Almost all I know about finishing,
I learned from a happy salesman.

In my travels I would cross paths with an inspiring source of information - Joe Golden. Most often it was at a bar in a small town in Pennsylvania where Joe would be holding court describing that day's problems and solutions. It seemed every third sentence would begin with :"It’s only common sense". To Joe it was , but to his listeners it was a revelation. Joe was a great teacher (and a great paint salesman). His lessons added the cachet of reality to college courses in paint chemistry and thermodynamics. After working out a theoretical solution I’d often call Joe and ask for his common sense perspective. Joe is gone but his lessons remain. Even today, I pull myself up short in a tough analysis and ask what Joe would do in a case like this. Some common sense:

Look at total cost. Filter disposal, cleaning solvents, etc., have to be factored into your total finishing cost. So do spraybooth operating costs including replacing heated air in the building. -- sometimes $10,000 per booth per year. Is it time to look at curtain and roller coating?

One supplier’s responsibility. It’s a good idea to have more than one source for finishing materials but it’s a dumb idea to mix two suppliers’ finishes on the same item. Blame is not the issue, it’s just that complex chemistry can create all kinds of little surprises. Shop for the best appearance, technology and price. Then set up a permanent partnership with one supplier for each product line.

Controlled conditions. If you want repeatability - the same appearance in today’s products as those finished yesterday, you must have a controlled environment. Start off with the simplest steps - record viscosity and gun pressure when you make samples and constantly monitor the production line to see that they are maintained. For real consistency flash tunnels and curing ovens are necessary.

Make it stick. Some finishes have solvents that melt into the prior layers; others react chemically if applied within a certain time period, but many rely primarily on mechanical adhesion. This is complicated by a few finishes which form a two layer film which must have the top layer removed before recoating. All these films require different sanding materials and techniques. Scuff sanding may not be the most desirable job, but if you want to avoid field failures invest in educating your staff . Motivate them with a clean, well lit and ventilated work area. Assist them with machines and fixtures. Make sure they have right sandpaper and constantly retrain them.

 

Gorillas in the Mist

 Joe Golden was the ultimate paint salesman and chemist but he knew where not to tread.  So sometimes he would leave an urgent message --- just a company name and the words "Gorillas in the Mist". This was his shorthand description of a company with primitive conditions, all material handling was pure grunt and groan and there was inadequate ventilation. It was a call for assistance. Joe wanted to sell his products into safe, controlled environments.

As I leaned on him for paint technology, in-turn, he pushed me to create great finishing rooms where his products would shine. Joe really enjoyed the following layout > > > >

Details, Details, Details

Drawing a layout for a dimension mill rough line or a kitchen cabinet finishing line is real easy. You can do it yourself or ask your equipment supplier to do it for free. You’ll get what you paid for - a good "college try" with the blinders of either an industry niche or a sales line. If you want to be the best get professional engineering help. A consulting company who specializes in the wood products industry can analyze your needs, propose viable solutions that fit your budget, and then properly plan the project - looking at the big picture as well as all the small details necessary for success.

Developing or revamping a plant layout requires microscopic attention to the details that maximize performance, reduce manpower, improve quality and comply with environmental and safety regulations. A new layout is just one step in developing cost-effective manufacturing. Methods, materials, equipment and systems all have to be evaluated. Do you have the time and experience to do it yourself?

If you want to be the best, get professional engineering help. Feldman Engineering specializes in the wood products industry and can analyze your needs, propose viable solutions to fit your budget, develop a realistic timetable, and then, working with your staff and suppliers, successfully complete your project.
<< Load and unload adjacent so one operator can do both.

<< In-floor towline allows operators free access to all sides of product. On-floor towlines or raised pallet lines are okay if product doesn’t have to be removed for off-line operations.

<< Washcoat & sap stain improve appearance and reduce wiping labor.

<< Locate paint locker near stain booths to reduce handling and piping.

<< Scuff sanding requires enclosure and downdraft ventilation.

<< Use downdraft booths for topcoats. Stop product in booth to minimize operator fatigue, and booth costs

<< Accumulate prior to booths

<< Cool down to room temperature prior to sealer sanding.

<< Maximize visibility of workstations to improve teamwork and supervision.

<< Place oven in corner to keep heat and noise away from operators.

Joe knew that having a great layout wasn't enough - a company needs great people and systems. Your job is to find the people; our job is to create a factory environment and systems that they can prosper within. Our system concept is called SIM*plicity and the following table provides an overview of it:

 

Manufacturing business software to help your company prosper:

Complete MRP / ERP software solutions customized  for your exact needs

 

         Please double-click either button for download!

 

 

 These are completely free!  They are not just demos. They are complete systems  without time limits or other restrictions for single user systems. Our only charges are for networked installations.  click  here for more information.

 

 

SIM*plicity tutorials:

(Click  any underlined item for more details.)

Features that help your company  Examples from SIM*plicity  Discussion and Features
Customer Orders

 
 

Order Entry Overview

  

<<< Please read this introductory overview first.

 
Customer Details: shipping information, history, etc. The utmost in options and feature controls. Automatic pricing with more than 400 variables (size, color, add-on's etc.)  Simple to set-up and easy  to use.  More than an "Order Configurator": these variables interact with dynamic (parametric) bills of materials to create complete manufacturing documentation. 

 
Item Details Options to enter and display product information.

 
Order Entry Tools Because we automatically transfer all pricing variables and "engineering limits" to  Order Entry,  SIM*plicity eliminates the typical delay for orders to first go to Engineering and Pricing prior to Order Entry.

 
Batch Order Entry Input Customer Order details directly  from Excel.

 
Order-Project Costing Display actual costs during Order Entry or during  "material takeoff" -Quotations.

 

Order Progress (status)

 

 Graphics display with real-time visibility of all in-process orders.
Product Entry Instructions

Guidance to the operator in entering complex items .

 
New Product Entry Add new customers and products on the fly.

 
Zip and Postal Code Tutorial

Factors in entering address data for uniformity and to ensure automatic freight calculation

 
Sales Discounts and Commissions Information on entering discounts and sales commissions.

 
SPEED-UP

Tips to increase order entry productivity.

 
Invoice Details - Setting Variables

Order Entry Display Variables

 

 Variables for printing (and exporting to accounting software) invoices

 Order Entry variables for display and printing

Deposits and Payments

Record and display deposits and partial payments

 
 MRP2/ERP  Planning and Shop Floor Control Advance Plan

 

 

Customer and factory (internal) orders create inventory and labor demand for specific days.  SIM*plicity schedules individual machines within each work station/cell and generates material requisitions.

 

Workstation Control

 

 Planners can control and balance workload at every machine.
Production Planner/Scheduler Shifting production (date or workcenter) automatically updates all related processes. Graphics displays with drill-down" information effectively links Planning to Shop Floor Control.
MRP2/ERP Tutorial

 

Workstation Control allows supervisors to fine tune schedules and report production.

 
Purchasing and Inventory Control Requisition/Purchasing

 

 

 

New orders automatically updates long-term material plans. Shop floor control module interacts with purchasing to automatically flag needs that won't be met and adjusts schedules accordingly.

Buy-out items are  purchased as soon as customer  order is processed - including automatic pricing of options and features.

 
Inventory Details

Knowing the materials "on hand" and what they cost is not enough! SIM*plicity calculates the exact date needed, where it should be stored and details of its physical characteristics.
Vendor Information

 

Access complete contact information on vendors and their employees.
Purchasing Messages

Inventory Adjustments

 

Adding Standard and Text Messages to an individual item Requisition or to an entire Purchase Order

Tools to record and adjust physical invnetories.

 
Accounting and Cost Control

Product Cost Summary

Options & Features Overview

Order/Project Costing

 

  

Know the true cost of every item that you build!

Automatically calculate the cost of "work -in-process" inventory.

Instantly estimate the complete cost of every Order and Quotation. Change an option or feature and the cost is automatically updated!

Please  also read ABC Cost Control
Product Engineering Bill of Material Flow Chart

Dynamic Bills of Material

Static Bill Display

Glossary

Bills of Materials  are the core of true manufacturing systems. They link together customer orders, manufacturing instructions with  material and labor requirements.

Dynamic (parametric) Bills of Material are used for entire families of products eliminating the need at most companies for 90% of individual Bills of Material. However, Static (Conventional) Bills of Material are still valuable and our system incorporates them with a full range of Options and Features
Plan and Perform Project Takeoff

Project and/or Product Estimate

 Estimate and control complex projects.
Sales Management

 

 Sales by Customer and Product Line

Marketing Program Formats

Cost of Goods Sold report for every order. Volume and margin reports for each sales rep.

For each customer select default discount programs, special product discounts and choose from multiple selling companies (OEM, etc.)
SUPPORT

Getting Started

FAQ's - SIM*plicity Support

Why Systems Fail

Favorite Story

 

 Training, customization and 24/7 real-time support by the developers of this software.  A commitment to excellence - today, tomorrow and for the past 30 years.