Supplier Woodworking Magazine Aug/Sep 2019 by Elite Publishing Co Pty Ltd

AUG/SEP 2019

W O O D W O R K I N G DESIGN + MATERIALS + TECHNOLOGY

UNIQUE CLIP ‘N’ CLEAN SYSTEM

Richard Cripps Kitchens by Design

Celia Visser Celia Visser Design

Toni Roberts Kitchen Architecture

Don’t just take our word for it - listen to testimonials from industry professionals

Contents

Issue #203 | Volume 35 No 3

News

Publisher’s Note

Welcome to issue #203 of Supplier Magazine.

Biesse Melbourne opening

Product Update

In this issue we include the highlights from some of the major suppliers at both Interzum and Ligna exhibitions that were held earlier this year.

16 Overseas News

We cover the Biesse Melbourne opening which was a great success.

New Ideas at Interzum

In our manufacturing section, we look at ways to keep up with trends through the use of tooling and a look at some of the new materials hitting the market.

Ligna report card

Manufacturing 42

All of this as well as our usual round up of all the news and product updates.

Will you be able to keep up with the trends in 2020?

Don’t’ forget to visit Supplier Magazine on Instagram, LinkedIn and Facebook.

Front Cover Weinig Powermat 3000.

Vicky Cammiade Publisher

Find Supplier Magazine on: @suppliermagazine

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News

Committed to their Customers

n their 50th year, Biesse Group have significantly advanced their presence ‘on the ground’, first with a major new campus and showroom at their Australian head office in Sydney; but more recently with new showrooms in Melbourne and Auckland. These investments come on the heels of new facilities in Dubai; Pesaro; Barcelona; Istanbul and later this year, Ulm in Southern Germany. Biesse Melbourne opened their doors to a very good turnout on a chilly June morning. Victorian sales manager Nick Trolio said, “I’m very happy with the attendance, some were here even before we opened up. Our main showroom is of course Sydney, but it’s important that we acknowledge the loyalty of our customers with a showroom close to their business. In Melbourne we have equipment that satisfies 80% of our local customer’s needs.” On display at the opening were edge-banders, CNC Nesting machines and vertical CNC boring machines.

The Melbourne showroom is entirely dedicated to the customer’s experience with Biesse Group. All parts and storage are held off-site. The campus is available for customer consultation, demonstrations, seminars and training courses. Biesse Group Australian CEO Michael Bullock said, “Victoria is a key market area for us. There’s a lot of building activity in Melbourne, both residential and commercial and some retail as well. Victoria’s economy is strong and Biesse are here to help our customers take advantage of that.” Nick said, “Very few manufacturer’s buy a machine off-the-shelf. Many will simply replace an old machine with a new one of the same type. It’s up to us to consult with industry and advise them of the technologies that can help their business. We can do this in our new showroom, but also by visiting them and offering advice as to what they can do to improve their bottom line.” As a technology supplier, Biesse Group is looking for sales; offering products that suit

Supplier Aug/Sep 2019

the manufacturer’s needs. However, Michael said, “We also want to invest ourselves into the industry and to grow with our customers. We think about the lifecycle of our equipment and if we get that right with service and after-sales support, our customer relationship grows. To do the job right in Victoria we have four sales executives, but ten technicians to support our customer’s businesses and keep their machines producing.” Biesse Group have fifty machines in Australia at any one time. In addition, between three and four million dollars of spare parts are located in the Sydney warehouse and available with a modern picking system for overnight delivery. Michael said, “With the machine serial number it will be possible to order parts online with our new (industry 4.0) tool, Sophia Parts.” Sophia Parts is a new online portal for ordering Biesse and Intermac spare parts. With Sophia Parts an impressive 93% of machine downtime orders are fulfilled within 24 hours and fits Biesse Group’s focus on service and support.❚

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News

SafeCode manufacturing – From design to manufacture

afeCode has been a leader in the Australian market delivering software solutions to the finance and leasing industry for over 10 years. With their acquisition of IdacsPLUS and the launch of Palette CAD Australasia in 2017, the business has grown to offer one of the largest ranges of CAD CAM solutions in the Australian market. Their group of companies and suite of products includes PaletteCAD, ASPAN, ToolCAM, COBUS NCAD, HSBCAD, TopSolid and ICB. On July 1st of this year, SafeCode incorporated the IdacsPLUS business into its operation and has now re-launched itself onto a stronger footing by adding in the software development team of SafeCode. The SafeCode Manufacturing business now boasts a full team working on developing advancements to its CAD and CAM solutions supporting their core products of Palette CAD, ASPAN, ToolCAM, COBUS NCAD and ICB. SafeCode is always looking to introduce new products and advancements to the Australian market, and working closely with their partners, they can now officially welcome ToolCAM to their suite of CAM products. ToolCAM is a simple solution for any customer who wants to do an output for any given CNC.

With over 500+ clients across Australia and New Zealand they saw a greater need for closer integration and automation within all the moving parts of a business. With the skills of their software team they are now able to offer integration with third party software, accounting packages, web development services and mobile app development for the many businesses in our industry. With the growth and expansion of the SafeCode business they introduced Jesvinder Singh as the new Operations Manager for their SafeCode Manufacturing and TopSolid Australia businesses. Jesvinder has been with the LeasePLUS Group for three years, joining in early 2017 and seeing success and promotion to other areas of the Group within a short time. Jesse is an experienced technical engineer and is passionate about developing strong relationships with

customers that create opportunities and contribute to growth. With the wealth of technical knowledge Jesse brings to the role, Norman Kurta (CEO of SafeCode) states that “SafeCode Manufacturing and TopSolid Australia will deliver the most extensive software offering to the joinery industry and with Jesse heading up the team as Operations Manager. His commitment will be to drive growth and opportunities for our customers into the future.” They look forward to seeing Jesse excel in his new role and contributing to the continued success of SafeCode Manufacturing and TopSolid Australia. The team at SafeCode will focus on its continued support of the Palette CAD, ASPAN, ToolCAM, COBUS NCAD and ICB product in Australia building out the team to have specialised support and staff across all parts of Australia. ❚

Jesvinder Singh Operations Manager

Why ToolCAM? • Complete CAM environment • DXF import • Enables users to define machining parameters and sequences • Preview imported profiles instantly • Manipulation of start and end point • Multi drill capability • Supports wide range of CNC controllers

Supplier Aug/Sep 2019

“SafeCode Manufacturing and TopSolid Australia will deliver the most extensive software offering to the joinery industry and with Jesse heading up the team as Operations Manager. His commitment will be to drive growth and opportunities for our customers into the future.”

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News

Big River Group continues to expand

Mr. Geaney will continue in a management role within the combined business and the existing Big River staff will transition across into the consolidated business.

International Expansion Big River Group has announced the acquisition of Plytech, Highbrook, and Decortech located in East Tamaki Auckland, New Zealand.

ot only is Big River Group continuing to expand its national network, but it has also started on its global expansion strategy, and is growing its business in the plywood and specialty segments in New Zealand.

National Expansion Whilst Big River already operates a building supplies distribution site in Townsville, its acquisition of Big Hammer Building Supplies, provides the opportunity to combine the strong and successful operating histories of both businesses to create a larger and more diversified business.

geographic area within North Queensland and over 300 trading accounts. “We have discussed this opportunity with the owner of Big Hammer, John Geaney, several times over an extended period, as the compatibility of the two businesses has been clear for many years,” said Jim Bindon, Big River CEO. “We are pleased to be able to offer the customers of North Queensland the opportunity of an expanded product offering and experienced team to increase the services we can provide for them and their businesses”.

“Plytech and Decortech will become an important part of the Big River network providing a strategic positioning in the New Zealand market,” says Jim Bindon, CEO of Big River Group. “The businesses are well positioned to continue to grow in their respective current markets with the ability to add Big River manufactured products to their range.” The acquisition continues the expansion of the Big River network providing them with an Australasian presence having added the two Auckland businesses to their current 15 sites nationally across Australia. These additional locations will enable them to roll Big River products into the existing New Zealand structure and introduce the Plytech products into the Big River network in Australia.

Big Hammer has operated in the market for 26 years, and is particularly strong in the alterations and additions area as well as having a strong client base outside of the Townsville region. Whereas Big River’s existing branch has its strength in the commercial and civil construction markets, in addition to having a considerable overlap in the supply of residential building products. Combining these two respective strengths creates a business of scale and produces a substantial opportunity, with an exposure to all construction segments, a wide

Supplier Aug/Sep 2019

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News

Plywood and Specialty segments in Australia, whilst building a platform for Big River to supply their manufactured products into the New Zealand market. The current owners of Plytech and Decortech will exit the business over a period of three months, however all staff will be retained and the management team of Henk Kamsteeg, David Kirby and Justine Atonio will remain with the business to ensure a seamless transition to Big River Group ownership. â?&#x161;

Plytech was established more than 30 years ago and has built a reputation as a professional and technically proficient supplier of architecturally specified panel products to the trade. Decortech is a niche manufacturer of veneered panels and

supplier of a well-regarded, architecturally specified cladding product, Trespa. The acquisition will provide both Plytech and Decortech with a platform to diversify, by leveraging Big Riverâ&#x20AC;&#x2122;s position in the

Slicing Manufacturing Cost with High-Shear Tooling efficiency

CALL O UR SALES T EAM TODAY ON 1300 13 5 127 www.leitz.com.au Supplier Aug/Sep 2019

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News

A dedicated effort towards ALPHACAM in Australia

he ALPHACAM Global Management Team is excited to announce the launch of AC Australia CAD CAM Solutions Pty Ltd to lead the sales & service of ALPHACAM in Australia. AC Australia is a dedicated effort to promote and grow ALPHACAM solutions across Australia and expand across multiple industries. Blake McCrossen has been appointed National Brand Manager for AC Australia. As the National Brand Manager, he will drive all ALPHACAM activities across Australia. Discussions are underway with both existing & potential customers to better educate manufactures on how ALPHACAM can increase the automation and accuracy of their production processes. The objective for AC Australia is to increase commitment to all ALPHACAM users within Australia. A key focus to the growth of ALPHACAM in Australia is to combine the strong brand recognition it has internationally and its successes, with the diversity of the software, to reach into broader markets and industries. By working closely with industry partners, they aim to provide a complete business solution to suit a variety of manufacturing needs.

AC Australia is backed by the infrastructure and resources of Planit Cutting Edge Solutions, ensuring a platform for strong growth and expansion. Customers will continue to have access to Planit's Help Desk services, alongside Blake's guidance. The ALPHACAM Global Development team recently released ALPHACAM 2020.0 to the public. This new version is led by major enhancements in post-processed simulation, automation, and advanced 5-Axis features

within ALPHACAM. Blake is excited to take customers through these new features and explain the improvements they can make to production processes. Following the launch, Blake commented; "I'm excited to see this new initiative take off. After seeing ALPHACAM used in a production business, I can see how ALPHACAM will benefit others. The advancement in Automation with ALPHACAM is going to be something many businesses will benefit from within their production systems. AC Australia gives us a strong foundation to best serve Australian businesses". Global Director for ALPHACAM, Richard Chappell, commented "I'm excited to see this next chapter of ALPHACAM in Australia. There is plenty of potential to see ALPHACAM expand and be a vital manufacturing tool for Australian businesses. We are all behind this great new initiative." â?&#x161;

Above: Blake McCrossen Supplier Aug/Sep 2019

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News

A bit of fun

upplier’s Phil Ashley has attended many trade shows over the years and while he is overseas, tries to visit as many suppliers as possible. Most companies are happy to host a visit and many of these visits result in an article in Supplier that generally informs the reader about the company and often; the product they make. Phil usually travels alone but recently he’s been seen around the World with a ‘friend.’ A few years ago, Phil bought a toy to play with his grandchildren. He has seven so far with a few more on the way. The toy is a rubber chicken but not one you might have seen on YouTube recreating music. ‘Boris’ as he was named, is much more handsome than that. It turns out that Boris was quite a hit and one day, when Phil was explaining that he was going away again, he was asked “Is Boris going with you?”

Supplier Aug/Sep 2019

After a momentary pause to consider the implications of carrying a rubber chicken around the World, Phil of course had to say, yes. Boris had taken on quite a personality in the family and pictures of him in far away and sometimes famous locations would make quite an album. But the squawk? To alleviate the prospect of drawing attention to himself at security points, something that’s never advisable, Phil decided to get a standin for Boris, one that Phil ‘operated on’ to remove his cluck. So, why the story? Well, one day in 2017 after visiting Ligna, Germany, Phil found himself the guest of Leuco Tooling in Horb near the Black Forest Region. Leuco’s Christine Brandl had organised a road trip to Beinheim, just over the French border. Christine noticed Boris in Phil’s bag and an amusing conversation followed, along the

lines of, “What’s that all about.” Christine saw the funny side of it all and at this year’s Ligna asked if Boris was there again. Phil doesn’t usually take Boris to shows, but Christine said they could have a bit of fun; and so, Boris went in. The ‘fun’ turned out to be a filmed interview by a Leuco film crew, so finally, Boris has his fifteen minutes (about three actually) of fame. Phil said afterwards that, “It’s great to see a major company having a bit of fun.” Leuco’s Australian Managing Director Neil Staggs was also amused, as were the many onlookers, who were no doubt wondering what was going on. There’s a Scottish proverb that goes, “Be happy while you're living, for you're a long time dead.” It puts life into perspective. ❚

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News

Hideaway bins celebrate their Red Dot win The prestigious international Red Dot Design Awards pay tribute to the best manufacturers and designers of the year. In 2019 there were 5,500 entries from around the world, and only the best products convinced the experts. The manufacturers and designers from the international design scene that created these products were honoured and celebrated on 8 July 2019, at the Red Dot award ceremony in Essen Germany.

Below: Allen & Jamie Bertelsen

It was a proud moment for Directors Allen and Jamie Bertelsen from Hideaway Bins, a New Zealand based company, to be recognised on the world stage for their innovative Concelo waste bin design. They enjoyed celebrating this honour in Germany and found themselves mixing with some of the best design companies in the world. The Concelo waste bin is now on display in the Red Dot Museum in Essen, alongside other award-winning products. It is also forever featured in the ‘2019 Red Dot DOING’ year book where the international

design community draw inspiration for future products and stay on top of the latest product trends paving the way forward.

honour to have our waste bin recognised for its unique design features that truly help it to stand out in the crowd” says Director Allen Bertelsen. ❚

“The celebration was glamorous, an experience not to be forgotten and a true

First PYTHA Asia Pacific user meeting The first PYTHA Asia Pacific user meeting was held earlier this year in Bali. It hosted almost 80 enthusiastic attendees from Indonesia, Thailand, Vietnam, Australia, Japan, Malaysia, China, the Netherlands, India and Taiwan.

extending their knowledge on various topics such as “Plotting in PYTHA”, “Workshop in PYTHA” or “Advanced Modelling”. They even had the chance to meet developers of the 3D CAD Software PYTHA and share their opinions.

The conference was the launching pad for all-things-V24, with delegates hearing the full run-down of the fifty-plus new features available in the most recent version, and

The international PYTHA team says a big Thank you to all attendees for the wonderful time we had! ❚

Supplier Aug/Sep 2019

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News

Top honours for Panel Tools Online co-founder Panel Tools online are excited to announce that their co-founder, Fraser Killen, has been featured in Queensland’s top 20 young entrepreneurs and business leaders.

The Nundah teen says his company, which has a turnover in the hundreds of thousands of dollars, has disrupted the panel tools market dominated by paper catalogues.

Thomas Morgan from The Courier Mail reported: Juggling a double degree at university whilst managing an e-Commerce start-up has not tempered one Brisbane teen’s entrepreneurial spirit.

Killen says Panel Tools Online has provided a digital marketplace for routers, saw blades and other tools with applications in kitchen and bathroom panel fitting.

Fraser Killen co-founded Panel Tools Online with his mentor Craig Honeyman in July 2018, selling tools with applications in carpentry and kitchen fitting.

He says the idea presented itself during a high-school internship at Accurate, a Brisbane-based tooling company. ❚

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Product Update

Carbitool extends its tool coating and regrinding services Acquisition of Carbitool by Sutton Tools, another Australian family manufacturing business, has seen a number of changes, but the woodworking tool specialist continues to manufacture at its factory in Victoria and is expanding its range. Continuity at its Moorabbin premises ensures both the continued engagement of its highly qualified, long-standing production personnel and the ongoing development of specialised tooling and manufacturing processes. Carbitool has made other improvements in recent months, particularly in its warehousing operations and on the workshop floor.

Responding to changing needs The ongoing expansion of its router bit range ensures Carbitool can continue to meet the growing requirements of a demanding market, as well as a new and developing market, as new materials continue to become available to the building and manufacturing industries. The expansive Carbitool solid carbide spiral flute range of cutters caters in part for composite material variations and newly formatted board product as it enters the supply chain. Where only recently a workshop may have only machined timber product or aluminium, it may now face the challenge of machining Aluminium Composite Panel (ACP), composite panel with steel/stainless steel, fibre cement sheet, carbon fibre, fibrereinforced plastic or fibreglass. Some may be machining plastics – from hard to soft, Bakelite to Nylon (PA) – including PET, PE, PVC, PP, PLA, PC, Acrylic (PMMA), Acetal (POM), ABS and even Polystyrene (PS).

Supplier Aug/Sep 2019

Compressor cutter range Carbitool’s range of compression cutters continues to grow, now encompassing single-flute, 2-flute, 3-flute, 4-flute and 4-flute rougher/finishers. All of the series, except the single flute, are available in short upcut for morticing as well as long upcut versions. Using coatings on compression cutters enhances their suitability and performance for a wide range of applications.

The expansive Carbitool solid carbide spiral flute range of cutters caters in part for composite material variations and newly formatted board product as it enters the supply chain.

Benefits of advanced coatings Suitability of cutting tools to perform adequately on difficult materials is now enhanced by the application of advanced coatings such as Titanium Nitride (TiN), Titanium Carbon Nitride (TiCN) and Titanium Aluminium Nitride (TiAIN). With more difficult to machine materials entering the market regularly, solid carbide tools are increasingly coated with these and other advanced coatings such as Chromium Nitride (CrN) and Aluminium Chromium Nitride (AlCrN). All coatings offer longer tool life and the ability to obtain superior finishes. Carbitool also holds stock of solid carbide spiral flute tools in a range of coatings. In addition, access to Sutton Tools’ coating facility, Surface Technology Coatings, now allows rapid turnaround on tool coating services for special requirements.

Extended regrinding capabilities Carbitool has also recently added two Australian-made ANCA RGX Automatic CNC machining centres from the Sutton Tools regrind centre. This improves its in-house capabilities for sharpening the complete

solid carbide spiral flute range, including compression cutters. The result is even greater accuracy and faster turnaround. For more information on Carbitool products, regrinding services or to view their new and improved catalogue, visit their website. ❚

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Product Update

Cabiseal – the solution

abiseal is the very clever idea of Damian Harpantidis, a furniture and cabinet maker based in the Melbourne suburb of Surrey Hills. The idea of a cover plate for dishwasher inlet/outlet hoses, came about when Damian saw a need to increase the standard of finish for his clients. Damian said, “We were installing thirty and forty thousand-dollar kitchens and on some large projects, drilling hundreds of holes in a year just to leave them all open. It was an accepted trade practice, but I wanted something better.” And so, after some research and development; patenting the idea and commissioning a die, Damian presented Cabiseal to the Australian kitchen industry, initially through Lincoln Sentry. It is estimated that 380,000 dishwashers a year are installed in Australia, with Cabiseal now servicing over 40,000 of those each year and rising in number. It’s a fifteen-dollar accessory that offers cabinetmakers and designers the opportunity to increase finish quality.

Cabiseal is entirely manufactured right here in Australia by Damian’s company, Harp Industries, employing other family and local small businesses. It’s made from chemicalresistant ABS plastic; it’s self-locating and easy to install; it’s re-usable and recyclable. It can be installed on-site after drilling a double hole in the cabinet base but ideally, the opening can be pre-cut on a CNC machine when the cabinet is being manufactured; an idea introduced by Harp Industries in 2013. Damian was recently assisted on a new dishwasher installation video-clip by Biesse Group from their Sydney Campus. Tests revealed one hour’s machining of the Cabiseal standardised cut-out in the factory could save up to four full day’s work on large multi occupancy

Supplier Aug/Sep 2019

projects. Soon to be released, Miele, Laminex and InstallEx also contributed in creating the industry guide as a demonstration of best practice. Another positive attribute to employing the Cabiseal system of a pre allocated opening with accompanying cover plate is the assurance of an approved repeatable and compliant method leaving no room for error, or jagged holes damaging supply hoses. Damian’s passion for the wood trades started with his Grandpa. Damian would help out in the workshop from a very early age. For a while he considered wood carving as his major pursuit until his father talked him into cabinetmaking. In TAFE Damian won the top apprentice craftsmanship award at Holmesglen Institute, returning since to sponsor a similar award and paying back the positive experience he remembers. Having completed additional courses to give himself the greatest spread of skills possible, he has been active in many related fields. From making Louis 14th furniture replica’s, to kitchen and bathroom manufacture, to wood carving and much more, Damian is prepared

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Product Update

to ‘have a go’ at almost anything and is always interested to collaborate on projects and learn something new.

405

He particularly likes doing projects that are not necessarily attractive as a business proposition, things that others would say were too crazy. This is what makes Damian the craftsperson he is, practising lost techniques like traditional gilding, using hide glue, and steam bending. Damian is driven by his passion for the Arts but is also appreciated for his common sense and ingenuity. Cabiseal is a recognised success but Damian isn’t finished yet, there’s more to come. Cabiseal is distributed by leading cabinet hardware suppliers including Lincoln Sentry; Furnware Group; Dorset Australia; Wilson & Bradley; Nikpol and Galvin Hardware. ❚

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Product Update

Panhans – 100 years of German engineering

or 100 years, the brand PANHANS has stood for “Superior German Engineering”. The dedicated employees who have learned their craft from scratch, experienced designers and trained service personnel justify the success. Panhans range of products are made exclusively from selected, high-quality materials. With many internationally renowned innovations, Panhans has set standards in the field of woodworking engineering. Ausmach is now pleased to offer the extensive range of Panhans machinery to the Australian market. Ausmach is connecting expert German engineering with Australian and New Zealand manufacturers as the sole local distributor of Panhans machinery. Ausmach are excited to be giving local manufacturers access to a global stage with internationally recognisable and trusted machines that have been tested around the world. Ausmach and Panhans support teams have built their expertise from the ground up. Ausmach and Panhans team members start their careers on the factory floor and gain invaluable first-hand experience and skills that translate into priceless knowledge throughout their careers. Ongoing training and immersion in industry trends mean that the Ausmach-Panhans team is equipped with the most advanced information to provide the highest standards of engineering in woodworking machinery. This devotion to mechanical engineering and material selection mean that Ausmach are giving the local market access to previously unattainable knowledge, precision and proficiency, through the provision of Panhans machinery,

Supplier Aug/Sep 2019

stimulating local businesses with innovative and relevant machinery. The range is hitting Australian shores as we speak and will be on show at AWISA 2020. The range includes: • Panel saws with various features and capability including the ability to tilt 45.5 ° in both directions. The Panhans aluminum double roller cart principle ensures exceptional ease of movement and maximum service life. The super precise and smooth-running double roller trolley can be infinitely locked in any position. The smoothness remains even after many years of loading. Options include 7.5 kW and 10 hp instead of the standard 5.5 kW and 7.5 hp motors. • Band saws of the Panhans BSB series are available in various versions. They differ according to the possible cut heights and cut widths and thus allow for a wide range of applications. A wind-free double chamber welding construction forms the basis for all functional elements. Both protective doors are secured by end switches.

The maintenance-free construction of the bearing with high-performance precision ball bearings guarantees long-lasting reliability. The finely planed thickness table is vibration-free and tiltproof mounted on 4 table spindles and ensures a perfect planning image.

Through the relationship with Panhans, Ausmach is also able to launch the range from Hokubema Maschinenbau GmbH lifting and ergonomic work tables. They realise that the use of height-adjustable work tables increases productivity and minimises health-related absences. Height-adjustable work tables are an investment in the health of employees and the company’s future that pays off in the long run. Scissor lifting tables of the TL lifting table series with simple scissor mechanism are available in different designs and sizes, with a maximum lifting height of up to 3,000 mm. The TL super-flat lifting table has 16 different designs and therefore can help your joinery business in many ways and applications. They are true all-rounders with a minimum height of 80 or 100 mm and a carrying capacity of up to 2,000 kg. The Panhans range can be seen in the Melbourne or Sydney showrooms of Ausmach. ❚

• Thicknessing machines are compact and robust in construction, and stand out due to the extremely quiet and quiet running of its dynamically balanced knife shaft.

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Product Update

Schmalz Develops Clamping Solutions for Nesting Table Systems – Precision Grip Guarantees a Clean Cut

n furniture production, every millimeter counts: Optimal arrangement of workpieces with different geometries is crucial when it comes to saving on expensive raw materials. Schmalz offers a flexible vacuum solution precisely for this purpose. In addition, the system holds securely on smooth surfaces and ensures short set-up times. The nesting process is commonly used to lower material costs. The individual elements are slotted together or nested, resulting in minimal waste. A wear plate is then clamped on the grid table of the CNC machine. The raw material is positioned here. The vacuum is so strong that the wear plate is able to keep even the smallest milled parts safely in position. Horizontal processing, such as drilling, is not possible during nesting, however, this is no longer a problem with the Schmalz clamping system.

Flat Construction

MDF wear plate of nesting machine tables. This means the user does not need to set up the machine, which avoids long downtimes. The suction cups are connected directly to the vacuum system of the CNC machine via hoses in order to generate the necessary vacuum. If the user places the workpiece down, a touch valve with a soft surface activates the vacuum block – this protects the workpiece surface. Unneeded suction cups can also remain on the machine table.

suction cup creates a high holding force, even on smooth surfaces. Schmalz has designed the connection to the suction plate with a robust main body made from plastic so that the suction plate can be easily replaced in the event of wear. Another advantage of the vacuum block series is its minimal operating height of 30 millimeters. This makes the VCBL-G solution ideally suited to 3-axis machining centers with low Z values.

The vacuum blocks of the VCBL-G series are particularly suitable for use directly on the

The friction pad on the underside of the

Flexible Modular System For users who want to use a vacuum block VCBL-B instead of a suction cup VCBL-G, Schmalz has developed the Adapter-Plate AP-G. The vacuum is still generated directly from the nesting machine system via a hose. The suction cup mount includes a grid: The vacuum blocks can be inserted in the AdapterPlate in 15° increments in any direction so that the suction area can be aligned as desired. The modular system—vacuum blocks are available in three different heights and with four different suction areas— increases flexibility and shortens set-up time. Due to the variable working heights, users can also use the Schmalz system for 5-axis machining centers. ❚

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New Ideas at interzum

Open plan concepts and ever smaller urban homes demand new furniture solutions. People like to hide functional spaces like fitted kitchens or home offices when not in use and Blum has come up with a solution. Pocket systems consist of large doors that close off spaces. When open, the doors disappear into narrow cabinets, or pockets. Doors open with a single touch and then slide into the pocket, disappearing out of the way for access to furniture units. A single touch is enough to gently eject doors from the pocket.

EGGER MORE+less

he importance of interzum to the Global interiors industry cannot be overstated. Attention is focusing on surfaces close in appearance to the real thing; sustainability and ecological footprints; individually tailored living solutions; the merging of living spaces; multifunctionality in furniture; increasing urbanisation and micro living; and digitalisation. There’s so much to see and do, you just cannot miss the next event in 2021 but for now, here are the highlights from the major suppliers.

Blum - Moving Ideas Blum presents products based on customer needs; the manufacturer, retailer or end user. Their main focus products are hinges, drawers and lift systems. First; the AVENTOS HK top stay with SERVO-DRIVE, the latest addition to the AVENTOS range shown at AWISA last year. The new stay lift is installed close to the cabinet top panel and blends discreetly into tall units and wall cabinets and can be set from the front without having to remove cover caps. With the electrical motion support system, wall cabinets glide open at a single touch and close again softly.

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Above: Blum's Aventos HK top stay Blum made the most of this year’s interzum in Cologne to present its SERVO-DRIVE smart concept study and show visitors how a motion support system can deliver connectivity to kitchens. Wall cabinets, pull-outs, dishwashers and refrigerators can soon be powered by voice control. Simply define a scenario, for example, “Clear away the shopping” and the relevant wall cabinets and pull-outs glide open by themselves. “Alexa, make me taller”, prompts Blum’s SPACE STEP plinth to move out of the cabinet to stand on, giving easy access to higher storage levels. Opening the waste bin pull-out without touching it is another useful scenario.

EGGER always comes up with a great stand. This year six room settings included highlight decors, surfaces and products influenced by the individual interpretation of trends, influences and materials. EGGER’s trend themes were Next Nature; Future Retro; Perfect Imperfection; Coloured Monochrome; Contrasting Harmony; and Technical Emotions and while these appear contradictory; in fact, they complement each other and form harmonious combinations. In the interzum awards: intelligent material & design 2019, the ‘Best of the Best’ award went to EGGER for PerfectSense Matt and Duo edging. The ST75 Mineral Satin texture newly developed for worktops as well as the new PerfectSense Topmatt worktop received the "High Product Quality” award.

Below: EGGER's compact worktop

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Everything EGGER sell, they make, and last year they made five billion Australian dollars in sales and spent eighty million Euros in R&D. Every interzum they have a raft of new releases. Imitating the appearance of very different woods and other surface material is a trend that shows no sign of stopping and appears today in many different forms. An example of the materials that EGGER’s R&D program is able to produce comes in a new EGGER surface ST20 Metal Brushed texture that imitates the look and feel of finely brushed metal. Features of the EGGER stand were surfaces with not only the look, but the (real) feel and touch synchronised with the printed pattern. Another EGGER novelty is the 12mm compact worktop and while it is stylishly thin, is also strong and stable. In line with the trend for fast, tool-less assembly, EGGER has produced furniture components with Clic technology for fast, uncomplicated assembly thanks to furniture components easily clicked into each other.

Fastmount hidden panel mounting The Stratlock Range is a heavy-duty hidden panel mounting solution for installing large interior panels onto aluminium or steel extrusion framework. A purpose-built system, the Stratlock Range is the only product on the market that provides versatility in modular design and adjustable panel

Supplier Aug/Sep 2019

installation, thanks to its Patent Pending dual locking function. The range fixes a pervasive problem that has not yet been answered by other products on the market, improving on frontal and bayonet fixings by offering strength, movement, and rapid installation. Fastmount is distributed in Australia by Michael Tiddy of Titus Tekform.

Above: Maxine Kelly from Fastmount

Fenix Style Centre Arpa Industriale welcomed visitors to the fair with an interactive exhibition space that combined design, innovation and sustainability. Designed by LEM Agenzia Architettura and inspired by a “style centre”, visitors were encouraged to touch and experience the materials from both an aesthetic and technical viewpoint. “Bloom” is the new lignin-based technology created by the company’s R&D department to increase the use of natural raw materials in the core of Arpa HPL and FENIX NTM. With Bloom, lignin technology has been introduced to significantly reduce the amount of phenol included in the resin by 50%. It is available for a selection of twentyeight HPL plain colours in three finishes as well as four new colours of FENIX NTM. The palette of FENIX now consists of 27 colours.

Above: Fenix Bloom These are material surfaces which are beautiful to look at and are also high-tech materials. Thanks to its blend of beauty and technology, the FENIX NTA metal surface has won two important awards: the “High Product Quality” Interzum Award 2019 and the “Product Design” Red Dot Award 2019.

Grass: Modern, Fresher, Younger Grass went to interzum 2019 with a new corporate image. The colour scheme and design have been slightly changed to adapt to the way such aspects are perceived in the age of mobile devices. “One definitive

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the furniture and their operation is easy. The smart Häfele Connect mesh system with its innovative firmware, wall switch and remote control also won an interzum award. Mesh is a standardised protocol based on Bluetooth, introduced in 2018 and will be available in Australia from October this year with further development to follow. The Connect Mesh module is integrated in all Loox5 light control components.

Above: Kinvaro T-Slim by GRASS highlight is our latest development Kinvaro T-Slim”, says GRASS manager Albert Trebo. “With this fitting, our designer has created an object with a timelessly beautiful design whose purist aesthetics will change the character of flap cabinets forever.” Kinvaro T-Slim blends into the furniture almost invisibly and unlocks new possibilities for overhead wall cabinets. Grass have reduced the complex mechanism of a lift-up fitting down to an overall size of 12 millimetres, which means that it can be inset into the furniture and disappears completely. For the Nova Pro range of runner systems, a new version will be added which combines high-tech with exceptional design. The new synchronised, full extending drawer runners extend further and are more comfortable to use. They are the great solution for waste sorting systems. When the drawer is opened and closed, it glides quietly and gently on new synchronised runners. With a load capacity of 50 kilograms, the full extending drawer is exceptionally robust, which makes the system safe for waste sorting systems in the kitchen. GRASS has also developed a Tipmatic Soft-close version for the bathroom

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where lightweight drawers don’t hold much, with extremely low resistance to close the drawer safely and comfortably.

Häfele – Thinking Ahead “Thinking ahead” was the Häfele motto and the hardware supplier presented innovations ready for the market. A standout product was Free Space, an innovation in the Free flap product range by Häfele. Free Space is a small but extremely powerful flap fitting available in a ‘push-to-open’ version in four ‘colours’. With its compact, very thin design, Free space creates more storage space in furniture than other popular flap hinges. Free space eliminates the need for large cover caps and with an internal installation depth of only 63 mm, opens up new furniture design for narrow cabinets. Developed in conjunction with Kesseböhmer, the fitting won a prestigious red dot award. Häfele is the Australian distributor of Kesseböhmer products.

Häfele’s third award-winning product is Ixconnect tool-less assembly that was demonstrated at interzum. The furniture and the drawer were completely assembled in a record time of 180 seconds. Häfele calls this ‘RTA 2.0 – Thinking ahead in RTA furniture’ and during the assembly of a drawer alone, the furniture manufacturer can save up to half of all drill holes reducing assembly time by up to 70%. The assembled drawer meets all standards of a similar IKEA 30 product.

Below: Hafele's Free Space

Digital technologies are a normal part of life; however, digitalisation will have a future in the furniture and living environment only if their integration into

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Hettich: Customisation is the New Standard At this year's interzum, Hettich provided answers to the noticeable changes taking place in life and home living as a result of megatrends that include urbanisation and customisation. A visitor magnet at the show was the Hettich ‘AvanTech YOU’ drawer system that takes drawer customisation to a new level. ‘AvanTech YOU’ permits exceptionally slimline, purist design without visible screw heads or cover caps. It’s easy to adapt their design to buyers' wishes. Design profiles can be used to create a huge variety of individualised eye catchers on the top edge and outer side of the drawer

Below: Topline XL by Hettich

side profile. ‘AvanTech YOU’ opens up great potential for kitchen and furniture manufacturers to set themselves apart from the competition: with their own furniture design in different price segments. AvanTech YOU will be released in Europe later this year and will be launched formally in Australia at the next AWISA. For some a life concept, for others a necessary decision because housing in towns and cities is scarce and expensive. Using the example of a fully furnished single person apartment on a floor space of just 18m², Hettich also showed how lovely a tiny space can be as a home and

demonstrates all of the surprises it holds in every corner. Maybe not in Australia yet, but as our cities grow and housing becomes less affordable, living in smaller spaces will become more common. And finally from Hettich; with TopLine XL, doors weighing up to 100 kg gently open and close with unequalled ease, almost making them appear to float.

Kesseböhmer: Six Metres of Action Visitors to the ‘urban smart kitchen’ on the Kesseböhmer stand at Interzum needed less than three steps to walk through the room. The small six-metre square metropolitan kitchen was cleverly planned and wellequipped with a standard refrigerator; dishwasher; oven; rubbish bin and a table, created a considerable amount of storage space. A very cool product was the new ‘TopSwing’; a simple, practical solution, developed with LGA, which is a child-proof product development. The dining table hangs on the wall, saving space, and gently lowers on demand after unlocking with one hand thanks to integrated damping. Kesseböhmer is distributed in Australia by Häfele.

Rehau: Beyond the Surface REHAU put up a unique show at interzum aptly named Future Apartment. The stand delivered a memorable experience beyond mere kitchenettes and conventional apartment solutions. REHAU introduced functions-embedded surfaces and technologies, adding new smart and emotional values to contemporary living. ‘Future Apartment’ follows a radical approach that reduces the kitchen, living room and bathroom to three highly functional blocks, almost sculptural objects. Each one remains deliberately abstract to highlight the many technical possibilities offered by REHAU in a never-seen-before and entertaining way.

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fittings, offering countless possibilities of style and convenience. Drawers finished in leather or fabrics in soft shapes coupled with illuminated shelves transform the walk-in wardrobe into an inspirational space.

Titus The needs of the consumer were centre stage at Interzum for Titus. Michael Tiddy was on hand to demonstrate where Titus is going with their ‘Confident Close’ program across their range of hinges and drawer systems. With Confident Close on both hinge and drawer systems across the Titus range, users can push the door or drawer of any size and weight, and then literally leave the room, knowing the door or drawer will always close quickly, decelerate and ‘land’ smoothly… every time. The Titus T-type hinge significantly reduces the time needed to assemble a kitchen, offering an efficient, economical application with guaranteed life-time performance. With its intuitive 3Way Snap-On hinge-to-plate mounting in three directions, mounting doors has never been quicker or easier, particularly for doors requiring three or more hinges. It ensures reliable door closing even in cases of accidental misalignment.

Below: Titus' Confident Close Above: Rehau's Future Apartment (top) and Salice Excessories. To address these three thematic blocks; REHAU envisioned the apartment of the future. It is a new path and holistic approach that rethinks and leverages the properties of previously unused surfaces, not only characterized by mere optical beauty and aesthetic added value, but also by the synthesis between technology and material. The core of the program is supported by an inspirational formula: more individuality, more space, more emotion. You had to be there to experience this futuristic display of Rehau’s product, used in most ingenious ways.

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Salice Excessories Excessories is the winner of the Interzum Award for Intelligent Material & Design 2019. A competition organized by Koelnmesse in cooperation with Red Dot; this prestigious award is given to products that best represent technological innovation combined with functionality and design. The judging panel conferred on ‘Excessories’ the highest recognition as ‘Best of the Best’ in the category ‘Fittings, glass and lighting.’ Excessories is a variety of solutions designed to optimise space and to facilitate the perfect arrangement of wardrobe interior

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Above: Vauth Sagel – SUB Comfort (left) and the Bark-cloth 'SKARV' (right). Vauth-Sagel OpenUp Vauth-Sagel's stand motto for the interzum 2019 was OpenUp and this referred just as much to the products as it does to their corporate culture. VS ELEMENTS; flexibility for all life stages is a storage solution where the basic element is a system frame with a customisable handle component. The frame can be equipped with various inserts and submodules; with a choice of modules for flat, hanging and standing storage. The inserts and the submodules, in their turn, can be customised with regard to their depth and width, extended or also removed and used separately, they are modules within modules for maximum flexibility. VS SUB Comfort is a low cabinet drawer system. It comes out directly towards the user when the cabinet doors are opened. VS SUB Comfort is based on clever kinematics that transfer the rotary motion of the doors in such a way that the speed at which the drawers come out is either increased or decreased at an even, gentle pace throughout until they are fully extended. The upper tray can then be pushed back in intuitively without the need for any additional action and therefore makes it possible to easily access the lower storage space level. The

Supplier Aug/Sep 2019

trays are attached to the door, so the drawer closes gently. VS SUB Comfort received the interzum award: intelligent material & design 2019.

Something Completely Different Bark-cloth is an unusual product made from Amazonian Tururi Palm fibre and virgin natural latex, both renewable materials. Bark-cloth can be used as an upholstery material and other products including

footwear. Another very unusual prototype is ‘SKARV,’ a scarf where the fabric receives digital impulses by means of an app, it enables the wearer to send gentle vibrations to the scarf and intertwines functional textiles with social media. SKARV is embedded with sensors and actuators which attempt to recreate the sensation of human touch. If you are thinking of a friend or loved one, you can send an embrace with a simple text message via the app in real time. There’s a possible use for this material as an upholstery fabric. ❚

Above: Supplier Magazine's Philip Ashley 'cant wait' until the next Interzum in 2021. www.suppliermagazine.com.au

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Ligna Report Card with minimum energy consumption and excellent cleaning due to the proven ALKO OPTI JET technology. The premium model in the series is the AL-KO POWER UNIT 350. With a filter area of 73 m2, IE3 motors, maximum energy efficiency and low noise levels of 71dB (A), the unit is a real alternative to stationary extraction and filter systems.

Over 90,000 visitors from over 100 countries went to Hannover to find the technologies to help them stay competitive and grow their business. Over 40,000 trade visitors came from abroad, an indication of the show’s international appeal. As usual, Supplier’s Phil Ashley was there to report.

AL-KO is a manufacturer of high-quality extraction technology and is represented in Australia by Ausmach. Three versions of the AL-KO POWER UNIT series were presented at the fair. The AL-KO POWER UNIT 120; 160 and 350 versions. What they all have in common is a high extraction performance

Altendorf Group revealed their new logo at Ligna and a new development for their panel saw. It’s called ASA for ‘Altendorf Safety Assistant’ and is the working title for this new development. To put it simply, it’s a saw stop device and while the idea of stopping a spinning sawblade quickly when it touches a finger is not new, Altendorf have built their own system using sensors and cameras; it’s a touchless system. Patent applications have been filed and the system in its final configuration may be available to buy before 2020.

Below: AL-KO from Ausmach

AKE tools are marketed in Australia by Salestech. At Ligna their focus was on a variety of tools with 2.0 background. 2.0 stands for preventing multiple chipping which provides much better processing results and longer service lives. Their main exhibits were the jointing cutter and shank cutter 2.0; the panel sizing saw blade 2.0 and the SuperSilent. Among the latest AKE developments in 2.0 is the extension of their panel sizing programme, with 70 new and altogether, almost 100 items. At Ligna, AKE visitors were treated to a robotic bar(person) that mixed cocktails on demand.

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IMA Schelling showed a fully integrated and automated batch-size-1 production that has been designed specifically for a big European front’s manufacturer. The work-cell was able to detect damaged spots on the raw panels and bypass them during the panel cutting process so that faultless components are produced, and the number of reject parts is minimized. The sorting cell consists of four storage racks, each with 60 stock positions, and has a storage capacity of approx. 1200 parts. The whole production was controlled by the IPC.NET plant control system. It performs planning tasks and the subsequent workflow control from panel storage, through panel cutting and edge processing, to component sorting.

Above: Biesse high output Biesse Group are committed to making Industry 4.0 technologies available to every one of their customers. Their claim: You can’t have a revolution unless the masses can use the technology. Last year was Biesse Group’s best year on record for sales and at Ligna the Italian giant received orders worth 40 million Euro’s. Three completely automated process lines showed customers the results that can be achieved with customised, flexible production. The stand saw the début of the new Stream A Smart and Akron 1100 edge-banding machines; the new Uniteam RC machining centres for housing, and the new FPS (Feedback Positioning System) worktables for their Rover machining centres. Felder Group in Australia is currently restructuring with a ‘young and keen’ management team, more sales staff and more technicians. At Ligna their stand-out display presented two major innovations. First is a new PUR glue application system that uses no glue pot and does away with complex processing and glue storage systems; wasted glue, and cleaning. GlueBox uses PUR glue extruded as a tape that is applied inside their new application device.

Supplier Aug/Sep 2019

It’s so clever but equally so is their second innovation. Five years ago, Felder Group started a project with the University of Vienna with Sascha Wein, master joiner and managing director of the Joiner’s Trade Guild in Munich. This all came to fruition at Ligna with a ‘saw-stop’ system completely integrated into the machine. Apart from the name ‘PCS Stop’ (Preventive Contact System) emblazoned on the front cover, you would never know this saw was one of the safest machines ever made. Homag Group presented two new, integrated workshop concepts, specially designed for carpenters and joiners with easy digital assistants and features; a fully networked, automated and completely autonomous concept for SMEs and a solution for high-performance furniture production at high-speed. Homag Group announced a new strategic partnership with Hundegger (prefab house construction) and the formation of the new Digital Printing Association (DIPA). What caught our eye was their ‘productionAssist Edge’ edge-band management system for the management and organization of edge band stock via a tablet.

Above: CAD+T (top) and Costa. www.suppliermagazine.com.au

Overseas News Below: Leitz Tooling

Leitz Tooling presented a number of innovations at Ligna. First, ProfilCut Q Plus and ProfilCut Q Premium Plus with resharpenable, diameter and profile-constant cutting edges especially for the window construction industry and for companies that process solid wood, plastic or MDF panels. The incentive for these new developments was the manufacturing costs due to the use of disposable knives for profiling. Second, a new compact hogger generation is ideally suited for batch size 1 production where the tool design has been modified in such a way that a significant noise reduction can be measured. And third, a swivelling bevel cutterhead with exchangeable cutting systems. Leuco Tooling announced they had won the German Innovation Award for their Airstream System. On the tool body a hole is drilled at a precise location to prevent the build-up of air pressure, leading to a measurable amount of noise reduction even when itâ&#x20AC;&#x2122;s not cutting (idling). A new HSK 32R tool is the result of co-operation between Leuco and HolzHer edge-banding and ensures a concentric clamping accuracy of two microns and this guarantee highprecision sizing on lower-cost machines. Also, on their busy stand, Leuco showed the

Supplier Aug/Sep 2019

development of the tooth geometry especially for plastic materials, particularly for many thermoplastics. The saw blades provide a close tooth pitch so that even very thin plastic panels can be processed with almost no cutting marks.

An SCM Group drawcard was a magnificent 12 metre table in ancient kauri wood, from the outstanding manufacturer Riva1920, designed by Renzo and Matteo Piano. Looking at SCM technology, the three main issues that connected with the CNC nesting of cabinet components are spoil board management, productivity (if compared with beam saws) and holding capacity on small pieces. SCM has designed, developed and tested innovative solutions to overcome these issues for the customers and gives them the opportunity to improve their productivity and flexibility at the same time. The results of work done in recent years are reflected in the new morbidelli x200 and x400 CNC nesting machining centres. The Weinig Group did very well at Ligna this year, lifting its orders from the show by 20% over the 2017 event. At their display a complex plant could be seen live in action, illustrating the competence across the entire value chain of solid wood processing. Then there was the Powermat 2400 3D. The moulder is equipped with the Alphacam software which allows the design of three-dimensional workpieces and the 38 creation of a CNC program.

Left: Leuco Airstream

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Two of the upper spindles are used for axial and radial 3D structuring. Controlled spindles from the right and left make it possible to produce workpieces with a wide variety of contours and small radii. Weinig has expanded the Conturex CNC series with their new ‘Artis’ CNC machine with a 4-axis main spindle for small shops.

Other technologies and news Manufacturing Execution Systems (MES) are computerized systems used in manufacturing to track and document the

transformation of raw materials to finished goods. ARDIS® PERFORM has used the experience of their MES custom solutions and leading Optimizer solution to develop the first MES system for the woodworking industry without the need for heavy customization. Barberán introduced TrueTexture, the latest development for texture generation, which synchronizes images with a 3D effect creating panels with exceptional finishes. This new treatment concept for panels allows the creation of haptic sensations

and deepness effects over boards including flooring. Once it is applied it can be covered with a matte or glossy finish. Eight leading European woodworking machinery manufacturers have formed a working group to define a common language, that enables a seamless communication between machines of different brands. The framework for a new standard, called “P&W, Plug & Work”, was launched at Ligna. The eight companies are Altendorf, Biesse, Burkle, Homag, IMA-Schelling, SCM, Weber and Weinig-HolzHer. ❚

Discover New Business Opportunities at the Surface + Design Event China 2019 The Surface + Design Event China (SURFACES China) is organized by Informa Markets and China Chamber of Commerce of Metals Minerals & Chemicals Importers & Exporters (CCCMC), and in partnership with The International Surface Event (TISE) - the largest North American floor covering, stone, and tile industry event. The Surface + Design Event China 2019, is taking place at Shanghai New International Expo Centre (SNIEC) on December 11-13, and aims to create an annual networking and business platform for the stone, tile, floor and wall covering industry.

and services, share expertise, and most importantly to develop new business opportunities. SURFACES China 2019 will present a free education program. The topics will cover: New Products & Innovations, Interior Design & Systems, Trends in Design & New Products, Best Case Studies in Applications & Installations, and Interior Environment

& Eco-friendly Products. It will also include hearing from architects and interior designers regarding the latest trends, design, case studies and innovations. Geographically positioned in China, SURFACES China 2019 will help the exhibitors to access this expanding market and open new business opportunities in growth regions across Asia. ❚

The comprehensive three-day exhibition and conference will showcase innovative products, technologies and services, and bring together distributors, wholesalers, retailers, designers, architects, builders, owners, developers and other industry professionals to help keep up with the latest trends, source the latest products

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MODERN FURNITURE PRODUCTION PANEL CUTTING | CNC PROCESSING | EDGEBANDING Effective cutting optimisation CNC processing made easy Perfectly invisible joints

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Michael WEINIG Australia Pty. Ltd.

4 Commercial Joiners reveal how Empower Factory Productivity & Scheduling Software has transformed factory productivity and profit By Sean O’Sullivan, B Com (Hons) Otago University

PEPPERTREE FURNITURE (ADELAIDE, SA) MARK TOZER, MANAGING DIRECTOR

“At 10 weeks of using Empower Software we got 46% increase in factory productivity, at 6 months we had got to a 86% increase and at 3 years we had got a 100% increase in factory productivity. On factory productivity increases alone generated by Empower Software our annual profit has increased by approximately $200,000”

Key Points • Empower is the tool that our factory staff use to bring their jobs in on budgeted time • Our factory staff culture is far better as a result of being time and job focused • Each factory staff member gets paid bonus for meeting their personal productivity goals. This comprises capping their downtime and meeting times on jobs each week • The brilliant thing about how Empower has worked for me from day 1 of putting it in, is it simply reported area by area, in small bite size pieces each issues that I could address, precisely where I needed to start focusing to get things in order and up to scratch, which I simply followed through on • We have used Empower accurate actual times on products to go back and accurately cost our labour and set consistent margin across our products and quoting. This has enabled us to significantly increase our profit margin across our sales.

PREMIER FURNITURE (SYDNEY, NSW) PETER LANGFORD, MANAGING DIRECTOR

“Empower Software has made a substantial improvement to factory productivity and bottom line and we would not be without it”

Key Points • Our factory staff have really stepped up to the mark and consistently meet and beat the budgeted times on the factory PCs, using Empower • Empower provides factory staff with a tool to be aware of their own productivity • The software is brilliant at staff performance reviews • We give individual factory staff reports on their weekly productivity. This is invaluable feedback to them to keep their productivity up • Empower gives us accurate times on jobs to allow us to carry out a sensible job cost (ie back cost) on completed jobs so we can refine our future budgeted labour in our costings and quotations • Empower is designed specifically for my role as production manager to ‘track, report and substantially increase factory productivity’ and it certainly works for us • Empower times are the truth and accurate – with evidence on issues I act immediately • Empower is the most positive thing we have done in 10 years • It certainly makes guys on the factory floor focus on their jobs and their times Core Products Manufactured (or Core Business)

Wide range of standard and custom office furniture

Any Key Background Information

2009 Empower Software was recommended to us, a factory productivity software and consultancy business, which had 10 years experience in our industry and a solid track record of increasing their clients factory productivity by 15 to 80%.

Core Products Manufactured (or Core Business)

Panel and Steel Tube Framed Furniture

Any Key Background Information

We operate the largest retail outlet for commercial furniture in South Australia

# Factory Floor Staff

# Total Staff

Annual Revenue (approx)

$4 Million

Annual Revenue (approx)

Confidential

Factory and Office Size m2

4100m2

Factory and Office Size m2

Large

# of CNCs

We run two Sleco beam saws, two Biesse borers, one SCM edge bander and a Stefani edge bander

# of CNCs

Geography Serviced

All Australia

Staff Times on Jobs Recording prior to Empower

Our production manager Robert advised “prior to 2009 we were attempting to run our factory and our labour the manual way, which was no different to how factories were run in Australia over 100 years ago. Stepping up to using factory PCs and time tracking software has been a quantum leap in professionalism and productivity for Premier Furniture

Geography Serviced

All States

Staff Times on Jobs Recording prior Our factory staff manually filled in their lie to Empower sheets at day end Years in Business

Staff Groups Tracked on Empower

All Factory Staff

Years using Empower

9 years to date (at 2018)

Years in Business

Since 1959

Number of PC’s on the factory floor with Empower on

8 @ 2nd hand PCs plus we have Empower on our CNC machines

Staff Groups Tracked on Empower

All staff in all work centres throughout the factory floor

Number of our Managers using Empower

Years using Empower

12 months to date (as at Jan 2011)

Estimated Factory Productivity Increase on Empower

I thought that my factory was productive before putting in Empower but really had no way of knowing whether I was productive or not at the time. Looking back on it I now know that my factory was terribly unproductive prior to Empower.

Number of PC’s on the factory 4 floor with Empower on Number of our Managers using Empower

Estimated Factory Productivity Increase on Empower

Substantial improvement to both our factory productivity and our annual profit

TASKER JOINERY (SYDNEY, NSW)

FINECUT JOINERY (SYDNEY, NSW) MITCHELL BLACK - PRODUCTION MANAGER

GREG TASKER, MANAGING DIRECTOR

“We have achieved a 25% increase in our staff and factory productivity”

Key Points “Using Empower we are getting 20% more joinery out the door each month. Our business consultant confirmed that a 20% increase in our factory productivity would increase our annual profit by an estimated 60%”

Key Points • For the first time in many years I enjoy coming to work, because the Empower system has my entire business monitored and well in control. I am no longer stressed as I used as I used to be, due to inadequate monitoring. I now feel as if my management, office staff factory staff and site staff are now “in the same boat and rowing in the same direction” • At 2 years of using Empower our factory productivity has increased by an estimated 20% • When I finally retire I will be able to pass on to my son a business with far better: systems and controls and a business that is far more: productive and profitable

• It has been much easier and more accurate for us to provide clients with an ETA, especially when using both Empower Time Tracking and Job Scheduling Software • Empower and the factory PCs force factory staff to be aware of their budgeted and actual times on each job and take responsibility for jobs they work on • Our factory staff are aware of how long they are taking on a job realise the importance of finishing on time • Empower has helped management and the sales team ensure that our prices are accurate as far as our labour component is concerned Core Products Manufactured (or Core Business)

White Good Appliance Displays mainly

% Production is custom made - one off designs (each job different to the last)

100%

# Factory Floor Staff

# Total Staff

Annual Revenue (approx)

Confidential

Core Products Manufactured (or Core Business)

Interior fit outs, commercial joinery and kitchens

Factory and Office Size m2

1000m2

# of CNCs

1 CNC and 1 computerised panel saw

% of Jobs Custom One Offs

100%

Geography Serviced

# Factory Floor Staff

Mostly Sydney and NSW, however we go nationwide

# Total Staff

13 2.3 Million approx.

Staff Times on Jobs Recording prior to Empower

No form of time tracking previously

Annual Revenue (approx)

Years in Business

Associations and any positions held

FIAA

Staff Groups Tracked on Empower

Factory staff, pre production staff in office and site workers

Years using Empower

3 years

Number of PC’s on the factory floor with Empower on

Factory and Office Size m2

800 square metres approx.

# of CNCs

Geography Serviced

Sydney mainly

Staff Times on Jobs Recording prior to Empower

Factory staff manually recorded their times on jobs daily

Years in Business

Associations and any positions held

Housing Industry Association

Staff Groups Tracked on Empower

Office, factory and site staff

Years using Empower

Number of PC’s on the factory floor with Empower on

2 PC’s

Number of our Managers using Empower 3 Estimated Factory Productivity Increase on Empower

Using Empower we are getting 20% more joinery out the door each month

We have achieved a 25% increase in our staff and factory productivity. We have maintained production levels and not had to replace 2 staff that left (1 position in factory and 1 on site), so our current 8 staff are doing the workload of our 10 staff previously. This is a 25% increase in staff and factory productivity.

Please contact us anytime for an information package, a software demonstration or pricing Founding Director Sean O’Sullivan B Com (Hons) +64 27 2284211, phone anytime sean@manufacturingandengineering.co.nz

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Manufacturing

Will you be able to keep up with trends in 2020? Written by Fraser Killen (Co-founder of Panel Tools Online)

s technology becomes more accessible and reliable, base level tasks are automated and systemised. As technology advances the complexity of tasks that can be automated and systemised will be increased. This often leaves us wondering, if all these base level tasks are being taken care of, what is left for humans to do? I always like to picture the human brain as a being broken into two parts, left brain and right brain. The left side of the brain is said to be the analytical or methodical side and right side is the creative or artistic side. In addition, I like to picture the base level thinking in the centre of the brain and the high-level thinking further out. The prevalence of technology gives people the opportunity to exercise the outer parts of their brain as less time is spent developing base skills. This is a current worldwide human condition that manifests itself in everything I see on a day to day basis in industry, on the news and in the younger generation.

and surface finishes with varying structural needs and in most cases a tight budget. The average design project can include dozens of different materials from wood, plastics, metals and composites. Each with their own manufacturing challenges. Aspen Commercial Interiors in Armidale create masterful office spaces and joinery for high-end clients across Australia and New Zealand. A large focus for their operations manager Roy Heaney is research and development. Mr Heaney constantly works with designers on new products to increase their offering to their clients. One of their recent designs uses colourful EVA foam desk partitions with curved edges to bring a softness to the working space. Mass producing this profile proved difficult as a clean edge couldnâ&#x20AC;&#x2122;t be achieved using their current wood CNC tooling and the curved

profile could not be achieved consistently or easily using a knife and panel saw. It seemed, they needed to invest in dedicated machines or outsource the work. However, all they really needed was a $35 tool with a specific geometry that suited the exact material. Without introducing any new machinery, expensive software package or hours of set-up they were able to produce the partitions. This is just one example of how a small investment in tooling can eliminate a large investment in capital or the cost, lack of control and lead times of outsourcing. It is also just one example of different materials becoming prevalent in the industry. Most of the input materials used in the cabinet industry currently can be broken down into four sub categories: wood, composites, plastics and metals.

Designers and clients are becoming more creative and engineers and tradespeople are able to provide more complex solutions to bring these ideas to life. The challenge is then put to manufacturers to implement these solutions and create the products that raise their entire industry to a new standard. Often, the challenge is in working with new input materials and manipulating them to suit specific applications. As many of you know, the input materials chop and change with each passing season. The architectural influence and changing designs require different shapes, fixings

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Manufacturing

Wood Natural and engineered wood products such as solid timber, MDF, chipboard and plywood are without a doubt the most prevalent materials used in joinery.

Plastics A plastic is a synthetic material made up of polymers. Compact laminates, acrylic, foams and corian panels are also increasingly used by joiners. Once again, each of these materials can be machined on a standard nester, given the correct tooling.

Modern manufacturers are constantly looking for materials that are strong, lightweight, cost effective and visually appealing to fulfil their increasingly ambitious designs. Composites A composite is the combination of two or more distinct materials to achieve certain properties that cannot be met by standard alloys, ceramics or polymeric materials. It generally has a series of layers in the form of hardened particles, fibres or structures with a soft or flexible core.

Metals Aluminium sheet has always been a major component of shopfitting and sign making. Thin sheets can be cut dry using standard tooling. Metal by-products such as vermiculite, ACP and magnetic panel are also common examples.

The composites that we are most excited about in the cabinetmaking industry is structural composites in the form of sandwich panels.

Modern manufacturers are constantly looking for materials that are strong, lightweight, cost effective and visually

Supplier Aug/Sep 2019

appealing to fulfil their increasingly ambitious designs. Composites make this possible by allowing the designer to handpick the materials with the best properties and combine them. Particularly used in aerospace and mega structures, composite materials such as honeycomb core sandwich panels, s-flute panels, steel foam sandwich panels not to mention fibreglass, carbon-fibre and magnetic sandwich panel can be used in applications that would exceed the capabilities of standard materials. CNC machines are the most versatile machines on the planet in terms of the number of materials and applications that can be performed. The only additional equipment needed to machine any two different materials mentioned in this article is a few tools. Client demands have evolved and will continue to. If manufacturers donâ&#x20AC;&#x2122;t familiarise themselves with the new materials hitting the market, they can miss opportunities. â?&#x161;

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Manufacturing

Our Machines are our Muscle Justin Macri is a young manufacturer who is going places. Metric Joinery has been in business for seven years now and a little over six months ago, moved into larger premises in Wetherill Park in Sydney’s west. Metric Joinery is growing, and Justin and his father Marco didn’t have the space to fully explore the potential of their impressive range of high-end German and Italian machinery. For Justin, efficiency is the key to success in manufacturing. Using machinery focused on what you need, what works best for your product and what’s best for your business is his way forward. Justin’s machines are his muscle; his machines work for him and he only invests in equipment suited to his work. He’s not someone who is tied in with a single supplier; he shops around, and he buys what he needs, what works for him. A big earner for Justin and Marco is the production of wide benchtops and other products that his

customers here and as far away as London, depend on Metric Joinery for. To ensure that this work is done as efficiently as is possible, Justin turned to Peter Vuille-Bille at Ville-Tec for a new planer sander that was essential to Metric Joinery’s continuing growth.

The new machine is a Costa K7-WCU 1,650mm wide calibrating and sanding machine. It’s the biggest planer-sander ever installed in Australia but it’s not the biggest the Italian specialist sander supplier makes. The K- Series family of machines is available all the way up to 3.2 metres wide! Costa have plenty of experience building some of the biggest sanders in the World and Metric Joinery have invested in that experience. Justin said, “Our new Costa sander was installed a little over three months ago and we haven’t looked back. We wanted a machine that was easy to use, easy to set up and would guarantee a straight, flat and smooth surface on every piece we put through it. The machine does everything Ville-Tec said it would.” Justin continued, “We do a lot of widened solid timber benchtops and it was a lot of work to plane it, then sand it by hand. Our old machine wasn’t wide enough and the rise and fall of the table was very inconvenient for us. It created a lot of

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Manufacturing

entire 1,650mm table width and finish to 150 grit, and to take a maximum 4mm depth of cut in a single pass. Justin’s machine is equipped with a 250mm diameter planing head with 600 cutters. Now, this might sound like a lot of work, four hours in fact to change the entire set, but the cutters last up to four years! Even with the most abrasive materials a year’s use is common. Justin says, “We’ve been using the machine now for three months and even though we’ve put a lot of Blackwood through it, the cutters look like they will last for at least two years.” And the machine isn’t out of action to change the cutters; the head is removed, and the machine goes right on producing with the two sanding heads. What Justin also considered when researching a planer sander was the savings in power that a spiral head gives him. The planer head needs 30hp to run but a sander head doing the same job requires twice as much. But there’s more! If Justin were to use sanding belts to do all the work, he would use four times as many belts. Justin worked out that these would cost him $15,000 compared to the $3,000 he would spend on a set of cutters over the same period. For Justin and Marco, the Costa machine was a no-brainer.

problems holding the tops level as they went through the sander. What took us several hours we now do in a minute or two, and the quality of the surface is excellent.” The fixed table of the Costa sander means the work can be fed on rollers straight into the machine with no effort from Justin or Marco. “We don’t make work for ourselves,’ says Marco. “We let the machines work for us and the Costa sander has saved us an enormous amount of time and effort.”

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Their Costa Series K machine is built to last for decades. There are well documented cases where Costa sanders are still in use after fifty years. A 55-year old refurbished machine was displayed at Ligna this year. Metric Joinery’s machine weighs in at almost seven tonnes so it’s as solid a machine as you will ever find. Justin says, “The build quality of the machine is like a Ferrari” but in reality, it’s really built like a tank. It’s possible to take a 2.5mm cut across the

Justin doesn’t advertise, he doesn’t need to; his work speaks for itself. The Macri family is heavily involved in the building and construction industry so they know what they’re doing, and they know what the industry wants. Their work is 85% solid timber and their main focus is on detailed joinery, and windows and doors. Their windows can be Australian standard, but they also produce a hybrid European-Australian style with double glazing. They also make staircases, custom timber furniture and do contract machining on their German 5-axis CNC machine; and now of course, contract sanding. They’ve found that with the range of equipment they have, half of their work is now contract for other joinery shops.

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Interior Design & Production Software

Complete software solutions for the furniture design and manufacturing business

Specialized for bespoke furniture “It’s ten times as good as our previous sander. It’s a totally different machine and we find it opens up totally new lines of work for us.” A recent job was to produce detailed, architectural joinery for Abuelo; an ‘Australian meets South American’ coffee house and kitchen in London’s Covent Garden. Metric Joinery’s unique, handcrafted timber joinery made from New South Wales Spotted Gum creates a relaxing, calm and warm space and has become one of London’s best advertisements for Australia. Justin welcomes a challenge and Abuelo’s unusual geometric shapes; while a test for Metric Joinery, was produced exactly to specification and to the satisfaction of the restaurant operators. Look at Abuelo’s website and amongst all the great food pictures you will also see Metric Joinery’s work. Justin has high praise for Peter at VilleTec Engineering. “When we were looking for a machine Peter listened to what we needed the machine to do. He didn’t try and sell me something that wouldn’t work, something I didn’t need. We got quotes from other suppliers but when we sat down and

compared what we were getting for the price, and what the machines were able to do for us, our decision to go with the Costa was an easy one. When we decided to go with the Costa, Peter came around to see us regularly and kept us up to date on the progress of the machine and delivery date. He’s very reliable and as a specialist supplier he knows what he’s talking about.” Justin loves his new Costa planer-sander. “It’s ten times as good as our previous sander. It’s a totally different machine and we find it opens up totally new lines of work for us. Our machine range includes some of the World’s most recognised brands including Altendorf; Holz Her; Martin; Wadkin and now; Costa.” He says, “Our machines are our muscle, they do all the hard work. We buy the right machines to make our work easier.” With Justin and Marco’s energy; Costa’s grunt and the support of Peter at Ville-Tec, Metric Joinery is on a path to success. ❚

CNC connection in less than a week Complete ERP system

CAD+T Australasia Pty Ltd 24 Franzman Avenue NSW, 2570 Elderslie Phone: +61 (2) 800 620 67 E-Mail: office@cadt-solutions.com Web: www.cadt-solutions.com

Manufacturing

An Intelligent Choice

and when I joined the company in 1976 I learned a lot about that side of the business. We bailed from manufacturing in 2001 because at that time everyone was doing the same thing. However we now have a terrific range of high-quality decorative products and we know we can offer a superior service supplying cut and finished products to our customers.” And so, late in 2017 Nover once again started out manufacturing but this time with edge banding equipment capable of delivering the Wow factor Steve wanted. The machine of choice was a Lumina 1584 from Holz-Her, a machine that was highly recommended by many of Nover’s customers as a machine that would produce the quality edge Steve was looking for. Brett Ezzy said “Edge banders have many more moving parts than almost any other wood working machine so we wanted something that was simple to operate; a machine that we could rely on to keep on producing with consistent quality results. We try never to let our customers down and the edge bander for us is a key piece of equipment. If we needed help, our Holz-Her rep would be there for us, he visits us regularly so he knows what we do and what we need; it’s a really good relationship.”

over was founded in 1954 and has been a family business for almost seventy years. It’s now run by Steve Cowley and his sister Lynn. An Australian specialist wholesale distributor and supplier of essential products for the Kitchen; Joinery; Shop-Fitting and Furniture industries, Nover has only recently ventured back into manufacturing. Managing Director Steve Cowley says “Our aim was to put a finished product in front of our customers that made

Supplier Aug/Sep 2019

them go Wow!” Putting together a high-tech workshop in their Eastern Creek facility, Steve and Production Manager Brett Ezzy installed a CNC router and Holz-Her Lumina 1584 edge banding machine to produce an extensive range of quality products where the cutting and edging matched the quality of the product itself. Steve said “We’ve had a history of manufacturing since the early 1960’s

“We’re supplying the industry with a superior product; cutting and edging decorative products such as our Luxe; Syncron and our award-winning Fenix product” said Steve. “We demand an excellent edge bond on both highly textured and high-gloss boards,” he says. To achieve this, Steve needs a reliable edge bond and depends on the security that PUR glue provides. All Holz-Her edge banders are capable of using both EVA and PUR glues but the definite advantage with the HolzHer machine is in the cartridge system. It’s amazingly quick to change over; in fact almost ten times as fast as a pot system. It’s clean; uses less glue and produces a glueline that’s almost invisible.

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Manufacturing

Holz-Her are leaders in edge banding machines and have championed the development of PUR systems. On a white board with white edge and white glue; the finish Holz-Her can achieve is as near as matters to that of a laser edge. While Nover’s machine is also capable of EVA glue, it’s not what Steve was looking for. “It’s not our business to produce with EVA, our business is quality. PUR is waterproof and permanent and it was absolutely essential on any machine we bought. We’re very, very happy with the performance and finish of our edged panels and the management of the PUR adhesive is a very small price to pay compared to the quality we achieve from the Lumina machine, in most cases with the very first piece we put through it.” Brett adds “There’s almost no issue managing the PUR glue. We know how many metres we get from a cartridge so glue wastage is almost nothing. When the machine tells us to refill the glue we know we have about thirty metres of production left on 16mm or 18mm board. We add the neutralising cartridge and when we hit the thirty metre target we stop production and press the ‘purge’ button. It takes about three minutes; we usually only do this once a week and it’s really that simple,” he says. Nover’s machine is a Lumina and this means that in addition to the excellent results produced with the PUR glue; it’s also possible to produce the so-called ‘laser’ edges very popular in Europe and becoming widely accepted around the World. Dozens of ‘laser’

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Manufacturing

machines are already in operation in Australia and New Zealand. Compared to a traditional laser system; Holz-Her use nearinfrared radiation (NIR) called Ltronic that is a fraction of the cost of a laser system. Not only is the purchase price highly affordable but the running costs are far less and the running time between changing ‘globes’ is far greater. Steve says “While our PUR edges are as close as makes no difference to a laser product, the small additional cost futureproofs our company and allows us to offer a ‘laser’ product when the demand is there. If we need to change from PUR to laser it’s really fast. We don’t need any downtime at all and the Lumina machine is very efficient. We think it’s a sound business decision.” Nover’s Holz-Her is also equipped with the MultiTool system that allows multiple edge banding profiles to be machined by a single tool, whether it is one, two or three millimetre rounded edges. Daniel Tasich is Holz-Her’s sales

Supplier Aug/Sep 2019

tech and says “This award-winning technology was developed together by Leitz and Holz-Her. It combines machinery with tooling engineering ability and is perfect for short runs. The profiles are changed on the machine computer through a gear system in the tool. It produces excellent results every time and there’s no manual adjustments needed.” To meet their expected quality requirements Nover demanded a machine with the most exacting tolerances. The Lumina; with its digital NC servo motors and complemented by the MultiTool is capable of getting excellent results on a cross-grain textured board. It can easily finish all Nover’s decorative panels from the incredible Fenix board to the high-gloss Luxe products with the touch of a button. Even the protective plastic film on high gloss boards, often with different thicknesses, can easily be taken care of by the servo motors and all at the touch of a button.

Steve says “We find that the Holz-Her Lumina is delivering a consistent quality product that both we and our customers can rely on. Our next delivery has to be as good as the last and we can achieve this every time. High on our list of ‘must-have’s’ was the ability to use PUR glue. We needed a high performing bond with an almost zero glue line. When we ran a test on white board and edge with PUR glue, we found the finish was actually as good as a laser edge. There is no line between the board and the edge tape; it’s seamless. The interchangeable glue unit is very efficient and takes almost no time at all to change. It’s literally only a few minutes. We bought the machine on the advice of many of our customers who’ve had Holz-Her machines for years and I can say it’s exceeded all our high expectations. What I really get excited about is innovation and with the Holz-Her Lumina, I’ve found it,” he says. ❚

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Manufacturing Advertorial

Nover. A Partner you can trust for all your supply needs. Spanning a history of 65 years, Nover is proudly Australian owned and operated. Specialising in the wholesale distribution of quality products to the Kitchen, Furniture and Joinery manufacturing sector, we have the industryâ&#x20AC;&#x2122;s largest product range. Our quality decorative panels include Fenix, Evostone, Luxe and Syncron, which can be cut to size in house at Nover. As well as our panel range, we supply drawer and sliding systems, sinks, mixers, basins, hinges, bins, cutlery inserts, handles, shop fittings, lighting & more.

FENIX NTM & NTA Decorative Panels FENIXÂŽ is a superior material created for interior design applications by Arpa Industriale. It is suitable for both vertical and horizontal use. The external surface of FENIX NTM is like no other as it is extremely opaque, has a soft touch and is anti-fingerprint. It is considered a SMART material which means that it has the ability for thermal healing of superficial micro-scratches and therefore makes it the most hygienic product on the market.

Our extensive distribution network covers the entire East Coast of Australia. To find out more, contact us on 1300 668 371, email info@nover.com.au or visit our website www.nover.com.au

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Manufacturing

Castlewood and Biesse, Blue for a cause.

eople are one of Castlewood Kitchen’s greatest assets. Directors Alison and Pat Abela work very hard to ensure their employees are happy and feel valued. A cup of tea or coffee in addition to their regular breaks, and a cake for your birthday are some of the small but welcome things their people enjoy in an otherwise busy workday. To say, “I’m here for you” everyone shakes hands when they arrive in the morning and go home in the afternoon. And if someone looks ‘down’ Alison and Pat are quick to find out why, but more importantly; see what they can do to help.

Biesse Group’s involvement with Castlewood started many years ago with the installation of a Skill nesting machine. This machine replaced their old method of cutting sheets on a sliding table panel saw and produced an immediate surge in output. From a factory in St. Mary’s to Riverstone to Minchinbury where they are now located, Biesse Group has always been their major technology partner. Through the years the company has grown; work has increased, and assembly has improved to the point where it became time came to review their equipment needs.

Alison and Pat are serious about the well-being of their office and factory staff. They understand there is growing evidence that when your employees are happy, your company thrives. With this in mind Castlewood Kitchens joined with Biesse Group to put on a Beyond Blue benefit and Barbeque in April, raising over $2,000 for this very worthwhile cause. Alison said, “Three million Australians live with anxiety or depression and every day about eight people take their own lives.” Staff were encouraged to (safely) dress in blue for the day; Biesse Group provided the Barbeque and drinks; and a team photo was taken to mark the event.

Working closely with Biesse Group, Pat and his team considered one new Biesse Rover B nesting machine. Pat said, “The salespeople from Biesse offered us a lot of advice, then left us alone to consider what they had said, and what we thought we needed. They weren’t pushy and they didn’t overpower us with ideas. We knew we had a pretty efficient assembly crew, but that storage was our biggest issue. We were thinking about moving to larger premises and we considered

this as well. We thought that if we could schedule our work and get it through the CNC machine efficiently, we could stay where we were and get the cabinets out the door in a ‘just-in-time’ or lean manufacturing process.” “After looking at all the options with the people from Biesse it was clear that we should bite the bullet and get a second machine at the same time. This would future-proof our production and make sure that we were able to get the material onto the CNC machines as close as possible to the delivery date,” Pat continues. “We thought, let’s do it once and let’s do it right. We had an idea on a new factory layout; Biesse fine-tuned the plan and everyone at Castlewood was very happy with the result.” Castlewood installed two Biesse Rover B nesting machines with auto labelling and infeed and outfeed equipment. Alison adds, “The two Biesse machines have helped us to become much more efficient; our factory isn’t congested any more and there’s a lot less pressure on our people.”

Castlewood Kitchens is a family company started in 1984 by their parents, Mario and Colleen. It wasn’t always easy but through all the struggles, Mario always looked after their people. The worker’s pay always came first and there were many times when Mario and Colleen went without so their workers would get paid. It’s this kind of commitment to their people that Alison and Pat have continued to practice since they became Directors three years ago.

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Manufacturing

employees they can make a difference. Pat said, “I met Biesse’s new General Manager recently and learned that he has a similar mindset to us about our employees.”

“Our business methods and our Biesse equipment have given us time to better our factory and get ourselves more organised.” Castlewood’s employees were also involved in the decisions leading up to the purchase of the new Biesse machines and production. Pat himself worked his way up through the ranks. He didn’t want to be known as the boss’s son so after his apprenticeship he started on the shop floor and did every job in the factory. It took fifteen years to make it to Director with Alison joining him from an admin role after twelve years. They know their business as well as anyone and their decisions are based on sound advice and input from the people on the workshop shop floor. The workers feel involved and very few leave to work at other cabinet firms. Castlewood Kitchens make all aspects of domestic cabinetry in a house. Alison said, “It’s mostly kitchens and bathrooms but we can do anything including full-house fit-outs. We work for some of the biggest builders in New South Wales including Sekisui, Allam, Clarendon and Metricon, some of who build up to 1,000 homes a year! We’re well-known for our supply

Supplier Aug/Sep 2019

Alison and Pat believe depression is a major issue in a family and work perspective. Alison said, “We don’t like to see anyone, especially our people coming to work depressed. We do what we can to try and understand what the problem is even if that means sitting down for several hours if that’s what it takes.” In manufacturing too many companies are overly focused on what they do and overlook who is doing the work. A recent study found there was a causal link between unhappiness and decreased productivity that had a lasting effect of about two years! For Alison and Pat, a happy workplace is a productive workplace, but happiness is more than a weekly pay check. The Beatles were right; money can’t buy love, or happiness. ❚

and service so our tradespeople and our equipment have to be up to the task. With Biesse, we’re confident that we can meet the needs of all our customers and at the same time; guarantee the work moves through the factory smoothly. We don’t want to be the biggest kitchen manufacturer around; we like to keep control of everything so we can still provide the personal touch.” Pat adds, “Our business methods and our Biesse equipment have given us time to better our factory and get ourselves more organised. During the last eight years we were doing some extreme hours to get the work out and this is another reason we needed help from Biesse Group. Their technology has helped us reduce our backlog of orders and our overtime labour costs.” When asked what he would like to say about Castlewood Kitchens Pat said, “We’re a family-oriented company providing support, opportunity and reward for effort.” Castlewood Kitchens and Biesse Group both share the same belief that together with their

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Events

OCTOBER 2019 9-12

IFMAC & WOODMAC 2019 International furniture manufacturing components and woodworking machinery exhibition Jakarta, Indonesia https://www.ifmac.net/ 10-13 Mumbai Wood 2019 Trade fair for furniture production technologies, woodworking machinery, tools, fittings, accessories, raw materials and products Mumbai, India https://www.nm-india.com/ mumbaiwood 12-16 Intermob 2019 Furniture side industry, accessories, forestry products and wood technology fair Istanbul, Turkey http://intermobistanbul.com/en/ 12-16 WoodTECH 2019 International wood processing machines, cutting tools, hand tools fair Istanbul, Turkey http://agacmakinesi.com/en/ 15-19 HOLZ 2019 Swiss fair for woodworking Basel, Switzerland https://www.holz.ch/

15-18 SICAM 2019 Exhibition of components, semi-finished parts and accessories for the furniture industry Pordenone, Italy http://www.exposicam.it/en/ 29 â&#x20AC;&#x201C; 1 Wood-Tech 2019 Nov International fair of machinery, equipment and materials for the wood industry Brno, Czech Republic https://www.bvv.cz/en/wood-tec/ wood-tec-2019/

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NOVEMBER 2019

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6-9 IFM2019 International furniture machinery and material fair Houjie, DongGuan, China https://www.fmmfair.com/en/ 19-21 Timber Israel 2019 International exhibition for the wood working and fittings industry Tel Aviv, Israel https://timberisrael.com/en/home-page/ 21-24 Ferralia 2019 Exhibition of accessories and equipment for the wood industry Porto, Portugal https://www.tradeindia.com/ tradeshows/13269/ferralia-2019. html

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