Machining Up

Until recently Wellington door manufacturer BDS Doors had little experience with CNC machinery, finishing their range of exterior and interior doors largely by hand. The purchase of an SCM Morbidelli M100 5-axis from Machine R Us earlier this year changed all that, and the changeover was surprisingly easy.

“In terms of technology we were pretty basic,” says Wellington Branch Manager Matthew Ashton. “We were using jigs to individually router each hinge and pre drilling holes for hinges and hardware by hand. It was very labour intensive with a lot of room for error.”

“We wanted to grow and improve our lead times without having to employ extra staff, which are very hard to find at the moment anyway, and we wanted the accuracy that a machine provides. We knew CNC was the way to do this.

“We narrowed our choice down to several machines largely through talking and visiting others in the area with similar machinery. In the end we chose the Morbidelli M100 5-axis because we liked the programming set up and were reassured by the global reputation of SCM and the local support of people on the ground which Machines R Us provided.

“The machine was installed in April over the Easter period, prior to which we went up to Auckland for a couple of days with the Machines R Us team for basic training. Following which they installed the machine and provided valuable on machine training. Fortunately we had one employee with previous CNC experience, he picked it up very quickly making it easier for the rest of us to follow.

“As we had little programming experience, and so as we didn’t have to start from scratch, Machines R Us set up a basic programme for us covering most of our likely requirements, and as we have progressed we have modified these files to fit our own needs. Assistance has been very good and any issues have been resolved quickly, often through remote access to our computer.

“In the few months since purchase the machines performance has been fantastic. We made a few errors initially because we really tried to run before we could walk. So we took a step back and took a more methodical approach which has worked well and in the last couple of months we are really where we want to be. We are still training the guys up and realise we will be able to add to the scope of what we do as we gain more experience. We have bought a Ferrari for a milk run if you like and appreciate and enjoy that it can do a lot more. www.machinesrus.co.nz

“Apart from the accuracy and speed of processing, a big advantage for us has been the ease of stock management and the reduction in overheads. Shorter lead times and improved processing capabilities mean we no longer are required to carry as much stock or as extensive a range of blanks. An example being cavity sliders which previously we bought in with the wheels already in the bottom. Now we can do that ourselves using a standard blank.

“No one in the factory has touched a jig for the last 3½ months, we are doing everything on the machine, nothing by hand. We have gone from perhaps the most basic among pre hung door manufacturers to among the most updated, and it feels good.

Following on from our experience in bringing affordable 5-axis processing into the New Zealand market, especially for those involved in solid wood furniture and shop fitting, Machines R Us have put together a package tailored to pre-hung door producers in New Zealand.

The basis of our system is the SCM Morbidelli M100 5-axis in pod and rail configuration. Fitted with a powerful 5-axis electro spindle and dedicated high speed drilling head all machining can be carried out including mitre cuts with saw blade, pilot holes for hinges and hardware, lock boxes and hinge rebates.

A specialised clamping system is fitted to allow the datum of the jambs to be constant thus eliminating variation in jamb length when cutting mitres or where jamb thickness is variable, this system negates the need for thickness probing of the door jambs top surface.

Using SCM's own Maestro software Machines R Us has developed a library of predefined parametric macros and programs to deal with hinge machining, locks, mitres etc so a long learning process for an operator is greatly reduced and the customer is ready to go from the outset.

We wanted to bring to the local market all the technologies required by pre-hung door businesses using standard machines from the SCM catalogue. Thereby providing proven affordable technology with practical and readily available local support.

The HOMAG sales representative was exceptionally knowledgeable; he was great at proposing the good solutions to meet our particular requirements without ever trying to oversell.

Tim Doran, Managing Director