Sizing up: computer software developments.

Like a homeowner committing to a hefty first mortgage, Ned Brown was excited and a little nervous as he signed the dotted line which committed himself and his Skillman, N.J., cabinet manufacturing facility to the purchase of a six-figure Busellato CNC point-to-point boring machine and personal computer interface.

"As with any major business purchase, many variables had been considered before making the choice. And there were many anxieties," Brown said. "But we knew it was time to take advantage of current technology and we also wanted to apply our computer skills to the machining portion of the manufacturing process. Sure it was an expensive piece of machinery, but we use it every day."

Employees of Country Cabinet Shop Inc. program the machine in the front office while the machine performs its operations on the workshop floor.

"The machine performs boring, grooving and cutting out toe kicks which used to require five separate machining operations. And it works so quickly. With over 100 parts to manufacture for the average kitchen, we are able to go from saw-cut panels through machining to the case clamp in four hours," Brown said.

Because Brown's facility is a custom shop, making minor adjustments such as changes in length, width and other dimensional changes from plans could pose lengthy set-up delays if the company used manual set-up operations. But Brown, like many other forward-thinking wood product manufacturers, is discovering that wood-working equipment assisted with personal computers and custom computer programs designed specifically for the woodworking industry are providing an incredible boost in productivity and accuracy. As a direct result, this technology is helping the industry benefit from just-in-time manufacturing and compete in the world furniture market.

"From a manufacturing standpoint, our industry has taken a big step," said John Rossey, marketing manager with Biesse America Inc. "Half of the top 100 manufacturers have each made $3 million to $10 million investments over the last five years."

For the benefit of companies taking the first steps toward using high tech automation, WOOD & WOOD PRODUCTS talked with numerous CNC machinery representatives for advice. Topics such as increased productivity, upgrading considerations, finding quality training programs and ease of operation were among the subjects discussed.

Speed in productivity

Software targeted at the woodworking industry has come a long way since its introduction almost 15 years ago.

"In recent years the connection between order processing, drawing and manufacturing information has improved," said Robert Gowen, president of Pattern Systems Int'l. "Now, once a drawing is done, it can be automatically converted to part sizes, labor content and even machining instructions. Information virtually can flow electronically from the drafting or design table right through the CNC machine."

Older CNC systems required programmers to manually type in G-codes, a numeric code operating on X and Y axes which the computer would use to translate a machining operation, such as a straight line or arc, to the machine. Today's improved software systems have eliminated laborious G-code typing. Instead, G-codes are automatically produced in translating the computer-aided design to computer-aided manufacturing.

"The computer industry is now dictating what computers and programs will be offered," said Dave Steranko, president of Digital Tool Inc. "Years ago the machining industry tried to create its own programs to make it independent, but that movement is dying. Fortunately for the industry, PC-based CAD/CAM systems have come along to simplify the programming process."

Brown outlined the process of creating a program in his operation. When blueprints of the casework are received (or created on-line by Brown), a programmer creates all of the cabinet parts using a cabinet design software package, which also prepares the cutlist. The file created serves as input to the custom software developed by Country Cabinet Shop. This program creates both the machine G-code to run the CNC machine and bar code labels containing information to link each cut part to its associated program code. The bar code labels are scanned into the CNC system on the shop floor to begin executing the program.

So what does this mean for rapid design and production?

"It means that I can now take an idea and have it ready to machine in 15 minutes," said Brown. "These systems are great for short production runs in that they can generate cutlists and machine codes in a matter of minutes, reducing set-up time considerably."

The end of the paper war

It's not difficult to imagine paper of cutlists piling up on a machine, but CAD (computer-aided design) programs designed on a personal computer in the front office and linked to a panel saw or other piece of machinery can allow machine operators to call up downloaded part dimensions and cut lists on the shoproom floor, thus eliminating the paperwork previously required.

"High level software has eliminated paper cutlists as well as shop floor machine programming and the errors associated with them," said John Park, general manager for Delmac Machinery Group. "The problem with floor programming is that the programmer is distracted if the machine is operating while he is are programming, and that can lead to errors. While it is true that a machine can be programmed while it is running, it's not a feasable activity to program and run the machine at the same time because of outside distractions."

New software programs for woodworkers are constantly appearing on the market to help facilitate the design of such parts as cabinet doors. Although it is possible for a company to write its own program, most do not.

"Small companies of 50 employees or less shouldn't try to write their own software programs for two reasons," said Gowen. "It's expensive and the program cannot be serviced."

One type of programming available from vendors that is finding popularity in design circles is "parametric programming." Parametric programs assist CAD system users by allowing variables to define a part or family of parts so any part can be scaled and the part file generated, according to Steranko.

"For example, if a cabinet manufacturer has a line of many small, medium and large cabinet doors with a certain decorative pattern, each door may have a machined feature which must be scaled in relationship to other features," said Steranko. "Parametrics can make these adjustments quickly."

Another term appearing in the woodworker's computer vocabulary is "open architecture." Open architecture is a term used to describe software which has the capability to run or support a wide variety of programs, making it useful when utilizing numerous programs when creating parts.

"Open architecture serves as a good vehicle which allows the customer to create programs, use support programs, or other CAD programs," said Park. "By using DOS as the platform for the machine controller, the user has unlimited possibilities to use IBM, Lotus and other Microsoft-type products."

Stay current

Even though computer programs can assist in design and other operations, users should be aware that the programs which they purchase are not usable forever. As technology changes and becomes outdated, so do programs,

Changes in programs require computer upgrades, such as with a Windows-based system. For example, a CAD program which works on a three-year-old Windows program may have difficulty functioning on the new Windows 95 program.

"Purchasers need to be aware of the frequent software upgrades and have them implemented in their systems," said Nucu lonescu, CNC training manager with Tekna. "The software will change the way the PC controller talks to the machine, and usually the upgrades will allow the machine to perform more functions."

Failure to stay on top of upgrades can be a costly mistake down the road. One interviewee tells the story of a company who failed to upgrade for five years. When the program broke down, the owner was upset that not only was the program unavailable, but the company would also have to buy five years' worth of upgrades to catch up with the new technology.

"Upgrading software is similar to machinery maintenance, you have to spend some money," Brown said. "Beyond the standard first year of free support, I make a choice on a case-by-case basis. If the vendor is meeting my needs in solving problems and adding new functions/features, I agree. If I'm just getting a new version of the software with no real improvements, I don't."

One way manufacturers can stay on top of current upgrades is through service contracts, which, for a specified amount of money, allow companies to obtain the latest updated program from software vendors. But service contracts can have their drawbacks.

"It depends on your company's location," said Steranko. "How much service can they offer you if your company is located a long distance away? A service contract might work for a company like Sears because they're located everywhere. Many machinery and software vendors aren't everywhere."

Specialized training

Jumping into a computer system in a woodworking operation can be quite a challenge. Not only will the manufacturing and office facility probably undergo some physical changes, but the greatest challenge to most companies is training operators and programmers to become proficient with the new equipment.

"If you take a well-established outfit and say `let's go computerized,' it's a change in culture," said Dennis Stephen, vice president of technical sales with Stiles Machinery inc. "A company must be prepared to integrate its workforce to understand, and that takes time. If you want to gain the full benefit of a $100,000 machine, you must have a well-trained technical manager."

When referring to computer-assisted woodworking equipment, training should be divided into two groups consisting of operators and programmers. Operators are the individuals who actually operate the CNC machine. Programmers are the individuals who take the design and enter the data such as boring depth, cutting dimensions and such.

"Even though the two groups need separate training, some cross training should be implemented so that both groups understand each other's responsibilities," said Mike Hawkins, sales coordinator with IMA European Woodworking Machinery.

In addition to training groups in separate programs, a different type of individual is also needed for each group. Requirements for some programs can be minimal, but some strengths should be emphasized.

"I've had to train operators who didn't know what a keyboard was," said lonescu. "Candidates for operator training need to operate a tape measure and have a general understanding of what the program does."

Hawkins agrees. "Operators need to have a general skill of awareness and know what's going on," he said. "In addition, they need to be able to quickly react to a problem if something is wrong with the program or machine."

Programmers need a more basic understanding of computer design and how it functions.

"Programmers should be familiar with the functions of an AutoCAD system," said Ben Radd, president of Northwood Machinery Mfg. Co. "Also knowledge of some general algebra should help."

If a company is considering hiring a designer outside of the company, Brown offered these words of caution. "Look for a candidate who has a background in cabinetmaking and who was later trained to be a computer operator rather than a computer operator who was trained to be a cabinetmaker. We scoured the CAD training programs for talented computer operators, but they didn't work out. Programmers must have a basic understanding of woodworking because they are working with woodworking machinery."

Where to learn

Once a company has decided to computerize or upgrade, where can they send employees for program training? Frequent answers include local community college courses and vendor training programs.

"Finding the right training program depends on a company's location and the type of training needed," said Stephen. "Many personal computer training courses at community colleges are good, but use caution. Some programs can meet a company's requirements and others can't."

Some suppliers also favor vendor-sponsored training.

"Vendor training is beneficial because it can be tailored to an individual company's needs and equipment purchase," said lonescu. "We usually have the programmers and operators travel to our facility for training before the machine is installed, and then we come to their plant and continue training after the machine has been installed."

The most important aspect of computer training, regardless of which group of operators are being instruct d, is that they feel comfortable with the program and material because it will ongoing educational process.

"The level of teaching has to be at their level," said Steranko. "Sending employees to company-led seminars and universities are too intense. The company and the employees involved with the new computer system need to remember that the computer technology they have just purchased only lasts from three to five years in our industry before it becomes outdated. Those employees will probably be going back to school in another three years for a refresher course."

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By linking machinery via a computer system to handle rapid part design as well as parts machining, companies can experience the benefits of increased productivity by taking one step closer to achieving just-in-time manufacturing. Although these high-tech products can offer companies rapid changeover, precision machining with fewer defects, and faster design layout, what does that mean for the future of machine operators and draftsmen?

"Tomorrow's woodworkers will not be woodworkers, but technicians," said Gowen. "Because we don't have a structured apprenticeship program in this country and fewer schools offer technical woodworking training, we're going to have a shrinking skilled-labor pool. Technology will fill that gap. Look in the schools today. Students aren't being trained on woodworking machinery, but computers. This is what they will understand, and the industry has to adapt to that. it's also exciting for the industry because this equipment will allow our manufacturers to produce better furniture cheaper and more effectively compete in the world market."

WINDOWS 95 -- WHAT DOES IT MEAN TO WOODWORKERS?

With a much ballyhooed media blitz, Microsoft's Windows 95 computer program was introduced to the public on August 24. Around the country, trend-hungry consumers stood in line eagerly awaiting to purchase Microsoft's latest offering.

But what does Windows 95 mean to the woodworking industry's high-tech CNC equipment software? WOOD & WOOD PRODUCTS asked computer experts Bryan Bredehoeft, senior business consultant with Kraft Foods Inc., and Don Imbimbo, vice president of product development with Pattern Systems Int'l, about what the pros and cons of the new program.

"Windows 95 is the replacement for Windows 3.1 and uses a graphical user interface (GUI) which means there are lots of user-friendly icons and menus similar to those used on a MacIntosh system," said Bredehoeft. "Windows 95 is primarily for home users. A better choice for woodworking operations is the Windows NT operating system."

"Windows NT actually comes in two types, Server and Workstation, and both of these programs will stick around," said Imbimbo. "It seems as though NT will become Microsoft's business solution for larger customers and Windows 95 will be aimed at personal business users."

More applicable to industrial applications, the Windows NT programs are better for mufti-tasking numerous operations.

"Windows NT Workstations' strength is that it can process CAD while the programmer is performing other functions, such as reading a parts cutlist or spread sheet," Bredehoeft said. "When using Windows NT, the industrial user is less likely to crash their computer Windows NT was an independant development, separate from Windows 95. Windows 95 is not an upgrade to Windows NT."

Regardless of the program being run on a computer, Bredehoeft warned that a computer with insufficient memory will run the risk of crashing.

"Even though Microsoft recommends 16 megabytes of memory for a Windows NT program. I would start at a minimum of 16 megabytes of memory, but you will get better performance with more memory. Think about using 32 megabytes. That extra memory will cost extra money, but it's good insurance against crashing."

SHOP OWNER OFFERS

COMPUTER ADVICE

Since he became interested in computer systems in the early 1980s, Ned Brown, president of Skillman, N.J.-based Country Cabinet Shop, has learned that woodworking facilities must stay up to date on current technology. After being involved in computer hardware and software purchases for his company, he offered his three most important pieces of advice to woodworkers looking to invest in computer technology. 1. Go to other facilities and see how the computers/ programs/machinery works. "See how the other guys are utilizing the system and observe the possible ways you could make it work for you. if you're looking at a program, see how long it takes them to to go from specifications to machined parts ready for assembly." 2. Don't underestimate start0up time, "Understand that the integration of the pieces, not opening the boxes and installing everything, is where your time will go. Don't assume you can push a button on day one and be able to produce any part you want to. Also remember that the more powerful and sophisticated a program or computer is, the more difficult it will be to learn." 3. Look for flexible software. "Find a software package that allow you to configure based on your needs and not vice versa. Look for open architecture that lets you communicate freely with other software tools you use daily. Your software vendors should be very knowledgeable about the products they are trying to sell. Most important, get a list of customers who have purchased the package from your vendor. Don't be afraid to ask the customers how the program has functioned for them."