1998 progress report.

Each year I conduct an informal survey to determine the progress of our readers with an emphasis on problems for which they have sought my help. I thank the readers who participated for their cooperation and send special thanks to those who have indicated this column has helped them improve their operations in at least some small way.

I'm pleased to report that my survey tells me that overall progress has been very good, maybe the best to date. Much improvement has occurred in the areas of drying, handling and storage of lumber. The industry-wide embrace of new and improved equipment has helped companies make big strides in product quality, material yield and reject reduction. Many readers say they have discovered the benefits of working closely with technicians of their sources for finishing materials and abrasives.

This said, I will turn my attention to touch on some things that are in need of attention. In doing so, I will mention some of the important points that appear from time to time in this column. This tune, though, I hope these reminders really hit home!

Lumber Buyers Beware

Companies that purchase dried lumber, I plead with you to specify the ideal 6.5 to 7 percent moisture content for hardwoods and check every board upon delivery with a hand-held moisture meter. Equally important, be careful about storage. Be sure storage areas are maintained between 60F and 80F and that they are well ventilated. Try to keep relative humidity as close to the 35 percent target as possible at all times. If you don't do these essential fundamentals, you are setting yourself up for some very painful and costly production nightmares.

I'll mention just a few things about machining. When trimming pieces, be sure the saw is good and sharp. In addition, don't run the pieces through the saw too fast.

When mitering, if there is room for dowels by all means bore holes for their use. Avoid tenons, and when cutting the miters, remember that you want the tip of the miter to touch first in assembly.

Remember, safety always comes first. Train your people to operate machines safely. Provide them with good lighting and a dust-free environment.

Reject Parts Before Assembly

In the assembly department, be sure to provide quality inspectors with ample time to check each part so they can remove any reject piece before it gets attached to another piece, or heaven forbid, before if becomes a part of a complete unit sent to the finishing department.

I strongly recommend the use of "dummy" drawer fronts and doors in case clamp operations. Doing so helps ensure an easier fit for every drawer front and door. Again, good lighting is a must for quality frame assembly. Be sure to remove any glue squeezeout before it can harden.

Work closely with your finishing equipment and material suppliers. Follow their expert advice closely to help you reach peak efficiency and quality quickly and smoothly. Remember, never use rags. Instead, clean up dust particles with compressed air. Always keep finished part samples handy to make sure you are achieving an exact match in color, gloss, texture, etc.

Keep any windows in the finishing department shut at all times. Keep dust out of the finishing process and maintain clean floors. These ideas are not great trade secrets; they are common sense and a must objective for all quality-minded companies to attain.

Listen Up, Managers

It continues to surprise me that there are many foremen who conduct their jobs as 9 to 5 clock punchers. One thing I always expected of my foremen was to arrive a little early, stay a little late or both to organize the day's work. The last thing a woodworking company can afford is a bunch of workers who are standing around with their hands in their pockets because their boss is still trying to figure out what needs to be done.

The foreman also needs to make sure that everything is in place at all times. Too much time is wasted when one or more employees leave their stations on an expedition to find something that should have been in their reach to begin with.

The foreman builds a well-meshed team through regular departmental meetings. He uses these meetings to discuss shortcomings and listens intently to suggestions from those in his charge. He also encourages and praises those who set good examples.

The chief inspector is the one who signs off on all finished pieces before they are shipped out for sale. The foreman makes sure that the inspector gets cooperation from workers. Parts and completed pieces that are rejected can lead to finger pointing. Oftentimes no one wants to take the blame. At times like these the good foreman is the master of diplomacy. He knows how to head off these personnel conflicts before they arise, or at the very least nips them in the bud after one or two occurrences.

Mr. Boss, you set the tone for your operation. Arrive on time and get out into the plant two or three times a day. Don't get in the way of what workers are doing but do make them aware that you take a firsthand interest in their efforts and results. Getting to know employees on a first-name basis and offering words of encouragement when appropriate goes much further than you may guess.

I'll conclude with a short note about the salesman's role. First and foremost, he must be able to educate retail salespeople about the quality and attributes - construction, finish, etc. - that will help them effectively sell the product. If this is not done, then everything else we have discussed in this column will be for naught.

That's one problem none of us can live with. Agreed?

Beware of Wood Counterfeiters

Q We are sending you four pieces that we presume are mahogany. Each is numbered for you to give your professional opinion about. We have an opportunity to make quite a deal, but I am a bit leery about these samples. I would be most appreciative for your thoughts. Mr. A.

A The pieces labeled "one" and "two" are mahogany. Number "three" is questionable, but I would give your supplier the benefit of the doubt that it too is mahogany. Number "four," however, is not mahogany. It is a good, "close" look, but is in fact cedar. Mahogany from the African coast is OK and reasonable. Just be sure you get what you pay for.

Q Thanks for talking us into attending IWF. With things as busy as they have been, it wasn't easy, but believe me, it was well worth it. We found some new hardware suppliers with interesting products that our current sources do not carry. In addition, I want to thank you for your advice on checking for green lumber in the loads that are delivered to us. We had no idea how much "wet" lumber we were receiving as kiln dried. Do you have any other readers who question your wisdom? Just send them our way. Many thanks. Mr. L.

A I am glad it all worked out so well. I'm sorry to hear that your lumber source was adding green stock to your orders. This can be frightful.

Q Please inspect the samples we sent and offer your opinion. The rough and torn edges are a problem. We checked our saws and blades carefully, and that doesn't seem to be the problem. What do you think is wrong? Mr. J.

A The stock is very soft and very dry. Try running the saws more slowly and compare the results. I am willing to bet that the problem will disappear.