shop. But with experience I learned that this looks contrived and is pretty dull. So I created a “studio wall” within my shop that became the background for my shooting. I staged the wall with tools to show the viewer that this was a wood shop, but not so many that they cluttered the focus of the video.
 
Note the two photos with this article. Both are part of the same bending project video. One uses the neutral backdrop, the other the staged wall. The neatly staged background does not distract from the photo, but in fact helps set the stage for the viewer, putting them subconsciously in mind of a woodworking shop.
 

      


Your facility may not all be camera ready, but removing distractions from the shot, and choosing a camera angle that hides unsightly cables or walls that cannot be removed will help your audience pay attention to your message. And a little judicious staging can help. I have used a large rolling tool box to hide things background items that are ugly and cannot be moved or shot around. Giving as much thought to what is behind your shot as what you are actually shooting, your overall video will be greatly enhanced.

Learn more about this topic during Ralph's session, "Video that Works" during the IWF 2018 Education Conference.

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Mixology: How to Create Unique Home Organization Spaces

by Editor 13. June 2018 13:22

By: Michele Weitzel, Northern Contours

Personalized design is one of the most in-demand trends today. With unprecedented access to social media and images from around the world, the imaginations of home owners are teeming with design inspiration for their spaces. With so much inspiration out there, the key to personalization is in the subtleties of melding or your own style with those inspirations, or combining elements from multiple sources of inspiration. This process of creating something uniquely you is the heart of a concept from Northern Contours called Mixology.  

Mixology with Northern Contours is a way to use our vast product line to your creative advantage, utilizing one source to capture the desires of home owners for something truly unique. From High Gloss Acrylic and textured 5-piece doors, to natural wood veneer and a vast library of 3D Laminates, you can create personalized designs by combining our different materials, finishes, and components.

Create a dreamy closet with a chic twist by combining white SuperMatte shakers with Gold Aluminum frames. Split glossy and matte color between functional floating shelves and lower cabinets in a laundry room for energizing contrast. Turn mudroom expectations inside out by pairing weathered woodgrain casework with our dust-repellant, anti-fingerprint FENIX NTM matte fronts in a livable, neutral tone. This is just a taste of the design possibilities with Mixology.

Join Michele Weitzel for her presentation “What’s Trending in Colors and Textures” at the IWF 2018 Closets Symposium to learn more about Mixology with Northern Contours.

About Northern Contours

Northern Contours is a cabinet door and components manufacturer with over 25 years of industry experience. We serve a variety of customers on a custom and volume basis in Kitchen & Bath, Home Organization, Commercial Furniture, and Refacing markets. Manufacturing expertise in membrane pressing, miter folding, laminating & edgebanding, machining & routing, and 5-piece door assembly. We operate six facilities throughout the US and Canada for full coverage of North America.

 

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From Laminate to Concrete: What you need to know

by Editor 13. June 2018 10:40

By Jeff Girard, The Concrete Countertop Institute

Many countertop fabricators, especially those who specialize in residential remodeling, are recognizing the consumer demand for more custom products such as concrete. As a countertop fabricator considers adding custom concrete countertops to his or her offerings, there are a number of practical considerations such as startup costs, learning curve, profit margin and the logistics of incorporating concrete into shop space and production process flow.
 
Startup Costs
 
Adding concrete countertops to your offerings incurs low startup costs. There is very little equipment to buy. The largest equipment purchase is generally a concrete mixer, at less than $2000. All of your existing woodworking equipment can be used for making the molds.
 
Learning Curve
 
Although templating and installation are almost exactly the same for concrete as for other countertops, concrete is cast, not cut. For shop employees who are accustomed to cutting countertops, creating forms and molds can be challenging because it is a different way of thinking - upside down and inside out.
 
Another learning curve involves working with the concrete mix, whether you use a from-scratch or bagged mix. It is important to understand technical aspects of concrete such as water/cement ratio, water reducers and admixtures, because the behavior of concrete depends on many factors such as humidity and temperature.
 
Profit Margin
 
Custom concrete countertops command a high price, generally about $80 to $120 per square foot or higher, depending on your market area. Due to the low startup costs and low material costs, the profit margins can be very good.
 
However, you need to be acutely aware of your labor costs. Custom concrete countertop generally require a high amount of hand labor. As with other materials, the biggest barrier to high profit margins in concrete countertop manufacturing is mistakes and re-dos. Avoiding re-dos in concrete countertops requires all of the normal quality control procedures you have in place, plus a good understanding of concrete as explained above.
 
Shop Layout
 
You will need to allocate space in your shop for casting tables to accommodate the concrete slabs during forming, casting and curing. You will also need space for the mixer and mix ingredients.
 
Process Flow
 
Templating and installation of concrete are almost identical to procedures for stone countertops. The time in-between templating and installation is very different, however.
 
As mentioned before, concrete is a high touch process requiring a lot of hand work. It requires forming, mixing, casting and curing time that do not come into play with other countertops.
 
Conclusion
 
By understanding all of these considerations and focusing on employee education, quality control and carefully thought-out procedures, you can profitably add concrete to your business. The benefits go beyond pure profit to building competitive advantage through diversifying and differentiating your business with this beautiful, unique product.

Learn more on this topic during Jeff's session, "Leapfrog from Laminate to High End Concrete" at the IWF 2018 Education Conference.

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ROUGH IT UP - TRENDS IN SURFACING

by Editor 13. June 2018 10:35

By: Jessica McNaughton, CaraGreen

Hard and shiny are out - warm and textured are in.  This is a trend, this is happening now.  The granite and quartz de facto polished finish, while the standard, is phasing out.  Most manufacturers are finding themselves forced into a honed or matte finish, and the stone fabrication market is having to scramble to make sure they are staying on top of new demands.  Difficult to match the surface texture on the edges, most shops usually polish to a high gloss, and as customers are starting to ask for more texture, the industry is having to shift.
What does this mean for manufacturers? 
 
STONE – TYPES

Granite as a category is trending out and being replaced with man-made quartz.  Quartz has a wary eye over its shoulder, looking at the much higher performing sintered stone materials that are catching on in Europe and making their way to the US.  Dekton has been around awhile, unfortunately losing its cache by being offered alongside laminate at Home Depot, but Lapitec and Neolith are the sintered stones to watch out for, specifically Lapitec with its seven different textures and through-body color.  Out of the gate, Lapitec was playing the texture game and it is available textured in multiple thicknesses for walls, floors and counters both inside and out. Rough like sand, high-gloss, and matte are just a sampling of the possibilities.  Texture, texture, texture.
 
INNOVATORS

PaperStone has been waiting for its time.  That time is now.  Warm to the touch, as durable as stone while less brittle than granite, this material is ready to steal the show.  With an organic color palette that patinas over time to look more natural (think mottled, like leather), PaperStone performs like stone but is naturally textured, so does not need any polishing, sealing or finishing.  It fabricates and installs like wood, but performs like stone.  It costs less, performs better, and its natural finish is trending right now.  Win, win, win.
 
SOLID SURFACE

I have heard repeatedly that solid surface is making a comeback. This is likely true, especially with health being a factor, and the seamless, hygienic properties of solid surface play well to the healthcare and education industries.  The nice thing about solid surface is that you can finish it to whatever you want and some brands do have a warm feel.  The brands that are all trying to look like granite and quartz are floundering a bit right now, trying to figure out how to stop copying each other long enough to innovate.  It will be interesting to see how this market responds to the textured trend.  Whether it will be the manufacturers or the designers (through the millworkers) who innovate.
 
Original content from CaraGreen©.

To learn more about this topic, check out Jessica's presentation during the Countertops & Architectural Surfaces Symposium at IWF 2018.
 

 

 

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Technology and the Human Hand: Are We Losing Touch? - Part 2

by Editor 13. June 2018 10:34

By: Scott Grove, Furniture Designer: ScottGrove.com

When I deliberated the question of using technology in my woodshop, I began by breaking it down to two questions: What is technology, and what is craftsmanship? Technology means using advanced machinery and knowledge often associated with science and math. Craftsmanship means creating by hand, actually touching the material. Sounds easy enough, but where is the line between the two? How advanced can the process be before the piece is no longer handmade?

Since prehistoric times, there has been some type of tool or machine, from chisels made from bone to steel saws powered by water, then electric tools, and so on; each advancement allowing us to work a little more efficiently. However, until recently, we still directly controlled the tool and the material with our hands. For me this is an important distinction. With hands-on control, I have the option to spontaneously react to the material and a tool’s performance, change in midstream, and go with flow. The relationship I have to the material is intrinsically intimate. Machines alone simply can’t do this.

On the other hand, I see many wood “craftsmen,” myself included, using advanced technology to produce furniture with laser-cut veneer and CNC devices turning precise duplicates and mill high-tolerance joinery—and these furniture makers are considered some of our best. Are they the best craftsmen? Or, are we now seeing a divide between true hands-on craftsman and now, designers?

As a hands-on craftsman, I strive for perfection, to make an exact joint, seam, curve, carved pattern, and finish that is absolutely flawless.
Obviously there are more questions than clear answers here. But one thing is for sure: Technology is here to stay and will keep advancing, helping us to become faster and more accurate, work more quickly and more cost effectively. The technological craftsman is a reality and our trade is splintering in two.

The dilemma is: How to use technology without losing touch with our craftsmanship? Or is that just cheating?  Be a part of the conversation during the "Technology and the Human Hand - Are We Losing Touch?" session at the IWF Conference on Wednesday, August 22nd from 4:00 PM - 5:00 PM.

For a 9 minute TedX talk overview of this discussion, please visit https://imaginegrove.com/
Scott Grove, ScottGrove.com ImagineGrove.com
 

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Software Acclimation

by Editor 12. June 2018 15:51

If possible, get acclimated to your software program long before you install the machine. Learn the software, use the software, and then the transition when you get the machine will go much more smoothly.

Chris Dehmer of Dark Horse Woodworks (Atlanta, GA) explains how he actually invested in the software ahead of time, did all of the design work in that, and then had it cut at another shop. Eventually he was ready to purchase his own CNC machine. “The mistake most people make,” Chris elaborated, “is that they buy the router first and then figure out how to use the software.” Buying the software first worked well for him.

Leland Thomasset of Taghkanic Woodworks (Pawling, NY) agrees with Chris’s method. “Many times, it’s not so much a mistake, but people go all in,” Leland explained. “We had CabinetVision for the better part of nine years before we purchased our CNC, so I had a good solid footing under me of how to use the software.”

Leland admitted that although it is getting easier, there’s still a steep learning curve if you take on CNC and software simultaneously. If you own the software and know how to use it when the CNC arrives Leland claimed “literally we were making cabinets the same day they set up the CNC.” It doesn’t matter what brand of software you use, he can’t stress enough that you should have a good grasp of and comfort behind the computer screen before you buy your machine.

Leland also recommends that after you learn the software then you should hire somebody who knows how to use it. At this point, you should have enough knowledge to understand what they’re doing.

If you are interested in learning more about how and why Chris and Leland learned their software first and then they bought their CNC, register to attend Buying that Big Machine during IWF.

 

 

 

 

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