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Project on Industry Manufacturing on Knife Blades

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Project on Industry Manufacturing on Knife Blades Powered By Docstoc
					                                    Spydor Wood Products Inc
                             Job Description and Pay Scale Categories:
                                             03-19-08
                                  For Benchman/Project Manager

Ability to get along with other employees Basic Evaluation Categories for all employees

    Understanding the Time VS Quality relationship
    Attendance
    Responsibility

    Work Ethic
    Ability to focus and stay productive and on task
    Willingness to work with others
    “Team Player” attitude
    Ability to pay attention to critical details including quality, organization and productivity.
    Consistency in the work place , with shop habits, decisions
    Desire to go forward in the industry including personal education and experience, self improvement,
     gathering information for your trade.
    Attitude: consistently promoting a positive attitude toward your work, other employees and the
     Company.
    Ability to learn things quickly and thoroughly.
    Communication- both written and verbal. Comprehend concepts within the media which we work with
     as well as communicate your ideas with others. Ability to understand drawings, sketches, cutlists etc.
    Safety and safe work practices.
    Ability to understand monetary value of time and materials and apply those values to work related
     decisions.




LEVEL 3 Basic Millwork

1.   Basic woodworking skills plus the following:
2.   Be able to perform all facets of the core operation, including quality control of components, knowing
     all the subtleties of the hydraulic press including maintenance and trouble shooting, quality control of
     all glue ups, glue film thickness for different adhesives and different temperatures.
3.   Be able to do all facets of panel stock preparation including glue up and cut to length and width.
4.   Have complete knowledge of all adhesives used in the glue up processes, including white glues, casein
     products, thermally set adhesives, pressure sensitive adhesives, polyester resin products, fillers, glue
     tinting, epoxy resins and mixing, and other commonly used adhesive products.
5.   Be able to use the vacuum bags for flat stock assembly both for “one at a time projects” and in
     production applications. Be able to handle the vacuum bags and equipment without damaging either.
6.   Be proficient with setups for table saws, including dado operations, feather board setups, accurate
     depth of cut with top over control fences, all tooling and blades associated with table sawing
     operations. (IE: difference between ATB, triple chip, rip , crosscut cut, crosscut combination, miter
     cut, thin miter cut, plywood cut, spline rededicated, steel vs. carbide, and all other blades associated
     with table saw operations. Be able to set up accurate cross cut operations on radial saws, table saws,
     and chop saws for both rough and finish mill operations.
7.   Be able to setup and run the resaw including knowledge of all blade types and their specific uses.
     Know how to set up the guides and when to stop and adjust guides, blade tension, change blades,
     power feed adjustment, and all other setup and adjustments required to make the resaw perform in an
     accurate and efficient manner. Be able to trouble shoot sawing and mechanical problems with the
     resaw. Be able to meet production and quality requirements on the resaw. Know the differences in
     resaw finishes and be able to produce acceptable resaw finishes.
8.    Be competent with most power hand tools including skill saws, jig saws (including knowing the
      different blades and their applications), belt sander, drills and other basic wood working tools. Be able
      to use most hand tools with basic proficiency including hand planes, chisels, scrapers, files/rasps,
      sanding blocks (flat, curved, and flexible)and other hand tools to perform basic hand tool operations.
9.    Be able to setup and run the blank/core edger including a complete understanding of it’s mechanical
      functions and trouble shooting the mechanical problems when necessary.
10.   Have a total grasp on material handling. Know the appropriate location for every wood type and
      species used in the shop, and be diligent about returning and storing these materials to their appropriate
      locations. Be able to understand why things are store where they are and provide input as to the
      efficiency of storage of materials (be able to make suggestions for effective change in material
      handling processes). Handle lumber with a sense of order and organization so that other employees
      know where to find lumber you have stored.
11.   Be entirely responsible for the quality and production of work which you perform including surface
      quality of all operations (knife marks, sanding grit finishes, preparation for next machining operation,
      product integrity( things are glued correctly). Take personal pride in your work, and be willing to
      make corrections on your work as a matter of pride, and not just because the job requires it. Be
      responsible for your rate of production on all tasks you are involved in. Know how long a job should
      take (because you have done it before and/or observed others perform the same operations) AND you
      have asked to find out how long each operation should take. Be responsible for your rate of production.
12.   Thoroughly know and understand the concept of production vs. quality, and pursue solutions to this
      problem on every operation that you do. Achieve production/quality goals including .75hr or better
      per core production. while having no glue failures. Regularly producing glue up operations including
      cores and panels with no waste or part rejection for quality reasons.
13.   Understand and implement the concept of tolerance at every operation. Know the tolerances required
      for most of the operations you perform including cores, moulding rip, door component rip/surface glue
      up required tolerance of fit, and other tolerances for the operations that you perform on a regular basis.
      If you are not sure of the tolerance, you ALWAYS ask or discuss the tolerance requirements with a
      supervisor prior to beginning any machining operation.
14.   Be able to edge glue and face glue any type of wood used in the shop. Know the difference between
      acceptable and unacceptable glue lines for different applications. Know the minimum and maximum
      temperature, clamp time and pressure requirements for all glues and woods including a good clamping
      schedule for most applications. Know and apply the concept of grain and color match, and efficiently
      perform that operation including knowing how to color and match using the # of way system (IE: 3
      way match, 4 way match, 5 way match etc.) Know when to match and a basic way # for most common
      woods in the shop. ALWAYS discuss type of color and grain match with a supervisor before
      beginning an operation. Level 3 employees should begin to develop an aesthetic since of what is
      appropriate for different wood colors and grain combinations.
15.   Basic maintenance of all tools that you use including cords, hoses, power tools, tooling, blades,
      material handling equipment, and be able to and be willing to perform maintenance operations without
      being told (as long as you are capable of and the operation is safe), or consistently advising the
      supervisor of maintenance issues and following up to make sure that necessary maintenance has been
      carried out.
16.   Know the various subtleties of surfacing, sawing, sanding and machining the different wood species
      we commonly use. ( IE: differences between machining ( how to plane, saw, sand, glue etc.)knotty
      cedar, furniture #2 pine, premium #2 pine, superior alder, frame alder, white oak, red oak, mahogany,
      hard maple, figured wood, teak, antique woods and other species we use on a regular basis). Know
      the differences in grade and species of all the woods we regularly use. Be able to pick out a grade and
      a species of any common wood an tell what species ,what grade it should be, and how it should be
      dried an prepared before each operation.
17.   Develop a good mechanical aptitude for dealing with machines. Be able to understand basic
      mechanical concepts and know when machines have mechanical problems that need to be fixed or
      adjusted.
18.   Understand the concept of straight and square to a tolerance of 1/32” know how to check that tolerance
      with straight edges and squares.
19.   Fabricate pocket door frames maintaining a consistent level of quality and production.
20.   Be able to perform basic assembly of simple components and including rough assembly of crates or
    sub assembly of some parts where assembly systems are set up.
21. Take a leader ship role for level 1 and level 2 employees working with you on projects, including their
    quality AND production. Use these employees as directed by the job captain or supervisor to make
    your quality and production meet shop standards. Promote a team attitude with all employees you are
    working with.
22. Always maintain a positive and productive attitude. Understand the importance of positive attitude
    and consistent productive work habits not only with your work but the affect that your attitude has on
    your co-workers. Exhibit a degree of enthusasium for your work and show a strong desire to learn and
    produce more so that you can improve your abilities and work up to the higher levels.


Level 4 Advanced Millwork

1.    All of the requirements of levels 1-3 plus the following:
2.    Be competent with executing most millwork projects from start to finish. Know shaper setup, head
      setup, basic tool room grinding procedures, operation of every tool in the shop (except the moulder).
3.     Know how to setup and run the wide belt sander. Know the difference between all the types and grits
      of belts, and follow the procedures for maintaining, handling and labeling the belts. Know when a
      belt is sharp enough to sand all the different species of wood commonly used in the shop, and know
      when to change belts to get the appropriate finish without wasting belts. Operate the sander without
      damaging belts or the machine or ruining pieces of work. Know how all mechanical parts of the
      sander function and be able to detect mechanical problems when they occur. Know how to diagnose
      and corrects most problems associated with sanding finish on the wide belt.
4.    Be able to setup and run any operation on the shapers including straight, curved, long, short, raised
      panels. door components, casing, radius casing and all other parts we make in the shop. Be
      thouroughly competent in tooling setup and application for all shaper operations. Know and
      understand the inner mechanical operations of the shapers including, belts spindles crank/gear
      mechanisms, motors and be able to tell when their are mechanical problems which need to be fixed. Be
      competent with power feeders and their multiple uses.
5.    Be able to quickly and accurately set up the boring machine for long and short runs. Be able to layout
      and verify cutlist on layout sticks, and verify component piece count on cutlists.
6.    Be totally familiar with standard cutlists, and know the standard breakdowns of numbers of
      stile/rail/core/blank relationships and be able to spot errors in the cutlists from these standards. Be
      totally familiar with computerized cutlists, and have a basic idea of how the programming/entry of
      variables works and be able to spot entry errors based on this knowledge.
7.    Be able to assemble doors with the door assembly press and maintain quality and production
      associated with that assembly.
8.    Be able to prehang doors, size doors tow width and length, mortise hinges and assemble interior and
      exterior door project while meeting quality and production standards. Be able to hang for production
      requirements and assist in close tolerance hanging operations.
9.    Know all grades and species of commonly used woods and most other woods including some exotics.
      Know the high and low end of all grades commonly used in the shop and be able to tell when a grade
      of lumber which has been included by the supplier does not meet industrially accepted grade standards.
      Know the expansion/contraction characteristics of each individual wood species and know how to
      design components for different expansion rates.
10.   Have a complete understanding of quality control issues including a good aptitude for understanding
      verbal communications concerning quality and production issues.
11.   Be competent at reading plans and shop drawing in plan, section, elevation and understand the
      standard drawing -detail reference system commonly use as drafting standards.
12.   Have a good understanding of tooling applications, including the differences between carbide and steel
      tooling uses.
13.   Know how to properly set up and sharpen and setup both the planer and jointer and the knives that are
      used for each machine. Know how to adjust feeding mechanism for planers and how all rollers,
      pressure shoes, infeed rollers bed rollers and other related components should be set for the different
      types of planning.
14.   Know all the fine points of table saws including blade diagnostics by reading the type of cut. Know
      how to setup radial saws in all axis to perform all type of cuts and including maintenance of all
      components.
15.   Understand the concept of straight and square to a tolerance of .0015”, and know when to apply that
      tolerance and know when that tolerance is not necessary. Know the concept of diagonal mathematical
      resolution and reverse straight reference for determining straight and square. Straight, square,
      tolerance, and the balance between production and quality control should be a religion at this point in
      your wood working career
16.   Be able to cost analyze your production and make procedural decisions based on the current shop
      hourly rate, and make basic decisions about your operations based on this concept.
17.   Level 4 employees should be generating some ideas for improving production, material handling and
      other operations in the shop. This level of employee should have a substantial assortment of hand and
      power tools which are well maintained. You should also be able to sharpen planes and chisels to a
      razor edge.
18.   You need to have comprehensive knowledge of cutting tools including saw blades, shaper cutters, 3
      wing carbide cutters, router bits, carbide tooling, boring bits, including all of the tooling which is used
      in the shop (with the exception of moulder heads and carbide moulder tooling), and know what each
      type of tooling is designed for, as well as hook and relief angles for different types of wood. Know
      different densities of tooling hardness, appropriate RPM for all cutter heads, how to set up 60
      corrugated tooling, and the specific tooling for specific jobs.
19.   Level 4 employees should have a through grasp of safety procedures for all the operations which they
      perform, including standard practices, and designing safety solutions for difficult operations.
20.   Know and understand all types of wood finished surfaces, and which machining steps are required to
      achieve what kind of finish. You should know what different types of stains and top coats look like
      when applied to different surface conditions and be able to make good judgment for machining
      processes based on the type of final appearance is required.
21.   Be able to write, follow and adjust machining schedules for all work which you are involved including
      all depths of cut and all basic operations. You should have an in-depth knowledge of fasteners
      including air nails, screws, and specialty fasteners, and know what fastener is designed for what and
      which fastener is appropriate for all operations you are involved in.
22.   You should have a good working knowledge of joinery and understand the structural principals behind
      most types of joints. You should have a good aesthetic value of what joint is appropriate for what type
      of application and be able to contribute to design decisions for both quality and production.

Level 5 Journeyman Benchman

1.    All of the items in level 1 thru level 4 plus the following.
2.    Be able to build a wide variety of projects including all of our interior and exterior door projects from
      beginning to end without assistance if required. This includes writing all cutlists, designing all machine
      schedules (for every tolerance and every machining operation in the shop), selecting all materials, and
      making all the critical decisions to produce high quality wood components. You must be able to build
      all types of door projects, both interior and exterior and be able to execute the most demanding
      operations for entry, and curved types of doors. You should be able tackle projects you have never
      done before, create and execute solutions for all types of joinery and machining operations which you
      have not been trained for (IE: have very good problem solving abilities). You must be able to not only
      build these types of complex projects but be proficient at using your time wisely and producing these
      projects in a timely manner. Where jobs are bid with good historical data, you should be able to
      perform these type of operations within the time and quality limitations of the project.
3.    You need to operate every machine in the shop with a high degree of proficiency (except the moulder
      although most level 5 guys should have at least fundamental moulder knowledge).
4.    You must be fluent at plan reading and interpretation, understand all the concepts and nomenclature of
      shop drawings, and have at an adequate understanding of blueprints and standard drafting protocol
      such that you can extract critical information from plans and specifications. You should be able to
      draw basic shop drawings by traditional mechanical means or Cad or preferably both, and be able to
      sketch ideas easily in plan, section elevation and some 3 D sketching.
5.    You must have a thorough knowledge of construction/carpentry practices on the job site to or
      equivalent experience, to know how the components which we make are being used, and what is
    allowed or expected of our products. You must be able to use this experience to expedite or improve
    the way we make or the quality of our products.
6. You must be able to have a fundamental knowledge of AutoCad programs so that you can extract
    critical dimensions from AutoCAD files of shop drawings.
7. You must have a full inventory of tools including all specialty tools for your particular interests. You
    must be able to repair most tools in the shop and be able to work on stationary machinery including
    repairing simple components on those machines.
8. Level 5 employees should be motivated to produce quality projects in a timely manner and do so in a
    consistent way. You should be able to manage at least 3 employees from other levels under the scope
    of your work, and utilize those employees while maintaining a good level of personal production. You
    should be able to maintain a strong positive attitude with those employees, monitor their quality and
    production, make suggestions for improvement in their quality and production, and work together as a
    team to produce the work.
9. You should have an ongoing personal program for personal improvement including reading trade
    publications, attending seminars, and working on home projects which expand your capabilities. You
    need a strong personal desire to constantly improve your wood working skills and the ability to learn
    new techniques.
10. Level 5 employees should be constantly generating ideas for improved production and quality, You
    should be producing implementation solutions for some of these ideas and have a strong focus on
    project and personal success.
11. This level requires that the employee completely understand the principals of manufacturing by
    component to specification, and be able to forego the technique of carpentry, when the nature of the
    project calls for it. Conversely, the employee should be highly skilled with all facets of carpentry and
    joinery, and be able to decide based on quality and efficiency, when to use which technique.
12. Level 5 employees should be capable of going on to the job site and perform any type of carpentry,
    cabinetry or related type of operation, including installations of any and all of the products which we
    make. You should be well versed in job site requirements and be able to work with the trades and
    superintendents on those job sites.


Level 6 Benchman/Job captain

1.   All of the items in level 1 thru level 5 plus the following
2.   You should be able to act as a team leader or job captain for all projects in the shop assigned to you.
     This includes quality control, associated record keeping, performance analysis and production
     management of your jobs. You should be able to plan and control the flow of the job including
     employee management, material requirements, machining schedules, communications with job site
     superintendents, machine performance and maintenance, all associated paperwork, produce
     cutlists(including computer cutlists), produce bill of materials for the job, and all other aspects of the
     project which you are in control of.
3.   You should be able to analyze production steps in each operation and work with the management to
     implement improvements so that when these small improvements are made on several operations, the
     result is a noticeable improvement in productivity and profitability.
4.   Be able to successfully manage several operations in the shop which are associated with your assigned
     job including overseeing rough mill, moulding, sanding, prehanging, and all millwork operations.
5.   Job captains should be able to manage the progress of the work, including meeting productivity and
     profitability goals, and working with all employees on their jobs to make sure that these employees are
     producing their work on time and of sufficient quality. Job captains should be able to instruct and
     motivate employees working on their jobs and be able to determine if these employees are performing
     in a manner which will bring their jobs in “on time” and “on budget“. Job Captains should also
     manage all quality aspects of the job including producing the level of quality required and determining
     the level of quality required for each individual project and individual customer.
6.   The level 6 employee should be constantly aware of the profitability required for all of his jobs, and
     meet these profitability goals on a regular basis. This includes analysizing production and costs during
     the course of work and advising management of short comings and solutions to resolve these problems.
7.   Job captains will need to multi task i.e.: work on the project while supervising other employees and
     operations in the shop. this includes being efficient with both your time and the other employees time
     so that production and quality control objectives are met.
8.   Job captains should initiate and maintain a constant flow of information and education to the
     employees who are working on their projects. This includes always going over all methods,
     procedures, potential problems, safety requirements, and tolerances for every new or inexperienced
     operator on every machine or operation which is involved in his projects. He should also maintain a
     routine of constant quality control and tolerance verification for all work done on his projects. He is
     also responsible for showing employees who are working on his projects, proper and effective quality
     control procedures which will assure that work performed on his projects is up to quality and
     production standards. This educational process needs to be performed quickly and efficiently, and
     good judgment needs to be exercised as to how much education and monitoring each individual
     employee needs to effectively produce the work.

Level 7 Project Management

1.  All of the items in level 1 thru level 6 plus the following
2.  Have the ability to manage millwork projects in excess of $100,000 if value from beginning to end.
    This would include communications with the contractor, architect, all other trades, our subcontractors
    or vendors, basically everyone including upper management. This would require all bidding, job cost
    management, procurement of materials, management of materials, preparation of a shop drawings,
    management of all labor and shop operations, scheduling and keeping the job on schedule, meeting
    profitability goals, and all other facets of managing the job.
3. Have the skills to manage multiple jobs in the shop with total project values in excess of $200,000.
    This includes all levels of management including delegating and administering tasks to Job Captains.
4. Have ideas and input for improvement in production and quality for all operations in the shop. Be able
    to formulate and illustrate these ideas in such a way that upper management is able to act upon these
    ideas and improve production and quality.
5. Be able to produce design solutions for most woodworking and machining processes. Design, set,
    refine and manage any jig, fixture or other mechanical apparatus for the production of any project in
    the shop.
6. Know the quality standards required by all of our customers (and the difference between customers
    quality expectations) and be able to taylor quality/production for each individual customer.
7. Maintain an ongoing program of self improvement and education including reading trade literature,
    attending management seminars, reading books and periodicals on management techniques, and
    implementing personal achievement goals for improving your role as a manager. Periodically update
    yourself on wood working and manufacturing techniques within the industry, by reading trade
    magazines, books and other literature on the subject.
8. Have a complete working knowledge all maintenance and repair methods for every machine in the
    shop. Be able to advise shop mechanics on all maintenance and most repair issues. Be resourceful for
    locating parts, techniques, tools, equipment and other facets of improving the mechanical operations
    which your are responsible for.
9. Have and maintain an attitude of leadership. Always promote a positive and productive attitude with
    fellow employees, including maintaining good personal relationships and understanding the individual
    requirements of each employee. Be impeccable with the concept responsibility , honesty , personal
    integrity, and be exemplary in these areas for other employees to follow.
10. Have reasonably good office skills including being able to run most computer programs including
    Auto Cad , spreadsheet programs, word processor and other basic computer skills. Be able to manage
    shop and office files, and organize the paperwork for all of the projects which you are managing.

				
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