Supplier Woodworking Magazine March/April 2020 by Elite Publishing Co Pty Ltd

MAR/APR 2020

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

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Contents

Issue #205 | Volume 36 No 1

News

Editor’s Note

During these challenging times the team at Supplier Magazine want to assure our readers that we will continue to be the industry communication link through our print, digital and social media platforms.

Product Update 12 Design & Trends

Inside you will find our Safety feature where we discuss the hierarchy of control as well as measures businesses must take to meet compliance standards associated with the occupational health and safety of their employees.

The house of 2020

Feature 18

Safety

Philip Ashley reports on PalmwoodNet’s mission to turn what was once a waste product into a commercially usable timber, resulting in what could be the most significant new wood resource in decades.

Software 26

Site measure to a 3D CAD drawing in a single step

Talking Business

Due to the worldwide ramifications caused by the outbreak of COVID – 19 many exhibitions and trade shows have been cancelled and postponed. As such, we will not be publishing an events calendar this issue and advise readers to check event websites for up to date information before making travel arrangements.

Pushing boundaries with Holz-Her

Manufacturing 36

Rising above adversity

Front Cover Multicam www.multicam.com.au

Don’t forget to join our online community and visit us on Facebook, Instagram and Pintrest. Until next time,

Michelle Cammiade

Find Supplier Magazine on: @suppliermagazine

Supplier March/April 2020

@suppliermagazine

Editor

www.suppliermagazine.com.au

News

AWISA exhibition postponement At the AWISA Ltd board meeting on Friday 6 March the decision was made to postpone the AWISA exhibition planned for 1-4 July 2020. The reasons all relate to the coronavirus. The board considered the health and safety of visitors and the staff of exhibiting companies. It is clear that in Australia the coronavirus is only in its early stages and on the basis of the experience in China and other countries, it still has many weeks or months to run its course. Normally an AWISA exhibition has a combined attendance in the order of 12,000, both visitors and exhibitors. At the moment, such gatherings are allowed but that may change. Then there is the subject of the confidence that people may have in planning travel in 15 weeks time. This confidence is already suffering. AWISA has never been in the business of running half-hearted exhibitions. The

association did not hold an event in 2010 because of the GFC, and the board feels that the circumstances today have similarities. In the board’s view, the shows that followed 2010 were far stronger than if a diminished 2010 exhibition had taken place. Then the board considered the effect of coronavirus on the woodworking industry worldwide. Three of the key countries that contribute products to AWISA exhibitions are Germany, Italy and China. All have cancelled or postponed exhibitions in the last few weeks. Many AWISA members are experiencing difficulty sourcing products from overseas in time for the planned July dates. Especially China where factories have been shut for weeks. Worldwide, there are shortages of components and of shipping containers, and in some cases products are not allowed to be moved within, or out of countries.

There is also the problem of getting technicians and product specialists to travel to Australia - all essential to the running of the exhibition. Some companies and unions in Europe have banned international travel. Such travel is also currently uninsurable. Many major AWISA exhibitors bring between 10 and 25 technicians and other staff to the show. All of them are essential to the running of a show of AWISA’s size. This decision has not been taken lightly. It is not a panicked or hysterical reaction, but a business-like reaction to what is actually happening in other parts of the world, and to what is highly likely to happen in Australia. The board is bitterly disappointed that this decision has had to be made. AWISA 2020 was close to being sold out. Discussions are being held with the venue regarding dates a few months later than originally planned. ❚

Important announcement from MEGT MEGT (Australia) Ltd is pleased to formally announce that they have maintained their status as a preferred provider for the Australian Apprenticeship Support Network (AASN) contract after the results for the new AASN contract were released. The new AASN contract sees MEGT retain its status as Australia's largest and only national Apprenticeship Network Provider. Under the new AASN contract, MEGT will maintain its current operations in all six states nationally. The primary objective of the new AASN contract is to increase apprenticeship and traineeship completion rates significantly. MEGT will achieve this objective by expanding

Supplier March/April 2020

its Gateway and In-training Services as well as implementing a new and innovative service delivery approach to their apprenticeship support service delivery. The expansion and refinement of these service offerings enables MEGT to continue to support employers, apprentices and trainees throughout the apprenticeship or traineeship life cycle. According to Senator the Hon Michaelia Cash, Minister for Employment, Skills, Small and Family Business said, “We are improving the Support Network to help get even more apprentices enrolled and trained up for rewarding careers and to help meet employers’ skills needs.”

Bridie Gildea, CEO (Acting) of MEGT commented, “MEGT is proud to again be named a preferred provider of the Australian Apprenticeship Support Network. We are pleased to be continuing to provide services across all six states nationally.” Paul Bennett, ANP General Manager at MEGT said, “Being awarded the AASN contract is a testament to the hard work and dedication of our team, and we will continue to improve and expand upon the quality of the services and resources we provide to employers, apprentices and trainees.” ❚ MEGT (Australia) Ltd is an Australian not-for-profit organisation that has been supporting employers, apprentices, trainees, job seekers and students since 1982. MEGT is committed to making quality training and education solutions accessible to all Australians.

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63mm

FREE SPACE ENGINEERED BY HÄFELE MODERN, COMPACT DESIGN Minimal installation depth of 63 mm with an installation height of 172 mm noticeably leaves more usable storage space in the cabinet.

EASY PUSH-ON MOUNTING OF FRONT PANEL Front panels can be installed and removed quick and easy with toolless installation.

OPTIMISED LOGISTICS AND PROCESSING Less components reduces transport and storage space. At the same time installation is less complex and more time-efficient.

COMPATIBLE DRILL PATTERN The plug-in pins on the base plate suit standard 32/37 mm line boring dimensions on the side wall and allow for a pre-installation of the fitting with just one hand.

SELF-EXPLANATORY ADJUSTMENTS Intuitive and comfortable tension adjustment from the front. 3D flap alignment with generous adjustment range. Integrated opening angle limiter 107° to 90°.

HIGH VERSATILITY IN PLANNING AND PRODUCTION One model series with a sustaining capacity of up to 10.7 kg for 400 mm high flaps allows for a wide application range.

info@hafele.com.au

1300 659 728

www.hafele.com.au

News

The MadeCo’s Hub has moved

3d Kitchen Software – winners announced

The team at MadeCo are thrilled to start the new decade in a new factory space, marking the next chapter in the MadeCo’s journey of innovation.

In conjunction with Supplier Magazine, Chris and Rose Adams of 3d Kitchen Design, are pleased to offer, free of charge, the 3d Kitchen Software package to Supplier readers.

After 13 years across two locations MadeCo is now united in one huge hub with the latest technology and processes designed exclusively to provide a better work-life for clients, suppliers and staff alike. Find the new premises at 34-38 Edison Road, Dandenong South, Victoria, 3175, all other contact details stay the same. The team is looking forward to showing visitors around. ❚

Chris explains, “We are now in the 12th year of this give-away promotion. In 2019 alone we gave away $46,500 worth of software. It seems there may be some hard times ahead, but 3d Kitchen has committed to continue this unique give-away offer. So, to those readers who have considered applying, please don't hesitate. The offer is open, genuine, and will be very valuable to your business."

Supplier Magazine would like to congratulate the following companies who have won the fabulous 3d Software package: • Northern Joinery and Cabinet Works Pty Ltd • Maple Ridge Joinery • Maarten Aantjes Joinery • Mc Villy Kitchens and Joinery Pty Ltd • J & B Joiners For your chance to win a 3d Software package go to page 46-47 for all entry details. ❚

Multicam Expo - a great success The Multicam Trade Expos recently held in Melbourne, Newcastle and Brisbane turned out to be a huge success for the Multicam team, whilst proving to be an eye-opener for many attendees. Invitations were sent to companies in the woodworking industry including; cabinet makers, kitchen manufacturers and shop fitters, who were invited to see a range of Multicam CNC routing machines, tooling and software in action. As Multicam CNC routing machines are utilised in a wide variety of industry sectors including; architectural composite material cladding, point of sale displays, insulation and refrigeration, trade training and education, invitations were also distributed to companies in these industries. Being less industry focussed and with a broader

Supplier March/April 2020

appeal, these expos allow visitors to see how and where Multicam machines can be utilised in their business, which often results in comments like, “I didn’t know we could do that.” Multicam CNC routing machines are 100% Australian made and supported Australia wide through offices in Melbourne, Newcastle and Brisbane. In view of recent events, a comprehensive support network is more important than ever. Businesses have come to realise the importance of accessibility to assistance in your local area and the importance of buying and supporting Australian made. The expos were supported by other great Australian companies including, CarbiTool and Four’n’Twenty pies, with representatives of CarbiTool offering great advice and discounts on tooling and Four’n’Twenty generously supplying pies to the visitors. ❚

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News

New public makerspace – FAB9 When Dennis Savic and a team of mechanical engineers recently moved their tools into a new public makerspace in Footscray, it represented a significant milestone on the road to production of Australia’s first electric motorcycle. It also represented a ‘coming of age’ for FAB9 – a superbly equipped workspace on the banks of the Maribyrnong River that is turning heads across Australia for its ground-breaking combination of skills training, start-up expertise, and the country’s most sophisticated collection of engineering and manufacturing machines. FAB9 is the brainchild of Hans Chang, a former Silicon Valley product manager, who after a career with the flash-memory company SanDisk, opened FAB9 with the world-renowned makerspace pioneer, Dr Evan Malone.

“FAB9 is an important piece of infrastructure in our start-up ecosystem, as it provides a particular manufacturing focus for startups wanting access to low-cost facilities to prototype, build and test products,” says Kate Cornick, the CEO of LaunchVic.

Chang’s experiment has also attracted significant support from the Victorian Government’s start-up agency, LaunchVic, which – buoyed by Malone’s backing – has funded FAB9 to the tune of $1 million.

The funds have enabled Chang to create “Australia’s best-equipped public makerspace”, with a range of machines usually available only to multinational corporations and research labs – including the laser-guided Markforged X7 3D printer, and the Multicam Trident 3000 CNC router – one of the most precise and versatile flatbed cutting machines in the world. The 900-square-metre workspace also has an extensive range of hand tools, power tools, electronic prototyping equipment, and manufacturing machines, including vertical bench-saws, thicknessers, laser-cutters, industrial sewing machines, and more.

Above: Dennis Savic with a production prototype of the C-Series electric motorbike.

Supplier March/April 2020

Moto madness While FAB9 offers a productive launchpad for DIY projects and maker-entrepreneurs, its huge range of tools and expertise also makes

it an ideal venue for serious start-ups and hardware pioneers. Dennis Savic, the 27-year-old wunderkind behind the Savic C-Series, says the makerspace was a perfect spot for him when he was considering venues to test, tune and assemble the country’s first high-performance electric motorcycle. “As we’re pre-seed, it doesn’t pay for us to lease an entire factory yet, when we’re basically working nights and weekends,” says Savic, who works as an optimisation engineer at Ford Australia by day. “At FAB9, we have a semi-permanent space in the metal workshop with our own bench and bike stand with plenty of space.” Savic launched the advanced prototype of his café racer at the 2019 Australian Motorcycle Festival in Wollongong in November and was ensconced at FAB9 within a week of returning to Melbourne. He says interest has been most intense in his top-of-the-range Alpha model – a 60kW machine “capable of 10 0-100 kmph in 3.5 seconds”.

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News

Big River Group Acquires Pine Design

The team is aiming to produce its first ‘founder edition’ bikes by August 2020 and has already received 99 expressions of interest for its first 49 vehicles, with formal orders opened in early December. Savic’s team is using FAB9’s workshops to test the electrical components, refine the motor tune, and finalise development of the bike’s powertrain. Savic says the company is in discussions with a number of venture capital firms, and is remains quietly confident of meeting its target for first commercial deliveries in January 2021. “FAB9 is perfect for us because it gives us a spacious workshop, with great equipment, friendly staff, and complete security,” says Savic. “Plus, of course, it’ll cost us less than half of what it would cost to rent a similar standalone factory space.” For Hans Chang, however, you don’t have to be the inventor of Australia’s next transport revolution – or even be particularly handy – to benefit from a membership at FAB9.

Construction industry leader, Big River Group, is continuing to expand its national network and increase its product offering with the acquisition of Adelaide based timber supply company, Pine Design Truss and Timber. Implementing an acquisitive growth strategy, Big River has grown considerably in recent years. The acquisition of Pine Design increases the opportunity to combine the strong and successful operating histories of both businesses to create a larger and more diversified business. Pine Design has operated in the market for over 30 years, and has a strong client base in the South Australian region. It is particularly strong in manufacturing roof and floor trusses and as a supplier of timber and building products, complementing Big River’s strength in the residential, commercial and civil construction markets. The combination of these two respective strengths creates a business of scale and considerable opportunity, with an exposure to all construction segments and continues the national strategic expansion of Big River. “We are pleased to be able to offer the customers of South Australia the opportunity

of an expanded product offer and experienced team to increase the services we can provide for them and their businesses,” said Jim Bindon, Big River CEO. “We believe both companies will benefit greatly and also believe that our customers will appreciate the wider range of services and products.” Pine Design will continue to operate in the same way, with the existing manager Chris Wray remaining with the business. Local contacts will also remain the same, with the added support of Big River Group, which has both manufacturing and building supply distribution businesses all around Australia and New Zealand. Big River Group has been operating for over 100 years, manufacturing and distributing timber and steel formwork products, timber flooring, building products, structural plywood and related timber products. It also distributes a broad range of other building products, including MaxiWall and MaxiFloor, primarily to the commercial, residential and infrastructure construction market segments. ❚

“You don’t have to have a watertight project or a detailed engineering plan before you come and see us,” says Chang. “All you need is an idea and the enthusiasm to further your journey. “You don’t even have to have any practical expertise – just an interest and a willingness to see how far you can take your making ambitions.” ❚

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Product Update

FREE SPACE – Engineered by Häfele Häfele has introduced an exciting new fitting system for flap doors. The Free Space flap fitting is setting new standards in the industry, it is the smart connection of less is more. Awarded for its compact design and versatile functionality, Free Space was granted both the Red Dot award and Interzum award for its compact design and its versatile functionality. The fitting itself is the most powerful flap fitting of its class, having less variations and more applications, covering approximately 80% of all applications with a regular flap opening. One can see and reach into the cabinet from all sides. Being compact it allows for more storage space as well as fitting into very shallow cabinets. The modern-compact design requires a minimal installation depth of only 63 mm and installation height of 172 mm. Häfele’s Free Space has a capacity of up to 10.7 kg for 400 mm high flaps and allows for a very wide application range.

With intuitive and comfortable tension adjustment from the front, 3D flap alignment with generous adjustment ranges and an integrated opening angle limiter of 107° to 90°. There are also many other advantages for the furniture manufacturer with a compatible drill pattern allowing for fast installation, coming equipped with just one pre-set fixing screw. The plug-in pins on the base plate suit 1:1 the 32/37 mm line boring dimensions on the side wall and allow for a pre-installation of the fitting with just one hand. Mounting is made easy as front panels can be installed and removed in a quick and easy fashion without any tools. With feather-light operation and multiposition stop, Free space increases efficiency and saves costs along the entire value chain offering more stability and wide but slim line front panels. Overall logistically, less components reduce transport and storage volume, resulting in installation becoming less complex and more time efficient.

The Free space expands the already proven Free product family. The basic functions as adjustability of the tension force, integrated soft-close or ‘push-to-open’ are just a given as are high reliability and quality from the Häfele plant. • Modern compact design Minimal installation depth of 63 mm with an installation height of 172 mm noticeably leaves more usable storage space in the cabinet. • Optimised logistics and processing Less components reduces transport and storage space. At the same time installation is less complex and more time-efficient. • Self-explanatory adjustments Intuitive and comfortable tension adjustment from the front. 3D flap alignment with generous adjustment range. Integrated opening angle limiter 107º to 90º • Easy push-on mounting of front panel Front panels can be installed and removed quick and easy with toolless installation. • Compatible drill panel The plug-in pins on the base plate suit standard 32/37 mm line boring dimensions on the side wall and allow for a preinstallation of the fitting with just one hand. • High versatility in planning and production One model series with a sustaining capacity of up to 10.7 kg for 400 mm high flaps allows for a wide application range. ❚

Supplier March/April 2020

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Design & Trends

The House of 2020

op homes experts, architects and interior designers reveal what will shape the homes of a new decade

The 1920’s saw the introduction of two influences on Australian home style driven by post-war exuberance and a desire for modern luxury. Californian Bungalow design captured American glamour through glazing and spacious verandas, while the emergence of the European Art Deco movement brought simple, clean shapes and an easy aesthetic that would come to define the next decade. Almost 100 years later, the home design of the new 20’s may not be as ‘roaring’, but rather defined by energy efficiency, new building technologies and evolving design trends, according to experts from across the industry. A window into Energy Efficiency “Energy efficiency will continue to dictate building design in the 2020s. Research shows that up to 40 per cent of heat escapes from homes via windows, while double glazing can decrease heat loss by almost 30 per cent,” says Christine Evans, Marketing Director, Stegbar.

“Building regulations will continue to push green building, new technologies in glazing and improved product engineering

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and design. This will facilitate better energy efficiency within the home and reduce the reliance on artificial climate controls,” she adds A Hamptons Home of Our Own “The Hamptons style will evolve from its traditional classic blue and white into an Australian look that imitates its unique landscapes, with the additions of muted greens and mustards” says Principle at Indah Island and James Hardie Ambassador, Natalee Bowen. “We’re more informal than the ‘high-society’ Americans that created the look and that will come through more in the next decade. Linea Weatherboard will remain a staple due to its ability to cope with our climate, while elements of other design styles will be added to create different takes, from Hamptons-Scandi to Hamptonscountry, this will keep the look evolving into the 2030’s.”

Warmer Tones and Comeback Colours “The mid-century vibe will continue to make a comeback in a big way,” says Christal Fyentzou, Interiors and Design Consultant and Founder of Brisbane Renovation company, Zou Build. “We will see the return of neutrals and warmer, earthy hues in home designs, such as mustard, terracotta, and rusty, muddy colours that will work nicely to create sanctuary spaces.” Nostalgia has always been an influential force on trends, especially when it comes to the way we style our homes. 2020 Houses will see antique and contemporary pieces sit perfectly together, and achieve quirky, unique spaces that reflect their owners. A New Construction “The biggest trend going forward will be building complete sections of houses in factories and then taking them to site and connecting them together,” says James Hardie Ambassador and Architect, Joe Snell. This trend will likely see a move away from masonry so that factories can build complete sections of homes that can be easily transported.

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Design & Trends

reduce water consumption, and this can start with checking they have a good rating within the Water Efficiency Labelling and Standards (WELS) scheme.”

“No matter what size your outside space, you can create a beautiful backyard oasis for relaxing and entertaining family and friends. My top tip is to take time in planning and aim to create a functional outdoor sanctuary that makes the most of your space to create the perfect getaway from the everyday.”

“One of the biggest opportunities from this change is more quality control and more time in the design phase all adding up to less excuse for poor design and inefficient building. Houses will go more toward the ways cars are built and tested before being used and occupied.” Time to Change “The construction industry is set to go back into growth within the next 12-18 months, making 2020 the perfect time to re-evaluate how we build,” says James Hardie Product Manager, Christian Hansen. “The market we had, has created a fear of missing out as homes were snapped up. The decline gives home owners more time to build a vision and a brief for their property. At the same time, hungry builders are now more likely to respond to unique design requirements”. “In terms of looks, we’re seeing a rise in simplicity and reduced consumption, which is driving a trend for better designed houses. Clean lines and contemporary housing styles, such as Mid-Century Modern and Minimalist aesthetics will continue to rise in popularity as home owners try to escape the clutter and business of modern-day life. This translates into more open and livable homes, with a focus on comfort and style,” he concludes. Saving water without sacrificing your shower experience “The ability to be water-wise in our homes is crucial to a sustainable future”, says Nick Swan, Methven Brand Manager. “One of the easiest ways to be water efficient in your home is to have taps and showerheads that

Supplier March/April 2020

“Consumers need not choose between an efficient shower and a shower that feels good, which is why we have seen a rising interest in consumers requesting more efficient showerheads since the introduction of the fourth star to the WELS rating system. The WELS registry shows that Methven tops the rankings and continues to lead the market by providing the largest array of four-star rated products in market, which is a particular passion for Methven, to deliver amazing water experiences which don’t cost the earth” he continues. Making the Most Out of Small Spaces The size of an average house built in 2018/19 is 228.8 square metres, that is a 1.3 per cent decrease from last year. Often, this steady decrease in property sizes translates into backyard and entertaining areas that are smaller. Luckily, whatever sized space you have to work with, from vertical gardens to built-in furniture and water features, there are countless ways to create an exceptional outdoor room to entertain, relax and spend time with the family. “Australians love the outdoors but are finding it increasingly difficult to achieve the right balance between indoor-outdoor living, especially when you have less space to play with,” explains Jason Hodges, DIY Landscaper and Adbri Masonry Ambassador.

Live smarter with home automation Home automation is continuing to rapidly increase in popularity, with the smart home market worth approximately AUD $1.924 million this year, and household penetration expected to hit 41.9% by 2023. The adoption of smart home technology, such as Luxaflex Powerview Motorisation, for your window furnishings, welcomes elegance, convenience and safety to both your property and lifestyle. “Personalisation has moved beyond merely heating and lighting,” says Vera Meharg, Marketing Communications Manager, Luxaflex Window Fashions. “Homeowners can take complete control in the management of shading, temperature control, energy efficiency and privacy in their home, all of which can actively reduce energy consumption and amp up security.” ❚

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Design & Trends

Hidden New Zealand innovation used in Dutch Museum

he new Naturalis Natural Biodiversity Centre in Leiden, Netherlands, has used 11,000 Fastmount clip sets in its latticepanelled atrium, which is 36 metres high.

Designed by Neutelings Riedijk Architects in collaboration with fashion designer Iris van Herpen, the entire Naturalis project covers a total of around 38,000m2 of which 18,000m2 is of renovation and 20,000 m2 is of new construction. With the interior fitout completed by Harryvan Interieurbouw, the Naturalis used Fastmount panel mounting systems in the

atrium of the building to attach the panels without seeing the fixings. The panels that line the latticed 36-metre-high atrium are 18mm oak veneered MDF mounted to a 15mm MDF substrate, using a total of 11,000 PC-F1A + PC-M2H/PC-VMX sets from Fastmount’s Standard Range. “We needed solid and blind fixing off the wall panels, which we could easily program within the model/shape of the panels on our CNC machine. Fastmount has a wide range of hidden fixing clips, which fitted the job perfectly. At Naturalis in Leiden, we used 11,000 sets of hidden clips for the shaped

wall panels in oak veneer at the stunning Atrium,” commented Peter Dijkman, Engineer at Harryvan Interieurbouw. “The Naturalis project demonstrates how many of our customers these days are using CNC machining for their panels in large scale projects, and how seamlessly our clip systems can be integrated to speed up installation time,” said Gregg Kelly, Managing Director and Head of Innovation at Fastmount. Harryvan Interieurbouw worked closely with Fastmount distributor Kroon B.V. in the Netherlands for technical support and product supply. Celebrating its 15th year manufacturing world-leading hidden panel mounting systems in New Zealand, the Naturalis project shows how a product once designed for the superyacht industry has been able to tack into a new field globally with success, whilst maintaining product manufacture in New Zealand. Fastmount is an award-winning New Zealand company designing and manufacturing hidden fasteners specifically to service the marine, architectural, aviation and recreational vehicle industries globally. With boatyards in over 50 countries using the Fastmount Panel Mounting System, its exceptional performance in the marine sector has since attracted companies in the architectural, recreational vehicle and aviation industries to use Fastmount products. Fastmount’s global network of agents and distributors combines extensive experience in the marine industry and understanding of the architectural and interior design sectors. ❚

Design & Trends

2020 Kitchen trends for German kitchen specialist

otpunkt, award winning designer and manufacturer of green German Kitchen furniture, reveal the latest kitchen furniture trends ready to influence the future of kitchen design in 2020. “As we move into a new decade, it is notable there is a greater need for creative furniture design that empowers independence and sustainability for the home and end user. I predict this will challenge any preconceived notions about kitchen design to welcome highly progressive, eco-friendly kitchen schemes and a need to support broken-plan arrangements and more transformative lifestyles,” says Matt Phillips, Head of UK Operations, Rotpunkt. Eco-friendly kitchens: As we move into 2020, research shows that eco-credentials are a growing concern to the modern homeowner and Matt explains, “We are extremely proud that Rotpunkt is able to pledge a zero carbon footprint in 2020 by manufacturing 100% carbon neutral kitchens from 1st January. Our pledge for sustainable kitchen furniture manufacture in 2020 is just one way for you to ‘feel good’ in the home, reduce its carbon footprint and ensure the high street can serve this growing demand.” Ethical consumerism is set to grow as we want to increase the value of our homes by reducing its carbon footprint. Eco-friendly interior solutions are helping to create homes of the future, which in every respect are design oriented and inherently sustainable. “As we continue to tackle the debate on climate change, it is only right that we start to consider the provenance and environmental impact of products in our homes. Over the past decade, Rotpunkt has

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worked hard to position itself as best-in design and from 2020, their new kitchen solutions will set the tone for 100% carbon neutral manufacture that promises quality without compromise.” Consequently, premium hypernature door solutions are set to grow next year with super-realistic natural effect kitchen schemes replacing genuine raw materials without harm to the environment. “The construction of your kitchen furniture is a great way to be more environmentally aware, as different materials can impact not only how your kitchen looks, but also its weight, cost and carbon footprint” says Matt. Freestyle Industrial: Drawing inspiration from the professional kitchen and the growing trend for urban renewal where redevelopment of brownfield sites like factories and warehouses is keeping openplan kitchen design in the mainstream, industrial design will remain a key element in kitchens next year. 2020 will welcome industrial-style kitchens that take a more fluid approach to space planning, challenge routine layouts and consider the working relationship between furniture and user. Dynamic cube wall storage systems, feature

handles and unique metal, stone and wood effect doors with innovative surface treatments, will continue to influence furniture specification for those looking for an ultramodern kitchen space that is compelling and systematically designed. “Given the ever-expanding role of the kitchen, designers in 2020 will need to support the core elements of cooking, dining and storage as well as an ever-expanding list of ‘extras’ like home office space, indoor herb gardens, wine storage and independent freestanding solutions.” This freestyle approach to furniture design and kitchen storage will prompt a new level of creativity, which will benefit from solutions like Rotpunkt's new taller dimensions, cube storage and wall-hung system solutions that exploit different eye lines, visual weights and furniture capacities in one scheme. ❚

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Safety in the Furniture Industry

Feature

Story by Philip Ashley

very business must comply with general occupational health and safety regulations. The furniture and timber manufacturing industries also have specific OHS requirements to prevent risks to workers through the production process and to ensure that their products are safe for the consumer. There are also Australian Standards for machine guarding; cutting tools and product specifications just to name a few. Add to these the requirements for first aid, workers compensation and return to work rehabilitation for injured workers and it all gets complicated, time-consuming and expensive. However, if you are unfortunate enough to be confronted with an accident of other safety issue, you need to show that you have done everything humanly possible to avoid that incident because the investigators will be looking to blame someone. Many OHS investigators are ex-police officers and detectives and their job is to find fault. It is therefore in your best interest to know as much as possible about the products you are using; any published literature on their use; any regulation or standard available that relates to every part of your business. The business that can supply plenty of documentation about their safety systems and procedures stand the best chance of coming out of an investigation with a clean sheet. Dr Asli Tamer Vestlund was a past research and consultancy manager at the Furniture Industry Research Association (FIRA) in the UK, one of the most highly respected international industry institutions. You may not be aware but the Australian Standards for wood working machine guarding were

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Feature

based on the British Standards so FIRA has significant relevance. Dr Vestlund said, “The woodworking industry, which includes furniture manufacturing, has one of the highest accident rates of all manufacturing industries.” She cites accidents caused by contact with moving machinery as the cause of the most serious accidents, followed by issues related to manual handling, hazardous substances and noise. Whatever your business, equipment or materials you use, there will be regulations to guide you. It is essential that you consider the safety pyramid, also referred to as the hierarchy of control when dealing with safety issues. Your first action, no matter what you are doing and no matter what material is to try and eliminate the cause of the danger completely. It is justifiable to get another company to do whatever the process is, the

responsibility then rests with someone else. The second control is substitution, replace the machine, process or material with a safe alternative. The third control is isolation; separate the worker from the machine, process or materials you cannot avoid using. The fourth control is engineering controls where the equipment could be re-designed. This must be done by a fully qualified person and you must be able to prove his or her competence. The fifth control is administrative, and this entails signage, rotating worker’s jobs or education such as in-house safety training and meetings.

find yourself in hot water if you are ever investigated. PPE is available in many price points but if you are serious about the welfare of your people, it should always be of good quality. A good example are CleanSpace respirators designed by a medical device engineering team. The more obvious issues will be the equipment and the product as these are the items you see every day. The less obvious issues and arguably the ones that will cause you long-term concern are things like wood dust, respirable crystalline silica created when dry-cutting engineered (artificial) stone found in kitchen benchtops, and noise.

The sixth control, once you have considered one to five and as a last resort is for personal protective equipment, or PPE. If you give an employee a face mask or earmuffs without pursuing the other five controls, you will

Assuming you are unable to eliminate or substitute the processes and materials that cause these issues, and your employees are separated as much as practicable from

am ales-Te S r u o Call on today

35 1 1 0 0 3 1

Efﬁciency Slicing manufacturing costs with high-shear tooling

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29.10.2019 16:26:20

Feature

the source of these issues, you might find yourself looking at engineering controls and there is a lot you can do here. Specially designed particle extraction hoods from all types of cutting or abrading machines are available on some equipment. Low noise cutting tools (saws and rotating cutters like router bits) are also available with features that control dust or silicates.

The WorkSafe websites in each state have a lot of information on machine guarding, noise and control of hazardous materials. There is a compliance code for managing exposure to crystalline silica and you can download this for free. In fact, WorkSafe has a lot of information on this subject. As you would expect there’s a lot of general safety information including for noise but

for machine guarding you will need to visit the Standards Australia website and most of the standards there come with a fee. You can apply standards from other countries but if you are investigated you will need to show that the standard you are using is equal to or greater than the Australian Standard. In other words, you could need a lawyer to argue this. The bottom line? Don’t risk it. ❚

A sawdust-free wood shop? A wood shop free of dust is achievable with Dust Extraction Solutions from Leitz Tooling Systems. Leitz utilises dust flow control tool gullet designs (DFC) to neutralize dust velocity and trap it within the hood. Once the dust velocity is neutralized, Leitz aerodynamic dust hoods efficiently extract virtually all of the dust from the cutting process and send it into your dust collection system. Hoods are designed with easy tool access, and adjustable gate features, for ease of use and maximum encapsulation of the cutting process. Leitz dust hoods are also available with noise-cancelling technology, which reduces cutting related sound by as much as 5dB. Sawdust is not only a daily clean-up and downtime issue, but excess dust can also lead to serious consequences for your employees, equipment, facilities, productivity, and the quality of your products. The airborne dust within your facility is inhaled by employees, sucked into machine motors, and coats everything within the facility, all of which lead to serious health, maintenance, and safety issues citable by OSHA.

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cutting tools are engineered to eject dust into the cutting path of the tool, and most machine tool hoods fail to efficiently trap and extract dust from the cutting process. A large percentage of the dust simply flows in the airstream around the tool and is ejected back into the workshop.

Wood dust is considered carcinogenic to humans (Group 1) (IARC). IARC states that wood dust causes cancer of the upper respiratory system and is linked to health issues related to the inhalation of bacteria, mould, or fungi within the wood. Wood dust is also associated with toxic effects, irritation of the eyes, nose and throat, dermatitis, and respiratory system effects which include decreased lung capacity and allergic reactions. (Canadian OSHA 2017) Dust on the workspace floor can cause slip and fall accidents. Dust is also highly combustible and can cause catastrophic explosions resulting in employee injury or death and destruction of facilities.

Leitz has long been a leader in engineering custom dust control solutions which provide a clean and safe environment for employees, improve product quality, and optimise process efficiency. Whether you need to upgrade existing machinery, or have new machines in the budget, put our 20+ years of dust extraction engineering experience to work, ensuring the safest and most efficient tooling and dust extraction solutions possible. Eliminate a costly and potentially hazardous contaminant from your manufacturing process with Leitz Tooling Systems. ❚

You may have invested in the best dust collection system available, with automated gates and spark arresting technology, but the problem originates at the cutting tool. Most

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Cutting, grinding or polishing? Silica dust can be toxic from the first cut. Donâ&#x20AC;&#x2122;t risk it.

Protect the lives of your employees and yourself. Learn more at worksafe.vic.gov.au

Everyone | Every workplace

Feature

Are you a worker or an employer in the stonemason industry?

n the last year Victoria has seen a significant increase in workers diagnosed with silicosis and about 80% of these have worked in the stonemason industry. When you do things like cut, grind, drill or polish products that contain crystalline silica, it releases very fine dust. Some of the dust is so small you may not be able to see it. When breathed in, this dust can cause silicosis and other related diseases. These diseases don’t discriminate – they can affect young workers just starting out, tradespeople in the prime of their working lives and older workers looking forward to retirement. Those in the stonemasonry, construction and the extractive industries may all be exposed to crystalline silica dust. Benchtop fabrication workers are at higher risk because they regularly work with engineered stone; a product that can contain up to 95% crystalline silica. In response to the alarming silicosis rates, WorkSafe has developed a free silicosis health assessment program for all past and present workers in the Victorian stonemason industry. If you have worked with or still work with crystalline silica it is essential you have a respiratory health assessment. To register simply call the WorkSafe Advisory on 1800 136 089 (option 1, option 3) or email healthscreening@worksafe.vic.gov.au and leave your name and contact number. The health assessment program has helped identify workers who have silicosis or associated diseases, such as lung cancer and autoimmune disorders. Early detection of these diseases can lead to far better health outcomes.

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Since the program began in May last year, close to 700 stonemasons have registered for a free health assessment. Sadly, there has already been over 60 positive diagnosis (all data is accurate as of March 2020). A number of stonemasons are still progressing through the health assessment program – completion can take up to three months. WorkSafe is taking the necessary steps to ensure workers in this industry are provided with safe and healthy workplaces. The WorkSafe silica action plan includes an increased focus on compliance, enforcement, awareness and education. Some core outputs of the plan are designed to ensure WorkSafe can help businesses prevent this disease in the workplace and support stonemasons through the health assessment program. There is still a lot that is unknown about silicosis and its associated diseases. However, WorkSafe is committed to ongoing research to ensure they can provide the industry with the best support and knowledge. As part of their continuous support for the industry WorkSafe has introduced a fast-tracked claims process, support for workers throughout the assessment program (including psychological support for them and their families) and re-training for those who, for their own health, need to down tools for good and seek new employment. There are controls available to reduce exposure to crystalline silica dust. Ensure you and your co-workers: • use tools with water suppression • on tool extraction • wear fit-for-purpose respirators • carry out air monitoring • regular health checks.

Regulation changes The Victorian Government amended the Occupational Health and Safety Regulations 2017 to ensure workers in the stonemasonry industry have greater protection. Uncontrolled cutting, grinding and abrasive polishing of engineered stone with power tools is prohibited. The amendments came into effect on 20 August 2019. Make sure you understand the changes by visiting - worksafe.vic.gov.au/crystallinesilica for further information. New compliance code Victoria’s first silica compliance code ‘Managing exposure to crystalline silica – engineered stone’ is now available. This code provides critical guidance for employers working with engineered stone. It includes information to assist with compliance with the ban on uncontrolled dry cutting and how to monitor workers’ health. This code applies to all workplaces where engineered stone is being handled. If you are an employer, contractor, supplier or manufacturer please read this code and implement the required changes to your workplace. Contact WorkSafe for a free health assessment Please call the WorkSafe Advisory on 1800 136 089 (option 1, option 3) or email healthscreening@worksafe.vic.gov.au to find out more and register for the health assessment program. Further information Please visit WorkSafe’s dedicated crystalline silica webpage for more information www.worksafe.vic.gov.au/crystalline-silica. ❚

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Silica dust can be toxic from the first cut. Protect the lives of your employees and yourself.

Use tools with water suppression

Wear a fit for purpose respirator

Carry out air monitoring

Use on tool extraction

Ensure annual health checks

Learn more at worksafe.vic.gov.au

Everyone | Every workplace

Feature

CleanSpace respirators – protection from crystalline silica dust

tonemasons, amongst several other industries including construction and mining, still need protection against crystalline silica dust, however, the current COVID-19 crisis has made it increasingly difficult to source N95 disposable masks. CleanSpace Respirators are reusable, which means industry can continue to operate safely and efficiently, without supply shortages that could cripple operations or put workers in danger. Silica dust is harmful when inhaled into your lungs. It is 100 times smaller than a grain of sand, so small it can be inhaled without knowing. Respirable crystalline silica exposure can cause silicosis, a debilitating and irreversible lung condition that can cut short careers, reduce quality of life and lead to death. Respirable silica is also linked to lung cancer, chronic obstructive pulmonary disease (COPD), and kidney disease. When looking to protect yourself or your staff from any airborne contaminants, Powered Air Purifying Respirators (PAPRs), offer high and reliable protection, far exceeding disposable masks. CleanSpace Respirators are a revolution in the area of respiratory protection because while they provide all the protection of a PAPR, they a free from belts, battery packs and hoses making them more comfortable and easier to deploy. When used in hot or humid conditions CleanSpace Respirators provide cool, clean air to the user and eliminate fogging and moisture. CleanSpace respirators are light, easy to put on, reliably safe and comfortable. These smart powered devices are easily

Supplier March/April 2020

operated using a one-button smart system meaning more workers wear the respirator for a full shift every time. CleanSpace assists their clients to be safe and compliant when working around silica dust. Compared to disposable masks, CleanSpace Respirators offer high protection in a reusable device, that completely eliminates the cost of replacing disposable masks. Disposable masks are well-known for causing fogging and discomfort, leading to low compliance, frequent stopping and mask changes. To guard against silica exposure, state regulators have moved to recommending staff wear powered respiratory protection using a minimum of a P2 filter. CleanSpace respirators meet and exceed these requirements with a P3 filter. Regardless of whether you see the dust or not, silica is a hazard you cannot afford to ignore. Under the Standards, all worn tight fitting respirators, (regardless of whether it is a disposable mask or powered respirator), must achieve a correct fit to ensure the wearer is protected. Facial hair including; stubble, beards, moustaches and sideburns between the edge of a tight-facing facepiece and the face, will prevent the respirator from sealing properly.

CleanSpace offers both half face and fullface masks. The full-face mask also has a high impact rating. CleanSpace Respirators are compact systems that have up to 6 hours run time and fast/top up charging. “The feedback we get from teams wearing CleanSpace Ultra, full face mask for mining activities, is that the mask is comfortable to wear all day, and the cool fresh air on the face is a dramatic improvement on disposable or reusable half masks,” said CleanSpace CEO Alex Birrell. “They have also told us there is no fogging or hot moisture on their face.” CleanSpace Respirators are available in different models with a range of particulate and combination gas filters depending on the task requirements. CleanSpace EX is intrinsically safe approved and can be worn in potentially explosive environments. CleanSpace Ultra is IP rated 66, making it water tolerant and CleanSpace2 is the standard model suitable for those that do not require the aforementioned features. The newly launched CleanSpace HALO is designed specifically for laboratories and testing facilities. The CleanSpace Technology team of product specialists can assist with on-site product training, fit testing, trouble shooting and instructions on maintenance. With the renewed focus of regulators and the industry on silica, it is a great time to reevaluate your sites respiratory program and equipment. ❚

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YOUR DEFENCE AGAINST SILICA CleanSpace Respirators exceed minimum requirements for new QLD Code of Practice on silica dust exposure.

sales@cleanspacetechnology.com WWW.CLEANSPACETECHNOLOGY.COM

Software

Site measure to a 3D CAD drawing in a single step

e have all experienced the unenviable task of having to site measure a project using traditional methods with a tape measure, laser level and then transcribing the measurements on a note pad. Some of the questions we all ask ourselves during this process include; how much is the floor out of level, is the wall plumb, is the wall leaning back or forward, does it have a twist, how can I reach those angles that are 5 metres off the floor? The questions just keep mounting up.

urthermore, back at the office you still have to spend hours drawing measurements in your CAD software, only to discover that you have forgotten to measure the location of that waste pipe or those electrical cables. Well, Flexijet 3D not only makes site measuring easy, but also draws the 3D or 2D CAD model as you measure. Simply check the drawn model during your measurements and verify that you have measured all the relevant item; no more forgotten measurements. When you are done, simply export the model and email it directly from site to the office so that work can begin immediately. Flexijet 3D will work seamlessly with software such as Pytha, Microvellum, AutoCAD, PaletteCAD, SketchUp and anything that can import a DXF or DWG file. It has been fourteen years since the first Flexijet 3D Laser Measuring System made its dramatic impact. Site measuring in the

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joinery, shopfitting, window and glazing, stair and balustrade, stone masonry, architecture and many other industries around the world have seen outstanding improvements in efficiency and accuracy with the technologically advanced Flexijet 3D. Using a tape measure, handheld laser, note pad and making tedious MDF templates are now a thing of the past. Imagine walking away from a site measure with a complete 3D or 2D digital CAD drawing in less time and with an accuracy of 0.9mm. The Flexijet hardware feels natural to hold and operate with user friendly controls. The most striking feature is the 7" touch screen which provides direct access to the most common CAD commands rather than having to access the FlexiCAD software on the nearby laptop. The CAD drawing is created as you measure in real time, which makes it easy to see any missed measurements. Drawing curved walls, pipe penetrations, bulkheads, windows, doors, niches etc are no problem for Flexijet 3D.

The device can be relocated using reference points, so whether you are measuring a small area, an entire room or even an entire building spanning multiple levels, Flexijet 3D has the ability to accomplish these tasks with ease. The inbuilt shock sensor will warn you if the device has been accidently kicked and the integrated WiFi provides reliable communication between the hardware and software on the laptop. Setup only take a few moments and the auto levelling feature ensures that your measurements can commence in no time, after which the system can be controlled either manually or with the internal motor via remote control. Flexijet 3D is not only an innovative measuring device but can also aid in on-site installations and set outs. Simply import a DXF CAD file into the software, click on a CAD point in the drawing and Flexijet 3D will rotate and the laser will precisely point to the corresponding position on the work site. Honoured with the German Federal Award for Excellence in Innovation in 2011 and the RedDot Design Award 2018, Flexijet 3D will not only improve your accuracy and efficiency, but will elevate your site measuring to the next level. â?&#x161;

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Software

Interior Design & Production Software

Clever Customisation From CAD+T Celebrating 30th years in the furniture production and interior design market this year, international software developer, CAD+T specialises in creating highly customisable software solutions for three and five axis CNC machines. “One CAD/CAM software package does not work for all and that is why our CNC software packages don’t work off a preprogrammed database system,” begins Martina Schwarz, International Sales and Marketing Manager at CAD+T. “Instead, we work with our customers to create flexible and bespoke solutions that will work specifically around our customer’s business model. This may depend on the nature of the business and its production rates, the machinery and tools in place and the materials being used.” CAD+T’s clever CAM Interface separates components and automatically generates CNC data from the customer’s construction drawings. A database of milling strategies, machining parameters and tools generate the machine files needed to complete the job, which in turn, creates a solution that doesn’t require the programming or reorganising of CNC data. In short, this means you can wave goodbye to timely manual programming, generic system inputting and the need for an experienced software programmer. Martina says, “It really is the next generation in CNC software and has been created to dramatically simplify our customer’s manufacturing processes and streamline production processes and material output.”

This software been designed to be quick and easy to implement into your business, by simply working off material specifications resulting in huge time-saving benefits of around 60% per order. It also offers a reduction in error prevention of up to 80% and with the added benefit of being able to run one software package on several CNC machines, saving you time and money throughout the production cycle.

“It really is the next generation in CNC software and has been created to dramatically simplify our customer’s manufacturing processes and streamline production processes and material output.” Martina adds, “Our adaptable approach to software design allows us to analyse the production process and create effective software concepts that work around our customer’s most challenging requirements. This is what separates CAD+T from other software developers. 90% of our customers in Australia and around the world work on CNC machines, with a growing trend towards 5-axis work. It’s a very important market for us and due to demand, we’re continuing to invest heavily in ongoing research and product development in this area. We work closely with our customers and we’re not afraid to talk to people in the industry to find out what they need. This approach has led us to create a wealth of problemsolving solutions that have been proven to be advantageous to the furniture industry.” ❚

Complete software solutions for the furniture design and manufacturing business

Specialized for bespoke furniture CNC connection in less than a week Complete ERP system

CAD+T Australasia Pty Ltd Level 5, 23-25 O‘Connell Street NSW, 2000 Sydney Phone: +61 (2) 800 620 67 E-Mail: office@cadt-solutions.com Web: www.cadt-solutions.com

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)

GREG TASKER, MANAGING DIRECTOR

MITCHELL BLACK - PRODUCTION MANAGER

“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) Factory and Office Size m2

800 square metres approx.

Years in Business

# of CNCs

Associations and any positions held

FIAA

Geography Serviced

Sydney mainly

Staff Groups Tracked on Empower

Staff Times on Jobs Recording prior to Empower

Factory staff manually recorded their times on jobs daily

Factory staff, pre production staff in office and site workers

Years using Empower

3 years

Years in Business

Associations and any positions held

Housing Industry Association

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

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

FACTORY PRODUCTIVITY & JOB SCHEDULING SOFTWARE

BE IN TO WIN FREE EMPOWER FACTORY PRODUCTIVITY AND JOB SCHEDULING SOFTWARE!

Email your company name and contact details to vicky.cammiade@elitepublishing.com.au for your chance to win. Conditions Apply.

Software

3D software - The right software for your business

hat is the big question that faces most cabinet makers at some stage. This decision point arrives at varying times and for varying reasons. • Perhaps you are just starting your business and would like to include software from day one. • Your business has been operating for 5 years, staff members have increased and your workload is far too heavy. • Your business is now 10 years old, is well established, but you or a staff member are taking too much time to get jobs organised for production. • Your customers are now asking to see some 3D prints of their project. • You have been trying to employ another tradesperson, but have not been successful. These are just a few of the issues that arise and will prompt you to consider a software program. At these points some businesses have researched the software issue and discovered that it is very good decision to purchase.

Why then have some businesses been reluctant to go down this path? Let's start with the obvious reason, cost, they feel they cannot justify it. Nothing could be further from the truth. Quality software is now available for as little as $19 per day (and that is for the top-level Pro Toolpath CNC linking version, much less for lower versions). So, around $6.50 per day will give you a full design package, costing, cutting and optimising. You simply lay out your floor plan and from that point create 3D views for your client, fully dimensioned 2D views for your workshop, optimised sheets for cutting and cabinet parts lists for construction. A job cost has also been created based on your labour times and material costs. There is a conservative 3 hour saving in the office preparation, 2 hours in the workshop and an hour on site (all cabinets and their parts are numbered automatically). As you can see the program has well and truly paid for itself in labour saving alone.

At this point some businesses dig their heels in and say - “no I can't afford to pay out another cent”. This is where the head must rule. That $6.50 is already accounted for in their current production methods; it is being spent many times over. A software program not only decreases your production time, it also helps you to eliminate costly mistakes. How many times has a number been written in the wrong sequence, and not discovered until it's too late? Another reason that is mentioned for not wanting to purchase software is that a business custom builds and customers are concerned that computer programs will not be suitable. A quality program will give you the ability to set your construction methods and allow you to change your methods to suit architectural requirements. Support is a big issue with all cabinet makers, who feel if they purchase software, they will be left in the dark or have to pay out for costly training. With all software It is vital that you receive good backup support, phone and remote assistance must be provided in the initial cost of the software. There should be no need to sign up for yearly maintenance. You purchased the program and as such this should be included. One of the big dislikes for most cabinet makers is the quoting process. It can be a very

Supplier March/April 2020

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Software

is made on a couple of doors, this can now cost you over $100. With a software program you can quickly and accurately quote this situation.

time-consuming task. The simple fact is that you must produce fast and accurate quotes and unfortunately as our industry has always offered free quotes, clients expect this and don't understand all the variables that are now possible in even the simplest kitchen. “Please provide a quote with three different door finishes, and three different drawer styles. Not to mention the bench tops and the internal fittings”. If a miscalculation

Simply place the required cabinets on the floor plan (no need to do a finished layout) add any accessories, generate a cost, then generate a different cost with any material. Software for cabinet makers has reached the point where you can now ask, when will we purchase a program, not will we purchase a program. You can no longer afford to be spending wasted hours doing job preparation. Consider the software as another

production tool, the same as your existing machinery. The 3D kitchen program has been in the market place for over 26 years and has a well established client base. The software is provided in a way that all cabinet makers will understand and is supplied with construction methods set up to your individual requirements. If you have reached the stage in your business where you know that things need to change, you will want to consider the 3D Kitchen software option. Operating a cabinet making business can be a very demanding task. You need to take advantage of anything that is able to assist you. Software is now a high priority on the list. ❚

Lincoln Sentry and Finista Finish with Style logos are registered trade marks of Lincoln Sentry Group Pty Ltd.

Italian style for any space with Finista Slim Finista Slim aluminium system brings a touch of Italian style to any room. Whether used in a modern wardrobe where all is on show or commercially for display, Finista Slim can be customised to suit any application. Create the perfect solution for your space with a range of accessories available to add shelving and drawer banks. Italian designed and manufactured, Finista Slim’s lightweight construction makes it easy to handle and simple to install. Available in 3 metre lengths in matt black or anodised aluminium finishes. w: lincolnsentry.com.au t: 1300 551 919 e: orders@lincolnsentry.com.au

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Software

Master Cabinets testimonial

aster Cabinets has been supplying quality cabinets to the building and retail industry since 1988. The company has seen the booms and busts associated with the WA economy while maintaining a steady course through it all. Walter Ferrari, more affectionally known as Wally, was always one to look for better more efficient ways of doing things. Wally, an early adapter of leading technology and one to invest wisely, purchased a Homag CNC machine and Cabinet Vision software in 2007. This allowed for a substantial boost in productivity whilst highlighting other constraints associated with the manufacturing process. Before long, it became evident that Master Cabinets needed to consolidate their multitude of excel spread sheets and documents into one system. They identified the need to embrace new technologies that would efficiently manage their day to day processes and requirements. After careful consideration, Jobman was awarded the ERP system for Master Cabinets. Master Cabinets has shone through adversity all the while winning many awards. Proudly customer focused, with a strong commitment to quality, Wally’s business has grown at an astounding rate. “The journey over the last 30 years has been a great one and the last 5 years has been a massive one,” says Ferrari.

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and procedures we have put in place,” says Ferrari.

Above: Walter Ferrari (left) and Alex Dudek. The purchase and integration of Jobman has allowed Wally to focus more on the business by relieving him of daily tasks such as quoting. Jobman streamlines processes such as purchase orders and job scheduling resulting in exceptional job visibility and control over all aspects of production. Efficient practices facilitated the purchase of a second CNC machine and the installation of new offices for Wally’s admin staff to meet increasing demands. “The highlight for me was that once we started using Jobman properly it was so easy for everybody to know where everything was at a certain time,” says Ferrari. With his order book consistently full, builders knocking at his door, the purchase of a stone company and no room to expand, the decision to move was eminent. The move to a much larger 2500m2 factory had to be assessed financially with minimal risk. Justifying such a move in the middle of a fragile market, when many WA cabinet shops were closing their doors, meant that Master Cabinets were doing something that their competitors were not. “I have seen a lot of growth and improvements with what we are doing especially because of Jobman and the systems

Alex Dudek, general manager of Master Cabinets, has been instrumental in the business’s success. “The Target Calendar provides us with the ability to have an oversight of where every project is without having to go into different programs and get lost in a maze of excel documents,” explains Alex, now a shareholder in the business. Alex finds his role rewarding and believes that having the rights tools at his side assists him face challenges as they present themselves. “Jobman has given us the ability to provide something extra to our clients that we couldn’t previously. When someone calls up or receives an email trigger knowing that their job is complete or the maintenance is complete or knowing they will have their quote within 3 days they can relax knowing they are in safe hands,” explains Dudek. Line managers equipped with real time reporting are able to identify a problem and have the necessary tools to report/provide solutions in time sensitive constraints.“It’s easy to sit back and worry and be scared of change, but when you see the benefits that it brings, it’s always, why didn’t we do that sooner, why didn’t we adapt and change?” says Dudek. “For anyone serious about improving or taking their business to the next level contact Jobman,” says Ferrari. “It is a pleasure to be able to help support such a great company and provide the necessary tools to achieve such success.” Aaron Crees, Jobman Director. ❚

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Software

Kitchen manufacturing – How we got through a tough year

upplier Magazine recently sat down with Mark Davis, Managing Director of Woodshack Kitchens, to discuss how his kitchen manufacturing business benefited when they began using Empower Factory Productivity and Scheduling Software in 2018. Mark explains, “In 2018 and the start of 2019 we were building high quality kitchens but essentially making two fundamental business mistakes. Firstly, we were under quoting the budgeted labour times on jobs and secondly our actual time on manufacturing and installing kitchens was taking longer than the labour we had budgeted in our quotations. It is accurate to say that these two problems at the same time caused us to haemorrhage financially. I thought we were being thorough, having our factory staff record their job times manually on time sheets and then we put these times into our job costing program. I used manual time sheets because that is what I was familiar with in my time working as a joiner on the factory floor, but in saying that I was well aware from when I used to fill them in, they were highly inaccurate. I estimate 40% inaccurate in job times recorded and the job cost report was typically 1 to 2 days after production occurred which was pointless. Other issues with manual time sheets include the fact they did not motivate our factory staff to work any quicker and because the times recorded on kitchens was so inaccurate, I could not refine the accuracy of budgeted labour in my quotations.” “Whilst using manual time sheets I was manufacturing entirely blind to my largest, most variable and most uncontrollable cost, my labour cost. In hindsight using manual time sheets was a very poor way to manage factory staff.”

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1 Our staff using factory floor tablets became patently aware of the labour times we had sold and budgeted parts of the jobs accordingly. 2 Staff using their factory floor tablets became aware of the time they took on each part of each job, immediately after they finished. Mark explains that in mid-2018 his company investigated advancing to using tablets on their factory floor, along with factory productivity and scheduling software, that would schedule and track jobs and staff live. He was aware of local progressive kitchen manufacturers and commercial furniture manufacturers in Christchurch who had been using Empower Software for many years and spoke highly of it. They also knew Empower Software had been developed for kitchen manufacturers and had been in the market place for many years. In going through the due diligence process very quickly Mark and his team could see the obvious advantages of using this technology.

3 As factory staff became fully informed about job times, they were able to complete their jobs much quicker and on budgeted time.

Woodshack Kitchens commenced using Empower Factory Productivity and Scheduling Software in August 2018. They set up a wireless network in their factory with two routers and two tablets on the factory floor for staff to access their jobs and be able to log on and off. They also set up one 50-inch TV monitor on the factory floor for all staff to see their jobs with both budgeted and actual job times live throughout the day. The team at Empower sent a highly experienced kitchen manufacturer to Mark’s factory and set up the software in one day.

7 Likewise, all rework and variations are tracked on Empower, which is managed tightly.

Mark says they witnessed the following changes to their business relatively quickly:

4 I could see job times live from the factory floor both in my office and when I was out on site via my tablet. Job times reported were accurate to the minute. 5 With the same amount of factory staff and hours worked we increased our weekly production up by 20% to 25%. 6 We now schedule and track jobs accurately in Empower, which is managed closely.

8 Empower reporting also helped us understand when jobs were not profitable and enabled us to adjust our target market accordingly towards more profitable work. Empower is simply an App available on subscription for a low weekly cost. Mark concludes, “The earth would freeze over before I would go back to trying and failing to manage nine factory staff and their time on jobs manually.” ❚

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Talking Business

Pushing Boundaries with Holz-Her

L Installations is a construction group located in Melbourne’s West. Their work is mostly for tier-one builders such as Multiplex; Schiavello; Built; Shape; Cod Build and others. They specialise mostly in feature walls and ceilings, and bespoke joinery items. Luke Lawry is the director and says, “We never do the same thing twice. The more complicated the work, the better we like it.” Luke is sold on Holz-Her as his machine of choice; he currently operates a Sprint 1327 edgebander and has just ordered a Dynestic 7535, a 5-Axis CNC machine due for delivery early next year.

needed a factory to produce some of their own products. They installed a panel saw ‘package’ that included a small edgebander, but this proved to be unsatisfactory. Luke says, “It produced an inconsistent finish, we can’t afford to have any product that doesn’t measure up to the high standards our customers expect. A few years ago, we decided to get a decent edgebander.” Over the last few years one factory has grown to five, but these will all be consolidated next year when their new building is complete. The new Holz-Her Dynestic 5-Axis machine will be installed and a new stage in LL Installation’s history will begin.

Luke is a young 39 years of age and jokes, “Sometimes I feel older” but despite this occasional feeling, he says, “We don’t mind being under pressure, we like tight deadlines. We have our own niche market and the type of work we do for high-end builders demands that we have good machinery. We’re always pushing boundaries with the various materials and processes we use. Our machines need to be up to the task, our reputation depends on it.” Luke started out in Bendigo building kitchens and as soon as he finished his apprenticeship, started out on his own with Hillcrest Furniture and Cabinets, a business his father still operates. In 2002, after a year overseas, he moved to Melbourne to capitalise on the multi-billion dollar building boom, establishing the Lawry Group, trading as LL Installations. The group operated for many years without a factory, working for companies like Charles Tims; JFK Interiors and Built, installing acoustic panels; structural steel joinery; external cladding; signage and other work. Relationships are the key About six years ago Luke decided they

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The more complicated, the better. Luke continues, “The Holz-Her edgebander is a stand-out machine. I did look at other brands, but I couldn’t ignore the references I was getting from other users who had a Holz-Her for many years and never had any trouble with them. Recently, Luke came up with an idea to apply 2mm solid timber to a box aluminium extrusion of up to eight metres in length. He’d noticed long timber parts in buildings that had bowed and distorted and said, “I’m not going to make that mistake.” Luke believes in relationships, both with his customers and his suppliers. Some of their work such as polishing, and powder coating is outsourced, and he’s used the same companies for the last ten years. Most of his 60-plus employees have also been with him that long. His relationship with Weinig Australia is also based on a working relationship that he regards as excellent. He says, “Their sales guys have a lot of time for you; their technicians are here when I need them and if I need them to come and help me with a new process, they’ll be here for that too.”

The ‘tenderised’ 2mm wooden edge strips come in 50-metre rolls from Germany and fit right onto the Holz-Her. We love their cartridge system for our PUR adhesive we need to bond to aluminium; the edge the Holz-Her puts on is premium.”

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Talking Business

Their new Dynestic 5-Axis CNC machine will be capable of handling 2200mm wide and 300mm high workpieces. The Z axis stroke is about 560mm which is standard for a rail and pod machine, but generous for a flatbed nesting machine. It will have a variety of vacuum pads for workpieces that need to be raised above the table, and a special ‘Atemag’ soft cutter pro aggregate, a reciprocating jigsaw for cutting insulation. The machine also has an overhead projector for pad and workpiece positioning, and a special laser line projector for manual cutting operations.

Luke says, “Weinig had never seen this done before but sent out a technician to help us set it all up. We rough up the aluminium on the sander and use PUR adhesive to apply the 2mm edge. The finished product looks just like a long, solid timber section but it’s 100% stable. We used this technique in a recent project at the Victorian State Library where we completed the new children’s quarter and loft as part of the governments Vision 2020 redevelopment.” Some of their other noteworthy jobs are Bunjil Place; all the timber veneer you see on the walls inside the Foyer and Theatre was sourced from a single massive blackbutt tree, saved by a sawmill in Queensland. Capitol Grand is an inspiring wave-form architecture designed by renowned architects Bates Smart and will be the tallest landmark building outside of Melbourne CBD. Timber veneer work and feature staircases at AGL headquarters and the solid aluminium façade at the Donald Whitehead building at Latrobe University are two more stand-out jobs completed by Luke and his team. LL Installation’s work is ‘design and construct’ where an architect will prepare a preliminary design and a contractor will complete the design and construct the project. In this case LL constructions as the contractor will take on the risks in the construction. While it may be possible to alter everything outside the overall shape and specifications, resulting in possible savings for the contractor, Luke is focused on meeting all quality and construction standards. Luke’s next machine will be a Dynestic 7535, 5-Axis CNC machine he saw at Ligna this year. He says, “It is not the cheapest machine, nor is it the most expensive, but the supplier’s service and reputation are second-to-none. It only takes one bad job to affect your business, so a premium machine is essential. We recently had to cut six thousand angled pieces on our panel saw and it took us a month! We expect the Dynestic would have done it in less than a week; it’s going to save us a lot of time. We’ve been working six days a week and for a few months, 24-hours a day and that’s not good enough.”

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“We like doing work others put into their ‘too hard’ basket. Feature walls and ceilings, anything that’s not straight forward, jobs we can sink our teeth into. We don’t ever want to just churn stuff out. We want our work to be admired so we depend on the best people and the best machines. We’re very happy with the Holz-Her product, it suits our diverse needs very well. On most jobs we’re pushing boundaries in materials and construction and our equipment must be up to the task. With HolzHer, we have a partner we can depend on to provide the machines we need, and to back that up with the support and service we demand.”❚

DYNESTIC SERIES Nesting technology for perfect formatting

The nesting CNC machining centres from HOLZ-HER enable you to machine and cut panel materials with optimised cutting patterns and minimum waste. With nesting technology in a gantry design, the DYNESTIC series expands the limits for nesting technology to new dimensions. The automation components for unmanned material handling make the DYNESTIC series even more efficient. Contact your local HolzHer Expert for further details and to register your interest for a live domonstration.

Michael Weinig Australia Pty Ltd 3 Widemere Road Wetherill Park NSW 2164 1800 736 460 sales-australia@weinig.com www.weinig.com.au

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Manufacturing

Rising Above Adversity

TJ Interiors is a company built off the sweat of hard-working migrants. They’ve been in business on the same site in Unanderra near Wollongong for sixty-five years. The company has grown from humble beginnings to become one of the leading manufacturers of commercial fit outs in Australia. The company now uses advanced technology including Biesse CNC processing centres and (Biesse) Viet sanding machines to produce their interior joinery. They bought their first Biesse machine in 1995 from Allwood Machinery and have enjoyed a profitable relationship with Biesse Group for the last twenty-four years. Paul Van De Haar is the Managing Director of the third-generation family business. He is ably assisted by his wife Alison, General Manager Alex Beccari and Factory Manager John Jessup. His father Hans is semi-retired now but still helps out when he can. They currently have four Biesse machines; three CNC processing centres and a Viet wide belt sander they bought earlier this year. Their technology is very important to their business that’s built on their ability to supply trades-like quality to their customers, generally large tier-one builders. Paul says, “Quality is something that’s made correctly; it’s the tradespersons attention to detail, you know when it’s right. Our Biesse machines produce the trade-like quality we expect.”

purchased land from Wollongong council. On the weekends Johannes caught the train down to Unanderra where he built a garage on the property. Nine months later the family moved into the garage that doubled as their first Australian home.

by trade, was contracted to build three prefabricated homes in Holland, ship them to Australia and erect them in Canberra. Things didn’t go quite as planned and for one reason or another the ship carrying the prefab houses and his machinery was delayed and Johannes was left without a contract, his machinery and the pieces of his prefab houses.

Johannes worked for a few years as a carpenter while he built his first factory on the site and in 1954 started out making joinery for housing commission homes, and windows for the local schools. One problem he had was getting building materials that were rationed at the time, so he started his own hardware store in the main street of Unanderra that still exists today as a ‘brother’ company. These are resourceful people who always find a way to get the job done.

Johannes, Alida and their three young children moved to Leura in the Blue Mountains and started looking around for what to do next. Johannes saw Wollongong and its proximity to Port Kembla with lots of housing commission homes being built for the migrant intake as an opportunity and

Over the next three decades or so Unanderra Timber and Joinery grew to be one of the leading joinery shops and shop fitters, doing commercial bank fit outs, shopfitting and high-end homes in all parts of Australia and internationally. Owner Hans Van De Haar once said “We won't be one of the big boxes.

Early Days It was the early 1950’s and the world was still recovering from the Second World War. Johannes and Alida Van De Haar had come out from Holland as migrants looking for a new life. The Australian Government were actively seeking skilled trades people to build the country and Johannes; a carpenter

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Manufacturing

An example of how Biesse group was able to provide a technical solution for a UTJ manufacturing ‘problem’ was on their fire doors. John’s experience is that fire doors are hardly ever true and that a machine working with reference to the machine table will produce varying results on the doors. Biesse’s solution was to provide a floating head that sits on top of the door while it’s cutting and produces cuts at a consistent measurement from the surface of the door. John believes this is one of the first times this solution has been provided on a CNC machine in Australia. We want to create a different experience.” But in 1989 tragedy struck and the factory was mostly destroyed by a fire that started on a long weekend. They were uninsured and Johannes and his son Hans had to rebuild the factory by themselves. Today you can still see parts of the structure that remained from before the fire. It’s an unusual factory, built on a slight slope with ramp access to the various levels. Johannes grandson Paul was in the second year of his carpentry and joinery apprenticeship at the time and recalls the low technology every company had to work with. He says, “We used to draw the jobs out on a set-out rod; a piece of board or on the concrete floor and measure the job off that.” Back then they made doors and windows and shop fit outs for banks, restaurants and top-end private homes but now it’s mainly detailed commercial joinery and specialist veneering for the biggest Tier-one builders in Australia. A big change in their equipment came in 1995 when they won a contract for the Star Casino in Sydney. UTJ Technology Standard machinery wasn’t going to get the job done so they purchased a Viet wide belt sander and a Biesse A-Framed pod and rail CNC machine. Both machines performed way beyond their expected lifespan. The Viet sander was only replaced with another one earlier this year. Paul remembers the CNC

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machine immediately made the factory a safer place to work. “My grandfather lost a few fingers on the spindle moulder. I can still remember several times, the cutters coming out and flying across the workshop!” UTJ now use a Rover C9 nesting machine that’s still running strong after fifteen years; a Rover B FT nesting machine with autoloader and labelling; and a recently-purchased 5-axis Rover A they use for anything from edgeprocessing panels for concealed hinges, locks and door-track systems, to stair stringers. Paul and his factory manager John prefer the Biesse brand for the easy-to-use software used across their machine range. John said, “The familiarity and user-friendly programming is very important to our operation; our employees get the machines working very quickly. We love the simulation the Biesse bSuite gives us, it’s a true WYSIWYG (what you see is what you get) representation and it really gives us confidence that we’re not going to damage the machine. The work we program is what’s going to come off the machine table, exactly as we expect it would.”

Paul says, “Our co-operation with Biesse starts when we identify a need for some new technology, or we need to alter or improve our manufacturing. We know what we want to achieve and the people at Biesse are very proficient at helping us with a solution. We look at other brands of course, but we think Biesse is better than the competition in many ways. When any new machine arrives, the delivery and installation has always been faultless. The process is always exactly what they said it would be; there are no surprises.” Paul is particularly impressed with Biesse’s service and response to any problem he says can happen with any machine brand. “When we need a part or have a rare breakdown, they (Biesse) jump on it,” he said. UTJ’s future has yet to be written but one thing is certain; their investment in their Biesse technology will be a big part of that upcoming history. Paul, Alex and John keep their eyes open for any opportunity to do a better job and secure their future. Working for tier-one builders means that your work must always come off the machines at a consistent, trades-like standard and UTJ’s Biesse machines ensure their customers are never disappointed. Throughout their history UTJ has risen above adversity and found a way to always get the job done. They don't stop halfway; they don't take short cuts; they get the job done and they do the job well, with Biesse as their partners in technology. ❚

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Manufacturing

Biesse transforming businesses “We look for technology that makes our processes easier and provides a competitive advantage and Biesse certainly does both those things.” Tom Acquroff If you look at any two businesses, time is always a great resource for measuring culture and aptitude. Measured over the space of a year, a business with a poor culture may look virtually identical to one that encourages intelligence and innovation. But measure the difference over the course of a lifetime - or in the case of S&A Stairs, 100 years and the difference is exceptional. A business that has a culture of learning and invention. One that values intelligence, family and craft will be so far ahead of its neighbor that it is not worth comparing the two. That is the story according to Slattery & Acquroff. Once a tiny local stair builder in a small suburb of Melbourne that serviced the high-end market in the inner eastern part of the city. Now Australia’s only national stair builder, making and installing stairs in more than 9000 homes a year. It is no coincidence that the rise in S&A’s inventiveness and growth correlates closely with their 25-year partnership with Biesse. A relationship that has seen S&A implement the first five axis CNC machines in Australia and then all but master the technology in the years that followed.

a generation ago. Largely, it is thanks to a culture that champions innovation, always invests in the newest machinery and importantly, people with the intelligence and dedication to program those machines. In the programming area, S&A Stairs have particularly excelled, carving out an idiosyncratic design and manufacturing that - to stair builders around the world - looks as much its own brand as Audi or Volkswagen does to people who collect cars. According to National Development Manager Tom Acquroff, S&A’s thirst for innovation is a lived culture, rather than something they have enforced. Thanks, in part, to Tom’s forefathers. “When the Great Depression came along, my great grandfather and his business partner would pack up a wheelbarrow and then walk everything to site. Sometimes in the next suburb.”

At the time, Ted Slattery and Alec Acquroff, two migrants from Scotland, had gone out alone and rented abandoned horse stables in the back streets of South Yarra. When times got tough, they spent the last part of the 1920’s doing whatever they had to do to survive. In the 1960’s, during the post-war boom, they became the stair builder of choice for Australia’s most beloved midcentury architects. “We had a very cosmopolitan workforce,” says Tom. When they needed new staff, S&A found an incredible resource in migrants from Europe, Germany and Italy who completely changed the skillset and culture of S&A. “We developed this new culture of quality and ingenuity, and many of those families who started with us in the 1960’s are still permeating through the business today. They are the second and third generation families that are the lifeblood of our business.”

Today, in factories around Australia, S&A Stairs are doing things that many furniture makers and stair builders haven’t even imagined, taking mere minutes to make pitched handrails, cappings, scrolls and wreaths that would have taken weeks just

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Manufacturing

By implementing CNC technology from Biesse, they became known for their ability to manufacture highly complex stairs at scale, something they’re still renowned for today. The new Biesse CNC machine cut lead times dramatically and improved the quality of the work. In the decades since, S&A Stairs have become a national business that supplies 8 out the 10 biggest residential builders in Australia, with 14 Biesse CNC machines across Victoria, New South Wales, Queensland and South Australia. “The Biesse CNC machines make a unique product very quickly but more important to us, very consistently,” Tom says. "We have to work to the timelines of major builders and with Biesse, we know what we are going to get. Stair making is a highly complex business, but it is intensely rewarding.” While furniture making is a repeatable game, the stair making process is, for S&A Stairs, still largely custom. 35% of S&A’s output is still for unique, custom stairs, so the challenge is to make bespoke products with both precision and efficiency. To achieve their unique set of production constraints, S&A Stairs rely on the Biesse Group to supply machines that can produce complex and unique components quickly, while maintaining the standards that the business has set for their customers. It is this attitude that pervades today, says Tom later, when recalling the story of his great grandfather. A unique work ethic and company culture that demands quality has seen S&A expand into Australia’s only national stair builder. Tom says it’s a way of protecting yourself from your competitors. “Quality is our point of difference. Quality and complexity are the tools we use to create barriers to entry. Innovation is safety.” But while there had always been a strong culture for craft at S&A, the thirst for technology developed later. Led by Tom’s father, Robert Acquroff, and current managing director, Robert Beard, S&A began working with Australia’s largest home builder in the early 1990’s, Henley Properties. Before long, they realised that a family business with 20 or 30 staff was desperately under-equipped to deal with the kind of quality and scale that Henley demanded. Tom remembers his father visiting William Russell Doors with Rob Beard, where they saw their first Biesse CNC machine in 1996. Rob famously remarked, on first look, that the machine was very impressive, but doubted it could be applied effectively to stair building.” Six weeks later to the day, they bought their first Biesse CNC machine from Allwood Machinery on the advice of Richard Lees from Spence Doors. It is widely recognised that Allwood and Biesse changed the landscape for furniture manufacturers in Australia, and with the purchase of their first machine, S&A were about to become a big part of that change. Over the next two decades, S&A Stairs became not only the biggest but the most well-regarded stair builder in Australia.

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FOR SALE

Wide Belt Sander 1350mm 1350mm wide belt sander, in excellent condition and very low hours. All with variable speed by inverter. Perfect for veneer and painted finishes. The specifications of the sander starts with a chevron cross belt, followed by a steel drum roller for calibrating, then a rubber drum for standard sanding and ends with a chevron belt with segmented pads for super fine precision sanding. CONTACT M 0411 604 603 E norman@morticeandtenon.com

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Manufacturing

“Biesse has transformed our business. We currently build and install 150 stairs a week, from split-level stairs to those in Toorak Mansions. With the consistent product produced on the Biesse CNC machines, our time spent installing stairs has been reduced enormously. We are not a Toyota production line; we are still artisans, specialists, and the Biesse product fits our needs very well. We are cross-material specialists using a range of Australian and imported hardwoods, softwoods, stone, acrylic, glass and stainless steel,” Tom said. S&A Stairs use many forms of software including AutoCAD©, 3D stair software and freeform 3D modelling software and they all interact with the Biesse CNC machines. “We also use bSolid for our 5-axes machining. It is a visual process that simplifies the set-up for our most complex parts. Some

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components that took several hours to machine are now made in as little as twelve minutes!” Tom continues. S&A have stuck with Biesse because they provide a good mix of hardware and software. “It is a mix that has really worked for us.” Tom Says, “It appeals to us from a value proposition. The ever-improving service is fundamental in our decision to continue our long partnership with the Biesse Group. One of the hardest things to achieve is high quality at scale. High quality at low scale is achievable due to our talented individuals. High volume without detail is achievable through processes and machines. High quality and scale are a mixture of both these things.” There are many talented stair makers in Australia, so Tom is focused on progression as a business; gaining more customers is a sign of their market leadership and Biesse is

fundamental to this goal. He says, “The Biesse is both flexible and powerful and produces high-quality work that is repeatable. Biesse is an excellent workshop tool for us.” Tom concludes, “In our work we find a balance between design, craft and technology. We produce stairs for some of Australia’s largest and most well-respected builders, ten of these for over 50 years. We look for technology that makes our processes easier and provides a competitive advantage and Biesse certainly does both those things. If we got a new Biesse CNC machine tomorrow, we would be running product on it ten minutes after it was commissioned. Our team understands the Biesse product very well and the people at Biesse have invested in us to provide the right outcome for us. We don’t feel like Biesse machines are anything but excellent.” ❚

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Manufacturing

A New Resource PalmwoodNet, funded by the German government and industrial partners, promises the most significant new wood resource in decades. Supplier was on hand at Ligna in 2019 where the project was released, to see what it’s all about. As the World’s forests are progressively closed to logging, manufacturers look elsewhere for their wood resource. Palm Wood as a resource is in plentiful supply and is soon to become widely available as solid wood and board products for the furniture and cabinet industries. To support the project, five core partners have joined to take on specific development and implementation tasks. One of these partners is Leitz Tooling and Supplier’s Phil Ashley caught up with their head of R&D, Andreas Kisselbach at Ligna last year. The resource The Palm Oil resource is large and getting larger; the total plantation area for Oil Palms amounts to almost 20 million hectares worldwide. Oil Palm plantations are exclusively planted for Palm Oil which is used in the food and biochemical industries as well as biofuels. The project deals with the utilization of the currently wasted raw material, Oil Palm Wood. As the oil yield

Above: Palm wood and silica Supplier March/April 2020

decreases after 25 years, the palms are replaced. The used palms are left to rot, in some cases chipped as fertilizer or even burnt. All three methods are detrimental for the environment due to rapid CO2 emissions.

Above: Three layer board of oil palm wood The wood itself has some very good properties. It has a wide usable density range of between 150–800 kg/m3. The range is from Balsa at the low end to Beech at the top end. It has high compressive strength in fibre direction. There are no knots, and the wood has sufficient screw holding capacity for use in solid wood and panel products. The material has very good resistance to flame, good thermal insulation and good acoustic properties. As timber it is stable with minimal warping for use in all weather conditions. Interestingly, an Oil Palm is not a tree (dicotyledon) but a grass (monocotyledon). There are negatives to the crop. Palm Oil can be found in a massive 40% to 50% of household products in Australia but to provide this benefit, an area the size of Germany has been bulldozed for Palm Wood plantations since 1990. There are the issues of environmental destruction, loss of biodiversity and human rights violations through massive and partly illegal planting of Oil Palm plantations and these have been widely reported. Resident species like

Elephants, Orangutans, Rhinos and Tigers have lost their habitat because of Palm Oil plantations that can be found in Asia, Africa and South America. The leading oil palm producers are Indonesia, Malaysia, Thailand and Nigeria. Based on a planted area of about 20 million hectares, an average of 0.8 million hectares need to be replanted every year. Estimates forecast 100 to 120 million cubic meters of trunks per year would either be burnt or could be available as a replacement resource for wood panel products. It is a valuable and untapped resource but there are manufacturing issues such as extreme density distribution within the trunk, high water content, silicates, sugar and starch. Because of these characteristics, fungal decay starts quickly so Palm Wood needs to be processed within a few days of harvest. Sawing will have to be done near the plantation, special drying technologies have been established, and modifications to machinery and materials handling equipment have been developed. The Partners The five core partners are Jowat SE (Adhesives); Minda Industrieanlagen GmbH (Plant engineering and conveyor technology); Möhringer Anlagenbau GmbH

Above: The Team www.suppliermagazine.com.au

Manufacturing

(Sawmilling); Leitz GmbH and Boehlerit GmbH (Cutting tools); and Palmwood R+D in Freiburg. Our image shows from left to right, Professor Dieter Fink of the Rosenheim University; Dr. Jurgen Graef (Leitz); Professor Arno Frühwald from Hamburg Technical University; Dr. Hubertus Zeddies from Minda; Dr. Stefan Mohringer (Mohringer) and kneeling, Andreas Kisselbach of Leitz Tooling. A number of private companies and plantation holders who have certified a substantial share of their plantation area according to international standards, have also joined in the study. The overall objective is the best possible use of timber from unproductive Oil Palms for the production of high value-added products such as onelayer and multi-layer panels, blockboards, gluelam in standard dimensions and cross laminated timber (CLT) in Thailand and Malaysia. In the framework of this project a Chain-of-Custody system for Oil Palm Wood which corresponds to that for normal wood products will be developed. Both Leitz and Boehlerit are developing cutting processes and establishing suitable working steps and procedures. This involves the creation of suitable cutting materials and tools to achieve the required quality and efficiency of cutting processes. Mr. Kisselbach said that several products had been designed and produced, along with a ‘handbook’ of processes for working the material. Mr. Kisselbach also said that Leitz had developed special carbides that will be used for sawblades for milling the logs, and that diamond tipped cutters would be needed for secondary processing on edge banders and CNC routers. The Meisterschule (School of Apprentices) in Ebern, Germany have produced sample panels and door elements using 100% Oil Palm Wood, or just the core in Palm, with the face layer composed of other types of

Supplier March/April 2020

Above: Acoustic panel veneers. The doors are 3kg lighter than a conventional wooden door with the same sound insulation performance as particleboard. Leitz’s CEO Jürgen Koppel said one solution for using the material as furniture where components need to be inserted was to use different densities of the wood in certain areas, removing the need for special nails. The Benefits The use of Oil Palm trunks can significantly reduce the pressure on natural forests by replacing the timber extracted. In Asia, the decrease in available timber from natural forests and relatively small volumes from plantations have already led to wood shortages. The use of Palm Wood means forests can be kept intact and this makes the forests more sustainable. Using Palm Wood that would otherwise be burnt is economically sound practice and good for the environment. Without using Oil Palm Wood, population and economic growths will convert Asia into one of the largest importers of wood and wooden products. Palm Wood was subjected to a Life Cycle Assessment study by the Institute for Energy and Environmental Research Heidelberg GmbH (IFEU) in Germany. The results show that Palm Wood, when used for wooden products, has a significant advantage

over wood obtained from conventional sources in terms of Greenhouse Gas (GHG) Emission Savings. Its production has lower GHG emissions compared to wood from conventional sources. Palm Wood is an Ecofriendly resource material that behaves like forests and act as green lungs for the world.

Above: Products and tools Oil Palm plantations have been heavily criticised in recent years but should provide a major source of raw material for the furniture industries in years to come. The first commercial production of the new resource should occur as soon as next year. PalmwoodNet’s mission is to turn what was once a waste product into a commercially usable timber. Global timber resources are under pressure due to the increased awareness of environmental issues but notwithstanding this often-debated concern, the use of a waste product to create value and replace existing wood drawn from nature’s forests, has to be a very good outcome. ❚

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Manufacturing

A Welcome Addition

raditionally, senior managers of major machinery, tooling and hardware suppliers have been people who have come up ‘through the ranks.’ These individuals have a wealth of experience, from technical and sales, right up through the management structure. Recently though, a number of new CEO’s and Managing Directors have come from industries where logistics and service are high priorities. It’s a measure of the importance of service that manufacturers in the furniture and related industries now expect. One of the more recent and more welcome

new Directors is Sam Czyczelis and he took the top job at Leitz Tooling here in Australia and New Zealand last August. Sam’s more recent background is in the area of logistics and engineering, defined in the general business sense as ‘the management of the flow of things between the point of origin and the point of consumption to meet requirements of customers or corporations.’ However, Sam is also a qualified fitter and machinist and as such, has a terrific understanding of the technical aspects of the tooling industry. The combination of these skills and international business expertise has seen Sam hit the ground running.

Leitz Tooling is a leading manufacturer of cutting tools for a wide range of applications. Their product range is extensive and covers many industrial applications. With over 140 years providing quality tools and know-how right around the World, the people at Leitz have accumulated a wealth of experience that Sam can call on to provide the right solution for any customer. Sam said, “We don’t just deliver tools, we supply solutions.” While this is a catchphrase we’ve heard a lot over that last few years, Leitz Tooling has achieved a leading position that allows them to make good on this promise.

Above: Sam Czyczelis (RHS) in the tool room Supplier March/April 2020

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Manufacturing

manufacturing. An additional Australianmade ANCA CNC tool machine has been installed and this will allow Leitz Tooling Australia to manufacture and export these tools to Mexico; the USA; Canada; the UK and Japan, all countries that manufacture furniture similar to Australia. Leitz has invested in Australia, demonstrating their support for Australian know-how and ingenuity. Sam said, “Here in Australia we see an opportunity for Leitz to continue the leading role; to advise, inform and grow the industry and to offer solutions in all dimensions.”

“We don’t just deliver tools, we supply solutions... We can assess the performance against recognised benchmarks and provide sound advice based on known outcomes. But we can also provide our clients with technical advice based on real-world knowledge.” “What this means is that we can look at our clients’ tools and manage them to ensure our customers get the maximum life from their investment. We can assess the performance against recognised benchmarks and provide sound advice based on known outcomes. But we can also provide our clients with technical advice based on real-world

Supplier March/April 2020

knowledge. At Leitz Tooling, we can provide a tool that meets the specific production needs of all our customers, no matter what materials they are cutting,” Sam said. It’s business as usual for Leitz customers, but Sam’s goals also include growth in new parts of Australia and New Zealand, and growth in sectors such as advanced materials that include aluminium; carbon fibre; Kevlar and metal laminates. In the building and construction industries advanced materials are designed for maximum performance and are considered to be one of the richest sources of innovation. Leitz innovation is well-known and their R&D centre in Oberkochen is continually developing and testing not only new tools, but also tools for new advanced materials requested by specific clients. Some recent trials include rice wood and palm wood, materials that could replace timber drawn from the World’s forests. In their Bayswater service and production facility, Leitz have recently doubled their ability to manufacture compression router bits for nested based furniture

Australian manufacturers use less than 10% of the range of cutting tools Leitz produce, but it’s that knowledge and technical expertise that ensures every Leitz tool is designed and made with thousands of hours of know-how to guarantee the very best performance and cost-effectiveness. Sam says, “We believe there is a huge scope for manufacturers here in Australia and New Zealand to benefit from that experience and technical competence. Manufacturers here really know their stuff; they realise the tool makes a difference to their quality and production output. They know that downtime changing unproductive cutters and saws is a waste they can’t afford.” Sam Czyczelis will continue the Leitz tradition of providing technically superior tools to a discerning local industry; providing competent advice and know-how, supported by speedy, local service. He’s worked for one of the largest family-owned service providers in the World with an international presence, just like the Leitz Group so he understands the business very well. What he’s most looking forward to in his new role is working with Australian and New Zealand manufacturers, helping them to succeed. Sam’s only been with Leitz for six months but with his unique set of skills, and the Leitz team behind him, he’s already kicking goals. ❚

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Manufacturing

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Being Agile - This is a phrase that many Australians are getting familiar with. Whether it is the agility to work from home or to be more agile in our spending and cost saving habits. As cabinet makers, designers and trade professionals we are always seeking ways to be more agile within our business and personal life. Modern businesses constantly identify ways to increase productivity, be more responsive, efficient and effective while in the process lower costs, and reduce environmental impact. Now more than ever, if your business is identifying ways to achieve these goals while maintaining production or if you’re an individual seeking to facilitate orders and work for yourself - goCabinets can assist you. The goCabinets platform connects you to local businesses capable of large production and allows you to easily order completely customisable cabinetry for any project. Being agile is a major aspect of the goCabinets platform as it looks to streamline processes in a variety of ways.

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2. From your computer you log into goCabinets and enter all the cabinetry items that you need for this job. You get an instant and exact quote on how much all of this is going to cost you, at trade price.

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6. Job Done. Mobility to work from anywhere As a completely free online platform, you have the ability to work on your project from any computer, tablet or phone without the hassle of having to install software.

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