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CONTENTS
Abstract ................................................................................................................................................................. 2
Introduction .......................................................................................................................................................... 3
Management Staff: ........................................................................................................................................... 5
Infrastructure: .................................................................................................................................................. 5
Raw material ..................................................................................................................................................... 7
Lay out of industry ............................................................................................................................................. 14
Seasoning section ............................................................................................................................................ 15
Carpentery section .................................................................................................................................... 19
CNC Router Section ........................................................................................................................................... 23
Finishing and Packaging Section: ............................................................................................................ 24
Comparison of Different Finishes used by the Industry ................................................................................. 27
Quality Control And Packaging ........................................................................................................................ 38
Project – 01 .......................................................................................................................................................... 40
Project – 02 ............................................................................................................................................................ 3
Project – 03 ............................................................................................................................................................ 9
Conclusion And Suggestion ............................................................................................................................... 14
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ABSTRACT
I did my one month Industrial Attachment at D. S. Doors India Ltd. which is one of the
renowned furniture industries of India situated at Faridabad district of Haryana. It is a unit of
DSW Group of Companies which has its deep roots in wood and wood based industries and
serving since 1977 in this field. Today they are acknowledged as a leading group of
companies. This Industrial Attachment report throws light on the use of various modern
technologies for manufacturing of modular doors and other furniture. This particular report
has been divided into three parts. The first part is dealing with the overall introduction to D.
S. Doors India Ltd. in terms of its raw material, manufacturing process, use of advance
machines for upgrading the quality of final products, managerial skills, marketing skills,
input cost and profit as well as quality policy of the products manufactured here. The second
part of this report is dealing with the Project Task as assigned in the curriculum for Industrial
Attachment of M.Sc. Wood Science and Technology. My topics for the project assigned to
me were as follow:
1. Statistical quality control analysis of four side planar
2. Training of workers for proper stacking and Comparison of drying characteristics
3. Types of finishes and gloss measurement
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INTRODUCTION
The D. S. Doors India Ltd has its deep roots in wood based business since centuries.
The owner of this company Mr. D. S. Sharma had started this firm in 1977, since then they
used their technical skills inherited from his ancestors and now this company is known as one
of the largest in India in doors and other furniture. According to him, this becomes possible
through his dedication, hard work and foresightness. He started his firm as D. S. Wood Work
Industry, later Known as D. S. Doors India Ltd. Now the same has emerged as a group of
companies named as ‘DSW Group of Companies’.
The DSW Group of Companies has following six units:
D. S. Doors India Ltd.
D. S. Woodtech Ltd.
D. S. Design Sense Ltd.
D. S. Timbers and Traders
D. S. Jangda Udyog
D. S. Law Consultants
The D. S. Doors India Ltd is specialized in Designer Wooden Doors, Wooden Windows,
Modular Kitchens, Modular Wardrobes, Wooden Frames and Modern Designer Furniture
which are made with craftsmanship.
The company offers exclusive designs and superb quality wooden products which has great
demand in India and abroad. According to Mr. D. S. Sharma, CMD, by the use of finger joint
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technology in solid wooden products all the items that they sell become more strong and cost
effective.
Visions and commitments of D. S. W. Group towards customer’s satisfaction:
All our products are subject to customer’s demand and specification.
All products are made of seasoned and chemically treated wood with latest
technology.
Special chemical treatment is also done on customer’s demand.
We adhere to the International Standards and provide unmatched quality at nominal
price.
Our products include wide range of Classical and modern doors and quality designer
furniture.
We also provide customized designs as per customers demand.
We believe in quality products.
We also provide after sale services to our customers.
Our entire team of Architects, Interior Designers and Technical Staff is fully devoted
to satisfaction and gratification of our valued customer.
Products Range:
Solid Wooden Doors (Finger Joint Technology)
Carved Doors
Wooden Panel Doors
Glass Doors
Engineered Flush Doors
Laminated Skin Doors
Wooden Windows
Wooden Door and Window Frames
Modular Kitchen Furniture and Wardrobes
Wooden Staircase and Flooring
Designer Furniture
Office Furniture
Sofa Sets
Dinning Sets
Kids Room
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Modern Bed
Dressing Units
TV units
Management Staff:
Name Designation
Mr. D. S. Sharma Chief Managing Director
Ar. D. K. Jangid Chief Executive Officer
Ad. Kunal Jangid Chief Director
Mr. D. P. Singh General Manager
Mr. Dharmveer Yaduvanshi Project Manager
Mr. Ravinder Singh Sales Manager
Mr. Praveen Bansal P A to CMD
Mr. Jabar Singh Purchaser
Mr. Amit Sharma HR department
Mr. Ashbir Singh Sr. Sales Manager
Mr. Pradeep Yaduvanshi Sales Executive
Mr. S. R. Matta Sr. Accountant
Mr. Shailendra CNC Programmer and Operator
Infrastructure:
Log storage facility
Seasoning Plants
Chemical Preservative Treatment Plants
Exclusive Show rooms and Exhibition Halls
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Office section
Finished final product storage section
Veneer and plywood storage section
Design Section
Conference hall
Crane and Freight Lift Facility
Four storey building having different manufacturing machines
First Floor-Finger joint, butt end joint section:
4 side planer cum Thickneser, 2 side planer, 1 side planer
Thickneser
Laser cutting machine
Vertical band saw
Circular hand saw
Circular saw automatic
Automatic finger joint machine
Auto Roller type glue spreader
Manual finger joint machine
Finger joint manual pneumatic press system
Automatic Clamp carrier
Under Ground Floor- Flush Door, Kitchen and Office Cabinets, Particle Board
Door Section:
One side planer
Thickneser
Circular saw
Vertical band saw
Clamp carrier
Automatic Cold Press
Manual Edge Bending Machine
Vacuum film coating machine
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Second Floor- CNC Router Section:
CNC Router
Automatic door boring machine
Beam saw
Auto CAD and Art CAM Design Section
Third Floor- Manual door making (Carpentry section):
Automatic copying lathe
Chain copying lathe
Moulding machine
Door Frame corner jointer
Chain mortise and tenoner
Chave machine
Router machine
One side planer
Dowel making machine
Groove making machine
Thickneser
Fourth Floor- Finishing and Packaging Section:
Belt Sander
Two Drum Sander cum Thickneser
Spray gun
Horizontal Band Saw
Vertical Band Saw
RAW MATERIAL
The raw material is wood logs of following species:
Ivory Coast Teak (IC Teak)
Central Province Teak (CP Teak
Mango
Shisham
Burma Teak
Marandi
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Vitex
Pine
Arjun
White ash
Physical and mechanical properties of some important woods MANGO
(Mangifera indica)
Mango is now cultivated throughout the tropical and subtropical world for
commercial fruit production, as a garden tree, and as a shade tree for stock. Mango timber
when properly seasoned has been used in furniture, for carving, as wall and floor panelling,
and utensil manufacture. Mango trees can grow up to 35-40 meter (115 – 130 ft) tall, with
crown radius of 10 meter (33 ft). (Wikipedia)
Physical Properties
The timber is gray-brown, often with a pink tinge. It is coarse-textured hardwood that
is easy to work and finishes well. The timber breaks down rapidly if exposed to the elements
without preservation treatment. Sapwood is not always distinguished from heartwood but
sometimes a fairly with large and distinguished brown to dark brown. Heartwood with light
and dark streaks observed. The wood is whitish yellow or grayish brown to buff in color and
is frequently discolored by stain.
Uses & Benefits
This wood is sustainable. It means that the tree is planted mainly for its fruit which
Asian farmers pick and export or use for local cuisine. It’s only timbered when it stops giving
the fruits. The main trunk grows up to 3-5 feet in diameter and 70-80 feet in height in a very
short time span. This makes it possibly the most important furniture material for the future.
Mango wood furniture can have a rather unique finish thanks to the great variety of colours
mango heartwood can have. It ranges from light brown to dark brown; some pieces even have
a tint of pink. With this great variety mango tree furniture will look unique and a fresh point
of any room or kitchen. Unfortunately the tree is very prone to diseases, fungi are particularly
dangerous. Thus, the furniture manufacturer should make sure they check each and every log
before they work them into furniture of any description.
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Specific Gravity = Light to Medium Light (0.59 )
Weight / Vol. (at 12% MC) = About 610 Kg/m3
Grains = Interlocked/Curly or Sometime Straight
Growth Ring = Hardly Distinguished
Table: Comparative Properties of Mango as Compared to Teak (Tectona grandis)
Suitability Indices
(With Teak as 100)
Weight 77
Stiffness as a beam 81
Suitability as post 77
Shock resisting ability 90
Retention of shape 100
Shear 92
Hardness 84
MOR (Kg/ cm2) 612
MOE (Kg/cm2) 91.2
Table: Mechanical Properties of Mango (Hossain and Awal, 2012)
Mechanical Properites
Compressive Strength
Perpendicular to Grain 28 MPa
Parallel to Grain 9 MPa
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Loss of Strength
(When exposed to: )
Water for 90 days 25 %
NaCl for 90 Days 12 %
Na2SO4 for 90 Days 13 %
SHISHAM (Dalbergia sissoo)
Shisham produces one of the finest all round timbers. It is a very useful tree which is
fast growing under good conditions. It adapts well to varying sites such as parks, dooryards,
wind breaks, dry ridges, spoil dump etc. This also can be grown as part of farm forestry,
agroforestry, alley cropping, silvi-pasture and social forestry.
Physical Properties
The sapwood is white to pale-brownish white, while the heartwood is golden brown to
dark brown with streaks. It can be distinguished from rosewood by the absence of odor. The
wood is hard (Sp. Gr.: 0.692) and heavy (770 Kg/m3) but not as hard as Rosewood. It can be
air seasoned and kiln seasoned without difficulty. The sapwood is liable to decay and attack
by powder post-borers and therefore useless as timber.
Uses
The heart- wood is most suited for timber construction in the form of short lengths,
small dimensioned pieces and makes excellent timbers for cutting disc-dowels to be used as
connectors in roof frame works, to gap large spans for workshops and factory sheds. The
wood is suitable for tool handles such as striking tools, scraping tools and handles for cutting
and shaping tools. For plywood it has been found very suitable and so also for making
laminated skis. It ranks among the finest cabinet and furniture wood and is suitable for bent
wood articles after steaming. It is used as posts, rafters, scantlings and boards in buildings for
carts and coach buildings, spokes, poles and shafts, musical instruments, carved articles, shoe
heels etc. The heartwood yields oil, suitable for lubrication.
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Table: Comparative Properties of Shisham as Compared to Teak (Tectona grandis)
Working & Finishing Quality
(With Teak as 100)
Suitability Indices
(With Teak as 100)
Planning 100 Weight 119
Turning 81 Strength as a beam 97
Boring 136 Stiffness as a beam 92
Mortising 89 Suitability as post 89
Over-all performance 113 Shock resisting ability 130
Ease of working 74 Retention of shape 87
Working quality index 90 Shear 109
Finishing adaptability 96 Hardness 121
Carving quality index 111 Refractoriness 82
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Table: Mechanical Properties Of Delbergia Sissoo In (Kg/cm2)
Sl.
No. Category Green Air dry Kiln dry
1
Static banding
MOR 721 1056 1079
MOE 87000 108300 114800
2
Impact bending
Maximum height of drop of
a 22.68kg hammer in cm
127 112 91
MOE 13650 127600 159400
3
Compression parallel to grain
Maximum crushing stress 381 614 646
MOE 93600 126300 117600
4 Compression perpendicular to grain
CS at EL 84 159 157
5
Hardness-load in kg to embed a ball
of dia. 1.13cm to half diameter
Side 640 885 870
End 592 873 830
6 Shear 112 137 146
7 Tension 80 66 70
SAL (Shorea robusta)
Sal wood is one of the three naturally lasting timbers of the Asian subcontinent, the
other two being Teak and Deodar. It is native to Southern Asia, ranging to south of the
Himalaya, from Myanmar in the East to India, Bangladesh and Nepal. In India, it extends
from Assam, West Bengal and Jharkhand to the Shivalik Hills in Haryana. Sal is one of the
most important sources of Hardwood Timber in India.
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Physical Properties
It is a hard to coarse – grained wood that is light in colour when freshly cut and
becoming dark brown on exposure. Sal is moderate to slow growing and can attain heights of
30 to 35 meter and a trunk diameter of 2 – 2.5 meter. It weighs nearly 25 to 30 kg to a cubic
foot.
The Sal wood is resinous and durable. It is difficult to plane and more so drive a nail
in to it. It is accordingly considered most suitable for railway sleepers, piles, beams, and other
load bearing parts of bridge structures, wheels, bodies of carts and other similar load carriers,
including motor trucks and super structure of house tops. In fact, Sal wood is most suitable
for all such applications where strength and elasticity are foremost requirements and where
polishing in not so very essential. Sal wood being so much sought after for construction
purposes, its demand is much more than the available supply
Comparative Analysis of Timber Species Used
MANGO SHISHAM KIKAR SAL
Specific Gravity 0.59 0.69 0.738 0.82
Natural Durability* VI II III II
Treatability Class** A E B E
Seasoning Behaviour* Liable to
discoloration
Good at
seasoning
Liable to warp
and spilt
Liable to warp
and split
Machining Behaviour Easy Suitable Difficult Difficult
Finishing Behaviour Easy Good at
Finishing Mod. Difficult
V. Diffic
ult
Transverse Strength* V III III IV
* (Troup R.S., 2007) ** (Kumar & Dev, 1993)
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LAY OUT OF INDUSTRY
Note: The end section of each storey consist of freight lift system to carry finished products,
some raw material needed from time to time. The Seasoning side building has two more
storeys above it. First floor has 6 large size rooms for storage of seasoned planks. Above it
there is a show room of Modular Bed room, Wardrobe etc.
Horizontal
Band Saw
Vertical Band
Saw
Seasoning
Plant No. 1
Seasoning
Plant No. 2
Boiler and Seasoning
Control System
Reception and Show
Room
Finger Joint and butt end Joint Section
having following machines:
1. Automatic Finger Joint Machine
2. Clamp Carrier
3. Four side planer cum Thickneser
4. Two side planer
5. One side planer
6. Laser Cutting machine
7. Thickneser
8. Pneumatic Finger Joint Press
9. Hand circular saw
10. Automatic circular saw
11. Vertical Band saw
Crane System for
uplifting seasoned planks
to other storeys
Passage for
vehicles loaded
with logs and
area for
stacking of logs
for primary
conversion
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SEASONING SECTION
Seasoning is the most critical part of any wood industry as it take care of the health
of the final product. In case of a careless seasoning the whole wood stack can be spoiled. In
ds doors (India)ltd, seasoning is done in two kilns of same size run simultaneously. Mixed
species have seasoned in kiln at high elevated temperature with live steam give first than
dry steam has given. There is no attention on air seasoning due to which end splitting is
quite regular feature in planks; there is no use of end coating on planks due to which
internal cracking is often seen on the planks.
Timber may be dried for many reasons.
First, drying increases dimensional stability. Wood shrinks considerably more across
the grain than along the grain when it dries. Because wood shrinks during drying, if it
is cut to size before properly dried, it will be undersized in its final form.
Second, drying can reduce, or even eliminate, decay or stain. Wood dried below 20
percent moisture content is not susceptible to decay or sap staining.
Third, drying reduces weight. Removal of most of the water in the wood reduces
lumber weight by 35 percent or more.
Finally, drying increases the stiffness, hardness and strength of wood. Most species of
wood increase their strength characteristics by at least 50 percent during the process
of drying to 15 percent moisture content.
Drying of wood in a controlled manner is termed as Seasoning of wood. It is a critical part of
any wood industry. Timber can be dried in various ways. The drying of wood occurs by
effecting evaporation of moisture from green wood by supplying Heat in a controlled RH.
This can be done by following 3 methods:
1. Convection (Direct Drying)
2. Conduction (Indirect Drying)
3. Radiation (By using Microwaves or Radio Waves)
Among these three, Convection is the most commonly used method. Industries are usually
using Convectional Steam Heated Kiln for timber seasoning. In such type of kilns, steam is
used for heating as well as for maintaining Relative Humidity inside the kiln.
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SHK 01 : 3000 cft
SHK 02 : 3000 cft
The main features of Steam Heated Kilns used by the industry are as follows:
The Heating coils and live steam pipes are provided in the kilns only on one side of
the stack.
No air ducts are provided in the kilns.
Vents are not satisfactorily working as they are not in the roof but on the upper side of
walls.
For air circulation Overhead Reversible Propeller Fans are installed in every Kiln
Dry Bulb - Wet Bulb is automated, but not found working satisfactorily.
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Under- ground floor- Flush door, Kitchen and Office cabinets, Particle
Board doors
Supervisor room
Vacuum film coating
machine
Circular saw for
cutting veneers
Circular saw
Vertical
Band Saw
Thickneser
Automatic
Boring
Machine
Cold Press no. 1
Cold press no.2
Clamp Carrier
Manual
Edge
Bending
Machine
Freight Lift System
Veneer,
Plywood and
Particle board
Storage section
Cabinets Assembly
section
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Manual Door Making Section ( Carpentry Section)
Supervisor’s room
FREIGHT LIFT SYSTEM
AUTOMATIC COPYING
LATHE
PARALLEL
COPYING
LATHE
CHAIN
COPYING
LATHE
SPINDLE MOULDING
MACHINE
BORING MACHINE
DOWEL MAKING
MACHINE
VERICAL BAND SAW
VERTICAL
BAND SAW
12 mm
Blade
SPINDLE
MOULDING
MACHINE
AUTOMATI
C SPINDLE
MOULDER
DOOR
FRAME
CORNER
JOINTER
ONE SIDE PLANER
THICKNESER
THICKNESER
CHAIN AND
CHISEL
MORTISER
CHAVE
MACHINE
ROOTER (AUTOMATIC MOULDING
MACHINE)
CIRCULAR SAW
FILLING AND LIGHT SANDING
DOOR END STEEL STRIP MOULDING
MANUAL DOOR CARPENTRY AREA
MANUAL TENON AND MORTISE MAKING
TENON AND MORTISE FITTING
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CARPENTERY SECTION
Industry is mainly using Dowel Joints, Mortise and Tenon joints, Finger Joints, Butt
Joints, Mitre Joint, and Tongue and Groove Joints according to product design. There
characteristic features and strength properties are as described in detail as follows. Among
them, Dowel Joints are used almost in every item.
Joinery:
Wood joint or wood joinery is the operation of joining two pieces of woods by
various means to improve its strength and modify it according to different end uses like
furniture, structures, toys, and other items. As joint is one of the key factors in wood working,
it can be modified with various appropriate mechanical fasteners, adhesives, chemicals and
wood itself which ultimately form products like furniture frame, constructional purposes,
case construction and so on (Zhang and Eckelman, 1993). Strong and inconspicuous wood
joints can increase a piece of furniture's (any service) strength and durability. A proper joint
is an essential feature of any carpentry project.
In early course of Traditional wood joinery technique, often their tasks were
performed with distinctive material properties of wood without using mechanical fasteners.
But nowadays, wood joinery is used with appropriate modified, scientifically proved
techniques. (http://en.wikipedia.org/Woodworking_joints, http://en.wikipedia.org/wiki/dowel
_joints).
Wood is Anisotropic in nature; its material properties are different along
different directions. It works very strong with stress along the grain (longitudinally), but in
weak across its radial (tangential) direction. It shrinks or swells in response to humidity less
longitudinally and more severely (considerable, but unequal) in tangential direction. This is
the reason why its natural properties prior to any mechanical work on it are considered very
essential. (http://en.wikipedia.org/wiki/Woodworking_joints).
1. Dowel Joints
Dowel is a pin, usually a round wooden rod of relatively small diameter, fitting into
holes in two adjacent pieces of wood to prevent their slipping or to align them for fastening
wood work. Dowel Joint is also a method of fastening two flat pieces of wood together to
form larger flat surface. Dowel joint is one of the ideal, easiest and cheapest techniques used
f
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from earlier ancestors up-till now (http://en.wikipedia.org/wiki/dowel _joints).
As the Dowel joint is the Modified and improved version of the Butt joints, it
can be used with other joints like butt joint, mitre joint, screw joint etc. to create better
product in strength and durability (http://en.wikipedia.org/wiki/dowel_joints). In earlier days,
butt joint was mostly used in wood working task because of its simplicity of design or
construction; but it is a very weak joint in practical applications or end products.
FINGER JOINTING IN WOOD
Finger joint is nothing but joining of pieces of shorts of wood to form a long lumber. In
Early days, box joint was considered as a type of finger joint in which four rectangular pieces
of woods are joined together. In that case the fingers were placed at right angles in to
grooves. And then these boxes are used for different purposes such as jewellery boxes,
packing cases. But now the concept has changed. Today finger joints are used mainly for
increasing the lengths of lumbers.
Finger joint is joining of pieces of shorts of wood to form a long lumber which
ultimately contributes to the supply and production of high quality lumber. The development
of finger joints was mainly aimed at reducing the waste of high quality lumber that resulted
from scarf joints. Thus they play an important role in saw mill recovery by reducing the
wastage. Strength values indicate that finger joints can be used as replacement for mortise
and tenon or dowel joints,
It plays an important role in saw mill recovery by reducing the wastage. Finger joint
gives a welcome solution to the high cost of lumber and its supply. They save wood and
hence are very profitable to saw millers. They help to join the short pieces of woods to form a
long lumber. The joint is strong especially when used with good quality glue, such as PVA.
The finger joint can also be used in such things as floor boards, timber roof and door
construction. Glue laminated beams are frequently made from a number of finger jointed
members and attention is given on quality of finger joint.
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Benefits of finger Joints
They give clear lumber from low grade stock
They help to reduce the wastage of wood thus contributing to saw mill recovery.
They convert short lengths of wood pieces into long lumber.
They increase the yield of unusable parts.
Finger-jointed timber is generally high quality timber obtained by cutting out defects.
Their strengths are higher than butt/ Scarf joints.
Joint configuration and orientation
Two types of orientations are used for finger jointing in wood. They are vertical
finger joints and Horizontal joint.
Vertical finger joints show more tensile strength compared to the horizontal finger
joint.
Adhesive type and gluing
Strength of finger jointed wood will also depend on the adhesives used.
Adhesives don’t have a significant effect on Bending and tensile strengths.
Finger joints of high flexural and tensile performance can be produced by using
isocyanate adhesives.
Isocyanate based adhesives produce high tensile bonds and cure at ambient conditions.
The bonds obtained were resistant to creep, moisture and heat exposure treatments.
CONCLUSIONS
Strength values indicate that finger joints can be used as replacement for mortise and
tenon or dowel joints.
Resorcinol adhesive gives an excellent bond for exterior conditions, but is visible
under a transparent finish.
Finger joints of high flexural and tensile performance can be produced by using
isocyanate adhesives.
Low slope of a finger can yield 85 to 90 percent strength of solid wood.
Strength of finger joints reduces with reduction in length of fingers
Vertical finger joint show more tensile strength compared to horizontal finger joints.
Optimum temperature range for finger jointing is between 5 -20 C
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Mortise and Tenon joints
Mainly, a mortise and tenon joint is used in
woodworking to join end grain to edge grain, or long
grain, it is a time honoured and proven technique. This
type of joint accommodates the active movement of
wood fibers and produces a super strong joint.
Basically, it's a peg that fits into a hole.
There are some basic guidelines you should follow
when making a mortise and tenon joints
1. A mortise should be penetrate about halfway
into a stile.
2. Structural shoulders resist stress.
3. At the end of stile, slightly bevel edges to
resist splitting.
4. Don’t undercut the tenon
5. Precise geometry is the key to effective
joinery.
6. Use sufficient amount of glue on the
joint, but avoid over glue.
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CNC ROUTER SECTION
OFFICE SECTION
FRIEGHT LIFT SYSTEM
CNC PROGRAMMING OFFICE
CNC ROUTER
FLEXICAN
10 BITS PNEUMATIC
AUTOMATIC EDGE
BENDING STRIP
GLUING MACHINE
AUTOMATIC
BORER (DOOR)
BEAM SAW (AUTOMATIC RIP SAW)
CNC ROUTER
BSA MODEL 3D
MANUAL
SPINDLE
TOOL CNC
ROUTER
EXCITECH
SHMS 1325
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FINISHING AND PACKAGING SECTION:
SOFA SET AND CUSHIONING WORK
SPRAY GUN- APPLICATION OF
LACQUER AND MELAMINE
(CLEAR FINISH)
BELT SANDER
2 DRUM
SANDER
CUM
THICKNESER
PACKING
SECTION MAIN FINISHING ZONE
1. MANUAL LACQUER
APPLICATION
2. LIGHT FINE SANDING
3. STAIN APPLICATION
4. GRAIN FILLING
FINE
MANUAL
CARVING
SECTION
FREIGHT LIFT SYSTEM
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FINISHING SECTION:
Wood Finishing refers to the process of embellishing and/or protecting the surface of a
wooden material. The process starts with surface preparation, either by sanding by hand
(using a sand paper or power sander), scraping, or planing. Imperfections or nail holes on the
wood surface may be filled using wood putty or pores may be filled using wood filler.
Following operations are usually involved in wood finishing:
1. Sanding
2. Staining
3. Sealing
4. Final Coat
Sanding:
Sanding is a process of fine smoothing of wood surface and it is the process of Surface
Preparation. Every professional polisher and wood finisher has its own preferences when
sanding before the application of Stains and Clear Finishes. It is essential as it reduces the
“Mill Glaze” (the shiny look a wood can have when freshly trimmed) which ensures proper
penetration of Stain or Finishes.
Wood can be either hand sanded or power sanded. Normally used Grit Sizes are 80, 100, 120,
240, 320 (used in power sanding sometimes)
Staining:
Staining is done usually to colour the wood. Normally it does not protect the wood in any
fashion. Staining is usually done according to the colour of the sample provided by the buyer.
Some woods such as pine or cherry do not take stain evenly, resulting in “blotching”. To
avoid blotching, a barrier coat such as shellac or “wood conditioner” is applied before the
stain. Gel Stains are also used to avoid blotching.
Commonly used stains are Walnut Stains, Teak Stains, Black Stains, White Stains, Rosewood
Stain etc. But usually to match the colour with the colour Buyer has demanded for, These
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stains are mixed in a definite proportion. This needs a great experience to make new colour
formulations and the industry has 2 – 3 experienced staff for this purpose.
Sealing:
Sealing of wood surface is done for protection of wood surface from external conditions such
as moisture, abrasion etc. It is recommended to dilute the sealer with suitable diluents
specified for the sealer so as to give more protection to wood by more penetration of the
sealer into the wood. The wood may have a slight rough surface after the sealing. This is an
indication that the pores of the wood have been sealed and wood has excess sealer on the
surface which can be removed by light sanding.
FINAL COATING WITH CLEAR FINISH
Final coat is done to get the desired level of richness in the finish.
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COMPARISON OF DIFFERENT FINISHES USED BY THE INDUSTRY
NAME OF
FINISH
Appearanc
e Protection
Durabilit
y Safety
Ease of
Applicatio
n
Reversibilit
y
Rubbing
Qualitie
s
Shellac
Some
yellow or
orange tint,
depending
on grade
used
Fair
against
water,
good on
solvents
except
alcohol
Durable
Safe when
solvent
evaporates
, used as
food and
pill
coating
French
polishing
difficult
technique to
master
Completely
reversible
using alcohol
Excellent
NC
Lacquer
Transparent,
Good Gloss
Good
Protection
Hard &
Durable
Uses toxic
solvents,
including
toluene,
Breathing
Protection
is needed
Requires
Spray
Equipments
. Brush on
products
also
available
Completely
reversible
using lacquer
thinner
Excellent
hard
Finish
Conversio
n Lacquer
Transparent,
Good Gloss
Excellent
Protection
against
many
substances
Hard &
Durable
Uses toxic
solvents,
including
toluene,
Breathing
Protection
is needed
Requires
Spray
Equipments
.
Completely
reversible
using lacquer
thinner
Excellent
hard
Finish
PU
Varnish
Transparent,
many coat
look like
plastic
Excellent
Protection
against
many
substances
, tough
finish
Durable
Relatively
Safe, uses
petroleum
based
solvents
Brushing
need good
technique to
avoid
bubbles and
streaks
Can be
stripped with
difficulty
using paint
removers
Bad
Water
Based PU
Transparent,
may give
cold bluish
tinge to
wood
Good
protection Durable
Safer than
oil based,
fewer
VOC’s
Brush or
Spray,
Brushing
need good
technique to
avoid
bubbles and
streaks
Can be
stripped with
difficulty
using paint
removers
Bad
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General flow chart for Solidwood Door Manufacturing at D. S. Doors
with use of finger joint technology
LOG SAWING
SEASONING OF PLANKS
STORAGE OF SEASONED
PLANKS
PLANING
THICKNESING
FEEDING OF PLANKS OF
VARYING SIZE INTO
AUTOMATIC FINGER JOINT
MACHINE
STACKING OF FINGER JOINTED
PLANKS OF SIZE 22 ft.
BUTT END JOINT AFTER
APPLICATION OF GLUE ON
SIDES OF FINGER JOINTED
PLANKS
CLAMPING THE FORMATION IN
CLAMP CARRIER FOR 2 HOURS
CNC ROUTING (IF NEEDED)
FINISHING SECTION OPERATIONS
SANDING, STAINING, LACQUER,
PU, & MELAMINE APPLICATION
PACKAGING and DISPATCH
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Apart from solid wooden doors the industry also manufactures flush door, Particle Board
doors with the use of MDF, HDF veneers. This could be the best utilization of the small
pieces of wood. And probably these doors are giving tough competition to solid wooden
doors in terms of its cost, manufacturing time and strength as well as look. Due to the
unavailability of door testing (mechanics) laboratory we are unable to check its strength
properties, but these doors are consumer friendly and popular.
Machines used in Solidwood Door Manufacturing using Finger Joint and
Butt End Joint Technology
1. Horizontal Band Saw: for conversion of logs into planks of 50mm thickness.
2. Vertical Band Saw: for cutting the sidings of planks to bring them into suitable
size for seasoning.
3. Surface Planer: for planning the surface of planks to get proper smoothness and
thickness.
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4. Two Side Surface Planer: it planes the planks from both sides, i.e. upper, lower
and two sides.
5. Thickneser: this is to bring the planks into proper required thickness from all sides.
6. Manual Finger Joint Machine: When the quantity of planks needed is less then
this machine is used to make fingers. It has two heads first ones planes the end surface
of planks by cutting it and another one makes fingers of 12mm depth. Manual gluing
and pressing is to be done later unlike that of the automatic finger joint machine
which apply the glue as well as pressure required for setting of fingers
simultaneously.
7. Finger Joint Press (Pneumatic type): this is used to set the fingers joints after
gluing of the fingers in manual finger jointing.
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8. Auto Roller Type Glue Spreader:
9. Butt End Joint Machine (Clamp Carrier): this is one of the most suitable
machine works on the principle application of pneumatic pressure for but end jointing
after applying glue on the sides of the planks. It takes one and half hour for setting of
ends.
10. Laser Circular Saw: this machine is provided with circular saw, laser pointer at
the head and a overhead conveyor. We can set the required measure on the scale and
laser set on the planks accordingly. Used for precise cutting.
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11. Angular Circular Saw: This circular saw can cut the wood, veneer, plywood at
different angles like 90°, 45°, and 60°.
12. Hydro-pneumatic press for flush door, particle board doors etc. -
this machine works on the principle of pneumatic pressure. It puts 1 tonnes weight on
the flush doors, PB doors etc after the application of glue and placing veneers and
mica.
13. Manual Edge Bending Machine: This machine is used to glue and bend the
mica sheets on the edges of the laminated ply. It is provided with glue spreader which
applies the glue on the edges of the laminated ply and next to it the pressure is applied
on the strips of laminates which gets attach firmly to the lam ply.
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14. Automatic Boring Machine: this machine has six different kind of boring bit
that is used to bore in the ply and cabinets in to different shapes. It works on the
principle of pneumatic pressure which holds the work piece firmly and then select the
required tool/ bit to bore into it.
Vertical Band Saw (12 mm blade): this band saw is used for fine cutting of
small pieces of wood like different moulding and chair and table legs to give them the
required shape. One can use this machine to shape out small pieces of wood into
different design objects to be used in doors.
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15. Boring Machine:
16. Instruments for Manual Tenon and Mortise joint:
17. Preparation of Flush Door: in this first of all 40mm thick and 6.5 ft odd length
planks are used as the frame. In that usually 2 more styles are kept at equal distance
and those battens of 1-1.5 ft length are filled up. After that gluing is done to avail the
layer of laminated mica over it. Then it is finally kept under pneumatic press for 2
hours for setting under 1 tonnes.
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18. Through and through Door boring machine: this is one of the amazing
machine which provides dimensional stability and strength to the door. First of all the
tungsten carbide boring rods make hole in the thickness of the door at three places.
Then rods of steel is fed inside the hole and screwed down with bolt.
19. Beam Saw: this is usually a rip saw used to cut the edges of the doors after the
final finishing in door making process. One can adjust the required size in it and then
feed the door into the machine, it will make sure that the thickness edges of the door
will be smooth and plane.
20. Two Drum Sanding cum Thicknesing Machine: this is the improvised
version of the three drum sander. It saves the time in flush door and PB door
manufacturing. It uses 60, 80 or 80, 120 combination grit sizes. First of all the
thicknesing of the surface takes place so that the door get planed surface and then
sanding takes place simultaneously.
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21. Automatic Copying Lathe:
22. Carving tools:
23. Chain Copying Lathe
24. Chain and tenon mortise machine:
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25. Dowel making machine
26. All you need for sanding and filling
27. Four side planer cum moulder
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28. Automatic finger joint machine
29. Automatic Edge Bending Machine
1. QUALITY CONTROL AND PACKAGING
In this era of ever-growing competition, it has become absolutely necessary for a
businessman to keep a continuous watch over the quality of the goods produced. Having once
bought the product, if the consumers feel satisfied with regard to its quality, price etc.; a kind
of goodwill for the product is developed which helps to increase the sales. However, if the
consumers are not happy with the quality of the product and their complaints are not given
proper attention, it shall be impossible for the manufacturer to continue in the market. Here at
this industry I find that every labour is working so cautiously that he ensures the quality of
the product himself. The labours are experienced and working with industry since long time.
From time to time Mr. D. S. Sharma, the owner of the industry himself checking the quality
of the final product as he himself possesses a vast experience of this field since 40 years. The
industry does not have qualified quality checking officer.
To ensure the good quality product quality control is essential at every stage of manufacture.
However, at quality control section the quality of the final product is checked. The product is
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first checked by the Quality Control Officers appointed by the Industry and then by Quality
Control Officers of Buyer. Quality Controllers of the industry do the 100% inspection of the
material and minutely frisk the material for all features i.e. Dimensions, Colour of the
products, uniformity of stains, frictionless movement of Drawers and doors and presence of
scratches etc.
Packing of the material is the very last step of the production in the industry. Industry has its
own permanent labour for packaging section. Products approved by quality control officers
are then packed in foam and bubble sheet.
Projects:
There were three projects assigned to me
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PROJECT – 01
Statistical Quality Control Analysis
of
FOUR SIDE PLANER – cum – MOULDER
For Fraction Defective
SQC ANALYSIS OF FOUR SIDES PLANER
SQC Analysis
In this era of ever-growing competition, it has become absolutely necessary for a
businessman to keep a continuous watch over the quality of the goods produced. Having once
bought the product, if the consumers feel satisfied with regard to its quality, price etc.; a kind
of goodwill for the product is developed which helps to increase the sales. However, if the
consumers are not happy with the quality of the product and their complaints are not given
proper attention, it shall be impossible for the manufacturer to continue in the market. There
are two different ways of controlling the quality of a product:
1. Through 100% inspection, i.e., by inspecting each and every item that is produced;
and
2. Through sampling techniques or the use of Statistical Quality Control.
The system of 100% inspection is not satisfactory because of the following reasons:
1. It is too expensive.
2. The inspection is made at the end of manufacturing cycle, and hence provides few
controls over the manufacturing process.
3. It takes too much time to inspect each and every piece that is being manufactured and
impossible where the production is done at a very large scale.
Statistical quality control (SQC) is the term used to describe the set of statistical tools used
by quality professionals. Statistical Quality Control is simply a statistical method for
determining the extent to which quality goods are being met without necessarily checking
every item produced and for indicating whether or not the variations which occur are
exceeding normal expectations. Quality Control methods are applied to two distinct phases of
plant operation:
1. The control of various manufacturing processes
2. The control of the product manufactured
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Control Charts:
A control chart is a statistical device principally used for the study and control of repetitive
processes, originated by Dr. Walter A. Shewhart. It is usually a graphic device for presenting
data so as to directly reveal the frequency and extent of variations from established standards
of goals. Control Charts are easy to construct and easy to interpret and they tell the manager
at a glance whether or not the process is under control i.e. within the tolerances limit. A
control chart consists of three horizontal lines:
1. A Central Line (CL) to indicate the desired standard or level of the process
2. Upper Control Line (UCL);
3. Lower Control Line (LCL)
Specimen of Control Chart
SQC Analysis for Fraction Defective
Since the number of defectives (c) can be converted into a percentage expressed as a decimal
fraction merely by dividing c by the sample size. This chart has its theoretical basis in the
binomial distribution and generally gives the best results if the sample size is large say, at
least 50. The steps in constructing the chart are:
1. Compute the average fraction defective (P) by dividing the number of
defectives by the total number of units inspected
2. On the chart draw a horizontal line to represent P
3. Determine the upper and lower control limits. The upper and lower control
limits are obtained by the average fraction defective plus and minus three
times the standard deviation as follows:
;
Procedure
L.C.L.
U.C.L.
C.L.
3 + Sigmas
3 – Sigmas
Quality
Scale
Sample Number
Out of Control
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Sampling and Inspection
We randomly selected 10 samples from one lot that is being processed from the machine at a
time. Then we inspected it for Machining Defects as given below:
Fuzzy Grain
Raised Grain
Torn Grain
Miscut Timber
Cutter Marks
In inspection Defect Value for each defect is assigned separately. After assigning the defect
Value Total defect value for each and every sample is calculated. Defect Values are assigned
according to the methodology as given below:
Methodology Followed: Defect value for each defect is given on the basis of following
criteria:
Defect Value 0 : Defect Free
Defect Value 1 : Minute Defect (can be removed by wide belt sander)
Defect Value 2 : Defect can be removed by Sanding properly
Defect Value 3 : Defect exceeding 50% of the area (needs extra
finishing)
Defect Value 4 : Defect exceeding 75% of the area (needs lots of
finishing operation)
Defect Value 5 : Severe Defect (can’t be removed even after finishing)
Total Defect Value = Avg. of all the Defect Values
If Total Defect Value exceeds defect value 2, the Sample is said to be DEFECTIVE.
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Statistical Calculations
We have inspected 15 lots each of sample size 10 (i.e. total no. of samples 150) for every
machine inspected.
After inspection total number of defectives in a lot is determined
Fraction defective of a lot is determined then by dividing the total no. of defectives in
a lot by the sample size
Then average fraction defectives is calculated by dividing the total no. of defectives
by total number of samples (150)
U.C.L. and L.C.L. are then calculated by the formula given above.
Note: If value of L.C.L. is negative then it is taken as Zero. (I.e. whichever is maximum)
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SQC ANALYSIS OF FOUR SIDE PLANER-CUM-MOULDER
SAMPLE
NO.
MEASURED DIMENSIONS FEED SPEED
(M/min)
DEFECTS OBSERVED TOTAL DEFECT
VALUE
Thickness Width Raised
Grain
Fuzzy
Grain Miscut
Cutter
Marks
Date: 29/10/2014 – Lot No. 01 – Species Used: Mangifera indica - Sample's Expected Dimensions: Width: 14 cm., Thickness: 1"
1 14 cm 1” 9.1 M/min 0 1 0 3 1
2 14 cm 1” 9.1 M/min 1 1 0 1 0.75
3 14 cm 1” 9.1 M/min 0 1 3 1 1.25
4 14 cm 1” 9.1 M/min 0 1 0 1 0.5
5 14 cm 1” 9.1 M/min 1 1 0 1 0.75
6 14 cm 1” 9.1 M/min 1 2 5 1 2.25
7 14 cm 1” 9.1 M/min 2 1 0 1 1
8 14 cm 1” 9.1 M/min 1 2 0 1 1
9 14 cm 1” 9.1 M/min 0 2 0 1 0.75
10 14 cm 1” 9.1 M/min 1 1 0 0 0.5
Date: 30/10/2014– Lot No. 02 – Species Used: Acacia nilotica - Sample's Expected Dimensions: Width: 65 mm, Thickness: 65 mm
11 65 mm 65 mm 9.1 M/min 0 1 0 2 0.75
12 65 mm 65 mm 9.1 M/min 1 1 0 0 0.5
13 65 mm 65 mm 9.1 M/min 0 1 0 1 0.5
14 65 mm 65 mm 9.1 M/min 2 2 3 2 2.25
15 65 mm 65 mm 9.1 M/min 1 1 0 1 0.75
16 65 mm 65 mm 9.1 M/min 2 2 5 1 2.5
17 65 mm 65 mm 9.1 M/min 0 0 0 1 0.25
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18 65 mm 65 mm 9.1 M/min 1 0 0 1 0.5
19 65 mm 65 mm 9.1 M/min 0 1 0 1 0.5
20 65 mm 65 mm 9.1 M/min 0 1 0 1 0.5
Date: 31/10/2014– Lot No. 03 – Species Used: Mangifera indica - Sample's Expected Dimensions: Width: N/A*, Thickness: 75 mm
21 N/A* 1" 9.1 M/min 1 2 3 3 2.25
22 N/A* 1" 9.1 M/min 1 2 0 3 1.5
23 N/A* 1" 9.1 M/min 1 1 0 3 1.25
24 N/A* 1" 9.1 M/min 1 2 5 3 2.75
25 N/A* 1" 9.1 M/min 3 2 5 0 2.5
26 N/A* 1" 9.1 M/min 2 2 0 3 1.75
27 N/A* 1" 9.1 M/min 1 1 0 3 1.25
28 N/A* 1" 9.1 M/min 2 2 3 3 2.5
29 N/A* 1" 9.1 M/min 1 2 5 3 2.75
30 N/A* 1" 9.1 M/min 1 1 2 3 1.75
Date:01/10/2014– Lot No. 04 – Species Used: Mangifera indica - Sample's Expected Dimensions: Width: 14 cm., Thickness: 1" (Finger Jointed)
31 20 cm 1" 9.1 M/min 1 3 1 2 1.75
32 20 cm 1" 9.1 M/min 1 2 0 2 1.25
33 20 cm 1" 9.1 M/min 1 1 5 2 2.25
34 20 cm 1" 9.1 M/min 2 2 2 2 2
35 20 cm 1" 9.1 M/min 1 1 0 2 1
36 20 cm 1" 9.1 M/min 1 1 0 3 1.25
37 20 cm 1" 9.1 M/min 1 0 0 1 0.5
38 20 cm 1" 9.1 M/min 2 1 3 1 1.75
39 20 cm 1" 9.1 M/min 2 1 0 1 1
40 20 cm 1" 9.1 M/min 2 1 0 2 1.25
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Date: 03/11/2014 – Lot No. 05 – Species Used: Mangifera indica - Sample's Expected Dimensions: Width: N/A*, Thickness: .75"
41 N/A* 0.75" 9.1 M/min 1 2 0 1 1
42 N/A* 0.75" 9.1 M/min 2 1 3 1 1.75
43 N/A* 0.75" 9.1 M/min 2 3 5 1 2.75
44 N/A* 0.75" 9.1 M/min 2 2 0 2 1.5
45 N/A* 0.75" 9.1 M/min 1 1 0 2 1
46 N/A* 0.75" 9.1 M/min 1 2 0 3 1.5
47 N/A* 0.75" 9.1 M/min 1 2 2 2 1.75
48 N/A* 0.75" 9.1 M/min 1 2 2 2 1.75
49 N/A* 0.75" 9.1 M/min 0 2 5 2 2.25
50 N/A* 0.75" 9.1 M/min 2 2 5 2 2.75
Date: 04/11/2014 – Lot No. 06 – Species Used: Dalbergia sissoo - Sample's Expected Dimensions: Width: 65 mm., Thickness: 65 mm (Jointed Planks)
51 65 mm 65 mm 9.1 M/min 0 2 0 1 0.75
52 65 mm 65 mm 9.1 M/min 1 1 0 0 0.5
53 65 mm 65 mm 9.1 M/min 2 2 0 2 1.5
54 65 mm 65 mm 9.1 M/min 2 2 0 1 1.25
55 65 mm 65 mm 9.1 M/min 1 1 0 1 0.75
56 65 mm 65 mm 9.1 M/min 2 2 3 1 2
57 65 mm 65 mm 9.1 M/min 0 0 0 1 0.25
58 65 mm 65 mm 9.1 M/min 1 1 0 1 0.75
59 65 mm 65 mm 9.1 M/min 1 2 2 1 1.5
60 65 mm 65 mm 9.1 M/min 1 0 0 1 0.5
Date: 004/11/2014 – Lot No. 07 – Species Used: Acacia nilotica - Sample's Expected Dimensions: Width: N/A*, Thickness: 1"
61 N/A* 1” 9.1 M/min 1 2 2 2 1.75
62 N/A* 1" 9.1 M/min 2 2 0 3 1.75
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63 N/A* 1" 9.1 M/min 1 2 3 2 2
64 N/A* 1" 9.1 M/min 1 2 5 2 2.5
65 N/A* 1" 9.1 M/min 3 2 5 2 3
66 N/A* 1" 9.1 M/min 2 2 0 2 1.5
67 N/A* 1" 9.1 M/min 1 1 0 2 1
68 N/A* 1" 9.1 M/min 2 2 3 2 2.25
69 N/A* 1" 9.1 M/min 1 2 5 2 2.5
70 N/A* 1" 9.1 M/min 2 1 2 3 2
Date: 05/11/2014 – Lot No. 08 – Species Used: Mangifera indica - Sample's Expected Dimensions: Width: 14 cm., Thickness: 1" (Finger Jointed)
71 14 cm 1" 9.1 M/min 1 0 0 2 0.75
72 14 cm 1" 9.1 M/min 0 2 3 0 1.25
73 14 cm 1" 9.1 M/min 2 1 0 1 1
74 14 cm 1" 9.1 M/min 2 1 0 2 1.25
75 14 cm 1" 9.1 M/min 1 2 0 2 1.25
76 14 cm 1" 9.1 M/min 1 1 0 2 1
77 14 cm 1" 9.1 M/min 0 0 0 1 0.25
78 14 cm 1" 9.1 M/min 2 1 5 1 2.25
79 14 cm 1" 9.1 M/min 0 1 0 2 0.75
80 14 cm 1" 9.1 M/min 1 1 0 2 1
Date: 006/11/2014 – Lot No. 09 – Species Used: Dalbergia sissoo- Sample's Expected Dimensions: Width: 14 cm., Thickness: 1"
81 14 cm 1" 9.1 M/min 2 3 0 2 1.75
82 14 cm 1" 9.1 M/min 1 1 0 2 1
83 14 cm 1" 9.1 M/min 1 2 0 2 1.25
84 14 cm 1" 9.1 M/min 2 1 2 2 1.75
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85 14 cm 1" 9.1 M/min 2 1 5 2 2.5
86 14 cm 1" 9.1 M/min 2 2 0 3 1.75
87 14 cm 1" 9.1 M/min 1 0 0 1 0.5
88 14 cm 1" 9.1 M/min 1 1 3 1 1.5
89 14 cm 1" 9.1 M/min 2 1 0 1 1
90 14 cm 1" 9.1 M/min 2 2 3 2 2.25
Date: 06/11/2014 – Lot No. 10 – Species Used: Acacia nilotica - Sample's Expected Dimensions: Width: 12 cm., Thickness: 1" (Finger Jointed)
91 12 cm 1" 9.1 M/min 3 1 0 2 1.5
92 12 cm 1" 9.1 M/min 2 2 0 2 1.5
93 12 cm 1" 9.1 M/min 1 1 2 2 1.5
94 12 cm 1" 9.1 M/min 2 2 3 2 2.25
95 12 cm 1" 9.1 M/min 1 2 0 2 1.25
96 12 cm 1" 9.1 M/min 2 2 0 2 1.5
97 12 cm 1" 9.1 M/min 0 0 0 1 0.25
98 12 cm 1" 9.1 M/min 2 1 0 2 1.25
99 12 cm 1" 9.1 M/min 2 1 0 1 1
100 12 cm 1" 9.1 M/min 1 1 0 2 1
Date: 07/11/2014 – Lot No. 11 – Species Used: Mangifera indica - Sample's Expected Dimensions: Width: 65 mm., Thickness: 65 mm. (Jointed)
101 65 mm 65 mm 9.1 M/min 2 1 0 1 1
102 65 mm 65 mm 9.1 M/min 3 2 3 2 2.5
103 65 mm 65 mm 9.1 M/min 1 1 0 1 0.75
104 65 mm 65 mm 9.1 M/min 2 2 0 1 1.25
105 65 mm 65 mm 9.1 M/min 2 1 0 2 1.25
106 65 mm 65 mm 9.1 M/min 1 3 4 1 2.25
107 65 mm 65 mm 9.1 M/min 2 0 0 1 0.75
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108 65 mm 65 mm 9.1 M/min 1 0 0 2 0.75
109 65 mm 65 mm 9.1 M/min 2 1 0 1 1
110 65 mm 65 mm 9.1 M/min 2 1 0 2 1.25
Date: 08/11/2014 – Lot No. 12 – Species Used: Mangifera indica - Sample's Expected Dimensions: Width: N/A*., Thickness: 0.75”
111 N/A* 0.75” 9.1 M/min 1 2 3 3 2.25
112 N/A* 0.75” 9.1 M/min 2 2 0 3 1.75
113 N/A* 0.75” 9.1 M/min 3 2 0 2 1.75
114 N/A* 0.75” 9.1 M/min 1 2 5 3 2.75
115 N/A* 0.75” 9.1 M/min 2 1 5 3 2.75
116 N/A* 0.75” 9.1 M/min 3 2 0 3 2
117 N/A* 0.75” 9.1 M/min 2 1 0 3 1.5
118 N/A* 0.75” 9.1 M/min 1 2 3 1 1.75
119 N/A* 0.75” 9.1 M/min 2 1 5 2 2.5
120 N/A* 0.75” 9.1 M/min 1 2 0 2 1.25
Date: 10/11/2014 – Lot No. 13 – Species Used: Mangifera indica - Sample's Expected Dimensions: Width: 14 cm., Thickness: 1"
121 14 cm 1" 9.1 M/min 2 1 0 2 1.25
122 14 cm 1" 9.1 M/min 1 2 0 2 1.25
123 14 cm 1" 9.1 M/min 2 1 5 2 2.5
124 14 cm 1" 9.1 M/min 1 2 2 2 1.75
125 14 cm 1" 9.1 M/min 1 1 0 2 1
126 14 cm 1" 9.1 M/min 2 2 0 3 1.75
127 14 cm 1" 9.1 M/min 1 0 0 1 0.5
128 14 cm 1" 9.1 M/min 2 2 3 2 2.25
129 14 cm 1" 9.1 M/min 1 1 0 1 0.75
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* (N/A : Not Adjusted)
130 14 cm 1" 9.1 M/min 2 1 0 2 1.25
Date: 11/11/2014 – Lot No. 14 – Species Used: Dalbergia sissoo - Sample's Expected Dimensions: Width: 65 mm., Thickness: 65 mm
131 65 mm 65 mm 9.1 M/min 0 1 0 2 0.75
132 65 mm 65 mm 9.1 M/min 2 2 0 2 1.5
133 65 mm 65 mm 9.1 M/min 0 1 0 1 0.5
134 65 mm 65 mm 9.1 M/min 1 2 0 1 1
135 65 mm 65 mm 9.1 M/min 2 1 2 1 1.5
136 65 mm 65 mm 9.1 M/min 2 2 5 1 2.5
137 65 mm 65 mm 9.1 M/min 0 0 0 1 0.25
138 65 mm 65 mm 9.1 M/min 2 0 0 1 0.75
139 65 mm 65 mm 9.1 M/min 1 1 0 2 1
140 65 mm 65 mm 9.1 M/min 0 1 0 1 0.5
Date: 12/11/2014 – Lot No. 15 – Species Used: Mangifera indica - Sample's Expected Dimensions: Width: N/A*., Thickness: 0.75”
141 N/A* 0.75” 9.1 M/min 1 2 3 2 2
142 N/A* 0.75” 9.1 M/min 2 2 0 3 1.75
143 N/A* 0.75” 9.1 M/min 1 1 0 2 1
144 N/A* 0.75” 9.1 M/min 3 2 5 3 3.25
145 N/A* 0.75” 9.1 M/min 3 2 0 3 2
146 N/A* 0.75” 9.1 M/min 2 2 0 2 1.5
147 N/A* 0.75” 9.1 M/min 1 1 0 3 1.25
148 N/A* 0.75” 9.1 M/min 2 2 3 3 2.5
149 N/A* 0.75” 9.1 M/min 1 2 5 2 2.5
150 N/A* 0.75” 9.1 M/min 1 1 2 3 1.75
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Methodology Followed: Defect value for each defect is given on the basis of following
criteria:
Defect Value 0 : Defect Free
Defect Value 1 : Minute Defect (can be removed by wide
belt sander)
Defect Value 2 : Defect can be removed by Sanding
properly
Defect Value 3 : Defect exceeding 50% of the area (needs
extra finishing)
Defect Value 4 : Defect exceeding 75% of the area (needs
lots of finishing operation)
Defect Value 5 : Severe Defect (can’t be removed even
after finishing)
Total Defect Value = Avg. Of Sum of all the Defect Values
If Total Defect Value exceeds defect value 2, the Sample is said to be DEFECTIVE
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CALCULATIONS
All these calculations are done using MS- Excel spreadsheet. Formulas used in these
calculations are given in front of the calculation itself.
A B C D
1 Lot
No.
Lot
Size
No. of Defectives
Found Fraction Defectives [Formula Used]
2 1 10 1 0.1 =C2/B2
3 2 10 2 0.2 =C3/B3
4 3 10 5 0.5 =C4/B4
5 4 10 1 0.1 =C5/B5
6 5 10 3 0.3 =C6/B6
7 6 10 0 0 =C7/B7
8 7 10 4 0.4 =C8/B8
9 8 10 1 0.1 =C9/B9
10 9 10 2 0.2 =C10/B10
11 10 10 1 0.1 =C11/B11
12 11 10 2 0.2 =C12/B12
13 12 10 4 0.4 =C13/B13
14 13 10 2 0.2 =C14/B14
15 14 10 1 0.1 =C15/B15
16 15 10 3 0.3 =C16/B16
17 P 0.213333333 =(SUM C2:C16)/150
0.129546217 =SQRT((D17*(1-D17))/10)
19 Z value 3
20 Control Lines : P +/- Z X
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After calculations Control Charts were then made using MS – Excel.
Fig.: Control Chart of SQC Analysis of Four Side Planer for fraction defective
Results & Conclusions:
Clearly from the Control Chart, the process is under control.
Four Sides Planer is working very efficiently as found during my study.
Some problems are found when it is used for double surface planning (where width is
N/A*)
It is found that Mango and Shisham are easy for machining while Kikar shows
resistance and the machine produce noise while planing Kikar.
Proper training of workers is needed.
Feed Speed should be maintained as per the species. Till now they are using 9.1
M/min for each species. For kikar especially, use of low feed speeds is suggested.
Pressure system of the machine is provided only for top and bottom holding. No
pressure system is there which can hold the wood edge wise
21 Centre Line 0.213333333 =D17
22 LCL (Lower Control Line) 0 =MAX(D17-(D18*D19), 0)
23 UCL (Upper Control Line) 0.601971983 =D17+D18*D19
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Project – 02
Training of Workers for Proper Stacking
& Comparison of Drying Characteristics of Different Stacks
Training of Workers for Proper Stacking of and
Comparison of Drying Characteristics
Stacking technique is one of the most important factors in satisfactory drying of
timber. Proper stacking of timber ensures uniform drying and reduce seasoning degrades
considerably, particularly warping and biological deterioration through mould and stain. The
rate of drying can be controlled to a certain extent by regulating the rate of air circulation
through the stack by adjusting the height of the foundation, width and height of the stack,
thickness of the crossers and spaces between the adjoining planks in a layer to suit individual
cases.
Timber is stacked in a special way to maximize the surface of each piece of timber exposed
to the air and to support each piece so it will dry straight and without unnecessary warping.
Proper stacking of Timber for air drying involves building a strong foundation, careful
placing and spacing of the boards in the stack, and providing roof protection.
During my industrial attachment, we found that the stacking techniques followed by the
industry are not proper. This result in severe drying degrades as the timber in the stack is kiln
dried.
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Following are some important facts that we observed during our survey:
1. For safety, workers are provided with mask and gloves.
2. Supply of the material is irregular and supplied material is usually non-uniform in
length and thickness as it was not sorted lengthwise in raw wood section.
3. Labour was unskilled and unaware about the proper stacking methods.
4. They were making the stack by using different thickness of the material within a
single stack and sometimes within a layer, which resulted in misbalance of the stack
when it is fork lifted.
5. The stickers (crossers) incorporated in the stack were of different thickness or
sometimes warped.
6. The base of the stack was being made by only 2.5” – 4” thick scantlings or squares.
7. They were using only two bases even for planks of 5 feet length and above.
8. After stacking, the stack was kept outside not with an aim to air dry it but it was kept
outside until a kiln is unloaded.
9. FIFO (First In First Out) Rule was not usually followed in the loading of stacks in the
kiln
Ds doors seasoning kiln and stacking of planks
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Suggested Stacking Techniques:
Foundation
1. Locate the Timber stack on a level site with good drainage and exposure to prevailing
winds in order to ensure some Air Drying to occur.
2. Always start with a good foundation.
3. Various materials such as railway sleepers, treated wood beams or concrete blocks
can be used to build the foundation and support the stack.
4. The supports should be tall enough so the first layer of boards to be dried is at least 12
inches above the ground.
5. They should be spaced no more than 24 inches apart to provide adequate support for
the Timber stack.
6. The cross-supports should be aligned because any low or high spot or twist from
opposite corners of the stack will result in Timber with the same amount of warp.
7. Covering the ground beneath and around the stack with black polyethylene can help
prevent moisture from moving from the soil to the wood, and weeds and grass from
growing and restricting air movement.
Stack
1. Ideally, the Timber should be sorted by length and thickness.
2. Timber of the same length should be put in one stack. If this is not possible, you can
“box pile” the Timber: For each layer, place the long boards on the edges of the stack.
3. These outside boards help tie the stack together, making it less subject to tilting or
falling over.
4. Place shorter boards on the inside, flush with alternating ends of the stack.
5. Do not let loose ends overhang without support.
6. Do not mix Timber of varying thickness within the same layer.
7. Put thicker Timber on the bottom of the stack. This positioning prevents some
handling of the heavier stock, and the weight from the top of the stack will restrain the
thicker material as it dries, preventing excessive warping. Furthermore, the thick stock
EXCESSIVE WARPING CAUSED BY
IMPROPER STACKING OF TIMBER
STACKS PLACED NEAR STEAM
HEATED KILNS IN DAMP CONDITION
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D. S. W Group
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will take longer to dry. If you plan to use certain boards first, place them near the top
of the stack for easier access.
8. Stack the Timber in neat layers as soon after sawing as possible.
9. Leave a 1- or 2-inch space between boards within a layer.
10. Wood strips, called “stickers,” provide the space between layers to allow air
movement.
11. Place stickers perpendicular to the length of the Timber and directly over the
foundation crossbeams to space each layer.
12. Stickers should be straight, uniformly thick, free of bark decay and stain, and
thoroughly dry.
13. Stickers are commonly 1 inch thick by 11/2 inches wide.
14. The length of the stickers should be the width of the Timber stack.
15. Building lathe doubled in thickness can be used if nothing else is available.
16. Orient the stack so that the prevailing winds blow across the boards.
17. The stack should be only as high as you can comfortably and safely stack the boards;
usually no more than head-high.
18. If properly stacked, the weight of the Timber helps prevent excessive warping in all
but the top layers. Therefore, low-grade boards should be placed on the top of the
stack.
19. Weights such as concrete blocks can be used to restrain the top layers.
Roof
The Timber stack should be covered. Practically any device that sheds water can be used as a
roof. The roof should extend 24 inches beyond the front, back and each side of the stack.
Leave an air space of 6 inches between the top of the stack and the roof.
Movement of Stack
1. Timber is usually stacked in the industry near the preservation cylinder.
2. From there it is lifted by the fork lifter to move it to an open space.
3. Stack should be tied properly before moving it so as to ensure proper movement of
stack without misbalancing it.
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Comparison of Drying Characteristics
Stresses develop in Timber as moisture is lost during drying. Shrinkage in width and
thickness will occur; warp, checks or other defects may develop. The potential for drying
defects such as checking and warping also increases with greater Timber thickness.
1. Warping is defined as the distortion of shape of the planks.
2. It usually occurs due to improper loading and stacking techniques as shown in the
figure given below.
3. Warping can be minimized through proper stacking technique and adding weight to
the top of the stack (about 40 pounds per square foot).
4. Timber dries several times faster from the ends of a board than from the surface or
edges. As a result, wide boards often crack severely. This defect is called “checking.”
5. Checking can be reduced by coating the ends of the boards by some bituminous
paints.
Correct way of stacking the timber always the crossers on top
of each other INCorrect way of stacking the timber staggering the
positions of crossers induces warping
STACK OF TIMBER FORMED BY A WORKER BY 1” THICK
MANGIFERA INDICA AS INSTRUCTED BY US DURING THE
TRAINING PERIOD
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We compared the defects occurring in different stacks and following points are observed:
1. Warping of planks is considerably less in the properly stacked timber than those
stacked improperly.
2. Defects such as bowing, cupping are less pronounced in the proper stack which is
placed under another stack.
3. In the industry, as discussed earlier, stack is not usually air dried, but sometimes it
takes some days to a kiln to be unloaded. Then the stack is kept outside in open air
where it is unintentionally dried.
4. It is found that timber stacked in such air dried stack is less likely to be attacked by
sap stain and attain a moisture content of 8 – 12 % within 5 – 6 days of kiln drying, as
observed in case of Mangifera indica (mango).
5. Timber stacked in stack which is not air dried is more likely to be attacked by sap
stain and takes 8 – 9 days of kiln drying to reach 8 – 12% moisture content.
PROJECT – 03
Types of finishes and Gloss measurement
HIGH LACQURED GLOSS
MDF
Sanding (220 orbital grit)
White sealer (PU white sealer) + Hardener + Thinner
4 hr
Sanding (320 Water Paper)
White sealer (PU white sealer) + Hardener + Thinner
4 hr
Sanding (320 Water Paper)
Colour Lacquer
1 hr
Sanding (1000 water paper)
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Clear gloss
12 to 16 hr
Sanding (1200, 1500 and 2000 grit size)
Waxing
Buffering
Sealer, hardener and thinner are mixed in ratio 1:0.5:0.5
Similarly clear gloss, thinner and hardener.
Sealer – commercial name : Milesi vernici – lacke – vernis – barnices
– coating, PU white gloss (KHR – 1)
Hardener ( LNB- 110) – Milesi PU – hardener for clear glossy/white
glossy.
Thinner ( NAX and KIRARA).
Gloss at different points are :
At central part
102.0
103.1
101.1
107.9
104.5
101.7
106.7
109.8
110.4
109.0
108.2
109.8
108.2
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At corners
85.5
93.2
Mean = 1561.1/15
= 104.07
THE GLOSS IS 104.07 GU
The value of gloss is more in the centre part of the board and less at the
corners because of improper buffing at corners
VENEER GLOSS
MDF
Sanding (220 orbital grit)
Clear sealer + Hardener + Thinner
4 hr
Sanding (320 Water Paper)
White sealer (PU white sealer) + Hardener + Thinner
4 hr
Sanding (320 Water Paper)
Lacquer
1 hr
Sanding (1000 water paper)
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Clear gloss
12 to 16 hr
Sanding (1200, 1500 and 2000 grit size)
Waxing
Buffering
All the composition is same as for high lacqured gloss.
Sealer, hardener and thinner are mixed in ratio 1:0.5:0.5
Similarly clear gloss, thinner and hardener.
Sealer – commercial name : Milesi vernici – lacke – vernis – barnices
– coating, PU white gloss (KHR – 1)
Hardener ( LNB- 110) – Milesi PU – hardener for clear glossy/white
glossy.
Thinner ( NAX and KIRARA).
Clear sealer – Shivam company.
Gloss at different points are:
Along the grain
120.5
121.1
111.3
115.8
123.1
119.4
121.4
121.7
111.0
122.5
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120.1
Across the grain
106.3
103.1
106.0
104.8
Mean = 1728.1/15
= 115.20
THE GLOSS IS 115.20 GU (gloss unit)
The gloss when measured along the grain comes out more than that of
across the grain direction.
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CONCLUSION AND SUGGESTION
1. DS DOORS INDIA LTD. is a well Maintained well managed and well organized
industry.
2. Apart from its management we felt that, they require little care and intention towards
seasoning section to get more or better results in production unit.
3. Seasoning section need to be improve.
4. Use proper seasoning Schedules according to species and species thickness.
5. There is a good possibility of establishing air drying sheds to dry preservative treated
wood before going for kiln seasoning.
6. If possible than seasoned the species separately according to each thickness class of
mango.
7. Use steaming of seasoning kilns/ chambers for at least 2 hours to check case
hardening.
8. Timely checking of Moisture detector sensors fitted in seasoning kiln and moisture
meter.
9. The wood of store room which comes their after seasoning should go to working
section by the principle of first come first go.
10. Joint the species part directionally.
11. Use of adhesive- polyvinyl acetate D3 adhesive and add of proper amount of hardener
to make D4 grade in the same glue.
12. Not use of extra glue because the flow of another surface.
13. Use of packed glue roller because not dry to fast.
14. After gluing or assembly, implement re-planning within 2-3 hours in four side planner
to minimize glue line problem.
15. If possible, use combination of Lacquer and shellac in proper concentration whenever
necessary according to product.
16. Steam heated bending and ammonia bending techniques are developed to minimize
the wood waste occur due to curvilinear parts fabrication, I suggest strongly that the
company should try bending technique to enhance the quality, beauty of products and
minimize wood waste.
17. Need 100 % inspection of finished products at industry level before exposing to
Buying House agencies to avoid repairing work at final stage.
