Lumber rules you should know. (Consult).

Mr. N. recently sent me a lengthy letter explaining that his company needed a complete set of "rules." He listed several key areas of interest to his woodworking operation, including purchasing, storing and purchasing kiln-dried No. 1 common and better hard maple.

Coincidentally I received a similar letter to Mr. N.'s from Mr. R. concerning the use of hard maple. The big difference here is that Mr. R.'s business is more vertically integrated and is equipped with fairly new dry kilns and a storage shed.

Close Cooperation

Being a small operation, Mr. N. can probably get by with hooking up with one good source of hard maple lumber. He is in a position to develop a one-on-one relationship with the headman of the chosen mill to make sure he consistently gets what he needs when he needs it.

Mr. N. makes it clear and in no uncertain terms that he expects his lumber to be in the 6 to 7 percent range and that he will not accept lumber with streaks and other defects. In exchange for superb service, Mr. N. gives the mill all of his business. While these specifications will be hashed out orally, they will appear on all written purchase orders - not only for legal protections -but so that there is no misunderstanding in the event of a change in personnel on either end.

Mr. N. meters every board for moisture content and check for grade at the time of delivery. Anything that does not meet spec is returned.

Mr. N. has already converted a wooden garage into a lumber storage shed, including providing adequate ventilation. Mr. N. should implement a system by which oldest stock is always used first.

Mr. N. also makes sure his overall plant conditions are maintained at about 65F to 75F and 35% relative humidity. His employees regularly check moisture f wood and parts throughout various operations in the plant.

Finally, Mr. N., being well organized, anticipates his lumber needs and gives the mill adequate time to fill his company's orders. Being that Mr. N. is a good customer who pays his invoices on time, the mill is more than happy to accommodate Mr. N.'s special requests.

Developing this bond of close cooperation is good for Mr. N. and for his lumber vendor. The lumber mill especially benefits as Mr. N.'s business grows, and with it, his fu-m's lumber needs.

Buying in Bulk

Mr. R.'s furniture plant goes through several trucks of lumber each day. He can no doubt buy large amounts from one or two mills, with a third and fourth mill getting any overrun business.

Like Mr. N., the purchase orders must be detailed and explicit as to grade and moisture content, in this case 30% plus or minus 2%. The agreement also prohibits boards bearing lumber streaks. Delivery dates are critical; a schedule is worked out to the satisfaction of all parties. Upon receipt, every board is thoroughly checked for grade and moisture.

Boards that meet spec are properly sticked in stacks in the lumberyard to air dry. The stacks are spaced approximately 15 inches apart at the bunk ends. Black tarps are placed on top of each bunk and extend about half way down the stack.

The oldest of each thickness is to be dried first. Drying is done on a seven-day basis with at least three samples checked for moisture from the top, bottom and middle of each bunk. The final "run up" process as set by the kiln manufacturer, usually takes about six days and is carefully monitored each day, including Saturdays and Sundays. A day or so is allowed at the end of each run for cooling before the bunks go to storage.

The lumber storage buildings must be set up to use the oldest stock first. Side to side ventilation is provided in the sheds; temperature and humidity controls are in place. Again, 35% relative humidity is the target.

When the stacks are removed from storage to be cut, metering is a must. In fact, parts are metered throughout the plant's operations; maintaining proper temperature and humidity controls throughout the plant minimizes problems. Care must be taken to keep doors and windows closed when advisable. Parts are carefully inspected at various production stages. Anything odd about any lumber at any stage of production is to be reported to the foreman immediately.

Both Mr. N. and Mr. R. want the most from their lumber and their suppliers. Observing the basic rules is the way to get it!

RELATED ARTICLE: Advice for branching out.

Q: We are at our best when it comes to making chairs. Now we have an opportunity to make a few occasional pieces. Do you see any reason why doing so would cause us problems? We think we have a good setup for production. After you have read the attached note about how we would go about it, please give us your opinion. Many thanks. Mr. D.

A: Your plans are unique and quite good. Be sure that you don't spread your skilled manpower too thin. Dedicate one key person to keep chair production on a roll and put someone else in charge of this new venture. With a little time, I think you will find that making occasional tables is easier than the chairs you are presently producing.

Q: We are looking into setting up a bonus plan and hear that you have a good one to recommend. We would like a plan that would involve foremen and workers. What more can you tell us? Thanks. Mr. T.

A: I frequently tout a foreman's incentive plan that can go either way. Simply put, it is based on the monthly production vs. the production payroll. If a foreman or department beats the scheduled production minus rejects, then an agreed upon amount is paid to him or his group. If the department misses its quota, then it takes two good months to get back in the deal. I am sending you additional details. Feel free to contact me with any specific questions you may have.

Q: We sent you a bunch of veneered panel samples sent to us by various sources. Most of them look OK to us, but none stand out. What are your findings? We're trying to determine who to buy them from. Thanks. Mr. E.

A: There are a few good panels in the lot but several others have poor cores, bad backs or both. I would have the manufacturers of the panels labeled "C" and "F" send you some additional samples. One or both may already be a winner!

Q: We followed your advice and threw all of our finishing material business to one company in exchange for technical service and advice. As a result, our finish has improved, and though we are paying more for the actual material, our overall costs have decreased because we have far fewer problems. Thank you. Thank you. Thank you. Mr. C.

A: I'm glad to hear things are working out. You can try this same concept with sandpaper next. You can save pennies playing one company against the next to drive prices down or make dollars by building meaningful partnerships with professionals.

Q: We have had terrible turnover and are now thinking about relocating our woodworking business in an area where we can find inexperienced people who want to become good woodworkers. Prospects are bare in our current location. Any suggestions? Thanks. Mr. K.

A: I think your idea of moving to a city that has a much larger high school is a good one. As long as you are patient in your approach to training I think you can be successful.

Q: I can't thank you enough for advising us to go to the woodworking show in Anaheim. We thought we had a pretty good grasp of the machines on the market, but did not fully appreciate all of the options available until we saw them demonstrated at the show. Attending the show has opened our eyes and our pocket books to invest in new technologies. Seeing is believing. Thanks again. Mr. M.

A: This magazine and this column have constantly harped on the importance of attending trade shows. There is no question about the effect these shows can have on the woodworkers who attend them. Even if you don't see the machine that will hit a grand slam for your production operation, you'll no doubt find a decorative or functional hardware item or the like that will at the very least help advance the runners. The big one -- IWF -- is coming up Aug. 22-25 in Atlanta. Anyone who is serious about succeeding in the woodworking industry should plan on attending. There are also several regional shows taking place that are worth the time for local companies to check out.

Q: I built a "gent's stand" for my father, who enjoys smoking cigars. Everyone who has seen it has called it "great," and many of them want me to make one for them. Because of this extremely positive response, I'm thinking about going into production with this idea. Do you see any reason why I should not go into this by giving exclusive rights to the leading dealer in each area? Thanks for your help. Mr. S.

A: I won't say it won't work, but it will take a series of such pieces to keep you in business. Each one will need to be a winner. If they are, then copycats will quickly be your next problem. Rather than enter the market with one piece, try to come up with a group or line based on the design or a variation there of? You may need to find a manufacturing partner that can help you hit the ground running. Let me know how things work out.

Q: We are taking over a small plant and are trying to reduce our costs by positioning major equipment near the existing dust collection piping. The enclosed diagram gives you the layout of the equipment. Do you think it will allow for the best possible production and workflow? Should we be investing in better or different equipment? We appreciate the attention you have given us. Our thanks. Mr. S.

A: I would spend money now and make changes that will give you the improved workflow you need to be successful. It looks to me that the former tenant had a very specific product in mind based on the setup it used. Before you begin production, bring in a dust collection consultant. Make sure he knows what products you will make and plans for future growth. Try to build as much flexibility into the plant layout as you can. Good luck.

Q: A few years ago our cabinet foreman up and quit. I tried my best to keep him but he claimed that his age was getting the best of him. Recently, he contacted me about returning as chief quality inspector. Do you see any reason why I shouldn't bring him back? He is very knowledgeable about woodworking. Thanks. Mr. F

A: If he is active enough and not "age worried," then I think you can do this. Invite him to your office to chat about the position and his goals. Odds are you'll find out he's bored with retirement and misses his livelihood and the "gang" at work.

Q We hate to complain but it seems to me that some of the associations can do a better job of policing their members. Too many are running ads displaying very cheap furniture but with descriptions like "gorgeous," "top quality" and such. To say this is misleading is putting it mildly. I don't think it's the newspapers' fault, but surely the industry should not stand for this. Is there any way that these exaggerated claims can be stopped? Thanks for your thoughts. Mr. H.

A I understand your frustration; I often see advertisements that make me cringe. Still, how a company decides to market Is product is mostly beyond the scope of an association. Let's not forget that beauty -- and quality -- is in the eye of the beholder. As difficult at it may seem, you need to find ways to educate consumers to understand what makes your products better. Only then can they begin to appreciate why your furniture costs more.

Q We area small outfit that needs to develop a top quality finish. We use various products from several sources as detailed in the attachment. What do you suggest? Please help us. Mr. T.

A I think you should phone the two sources I have highlighted on your list. Ask them to send a technician to come to your plant to inspect your methods and procedures. See which one of them comes back to you with the most useful suggestions. If one stands out, give his company all of your business with the understanding that it will help you troubleshoot any problems. Let me know how things work out.

Q I would like your opinion on how we can dehumidify our plant without incurring the expense of air conditioning. Also, we are adding a couple of new pieces of equipment. Do we have to hook them all up to a central collector? I thank you for your help. Mr. K.

A An inexpensive way to dehumidify your plant consists of closing all windows and doors and using portable dehumidifiers and fans where needed -- storage, finishing, assembly. etc. Unfortunately, that doesn't provide the same comfort of air conditioning during the summer. That's a choice you need to make. As for dust collection, I think you need to look at upgrading your central collection system. There is no substitute for a good, efficient dust collector both in terms of energy efficiency and collection efficiency. Dust in your finish will cost you a lot more in the long run plus you owe it to your employees to keep as much dust out of the air as is reasonably possible.

Write to Jerry

Send questions and samples that will fit into a small envelope to Jerry Metz, 2203 Southridge Drive, Palm Springs, CA 92264. A self-addressed, stamped envelope must be enclosed to receive a personal reply. Questions of general interest may be published in this column.