Sunday, November 14, 2010

Small-scale Manufacturing Processes



When I made my windows, in order to streamline the process for manufacturing 9 window units, I developed my processes to be easily repeatable. The window sashes required multiple passes on the planer, and multiple passes through the table saw: first to cut the profile of the sash, and then to cut the joints at the corners. Each precision setup on the table saw would be run however many times were needed (sometimes up to 36 times) before breaking down the setup and making a new setup. Special jigs had to be made, which attached to the table saw, in order to keep the operations precise.






Jigs are important; when the same cut must be made tens or hundreds of times, making a jig saves a tremendous amount of time, saving the measure, cut, measure, cut process. I applied this principle a number of times: cutting the siding (every piece cut to 72 1/4" inches), manufacturing the trim (every one had to have the same lap cut in it), milling the windows, and cutting the joinery for the doors.

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