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Furniture frame machining

9/19/17       
Phill

Hello all. We cut furniture frames for a rapidly expanding company, primarily 1/2" and 3/4" plywood. We receive the dxf files from the company that designs and assembles the frames, and import the files to cut. Because of the number of parts, as well as the close proximity of the nest, we will have smaller parts move. We may have as many as 50 parts or so on a 4X8 sheet. We generally cut a first pass, leaving .5MM skin, then cut through with a second pass.
My problem is that though we lose less than 2 percent of these small parts, my customer feels I should pay for the material and cutting costs to replace them. I have tried to explain that due to the sizing, we will inevitably lose parts, he feels I should share in the costs of the replacement cuts. We currently will avoid the second pass on numerous selected parts on the sheet in order to avoid movement, and will hand rout these after pulling from the table...no additional charge.
My question is, does anyone have a percentage of product loss that might be deemed standard when cutting this type and size of product?
This is an excellent customer, and I have considered sucking it up and sharing in the cost, but would appreciate feedback.
Thanks in advance.

9/19/17       #2: Furniture frame machining ...
Dropout Member

I do a bunch of that stuff too.

If the sheets are repeated, a plastic staple or two can save you.

I pay lots of attention to cut order.

I used to onion skin and do a second pass but I started using tabs and only doing 1 pass.

I'm using a 3 flute 3/8 slow up spiral roughing bit at 600 IPM and 15K RPM.

Trim the tabs while the next sheet is cutting.

Haven't lost a part in months.

9/19/17       #3: Furniture frame machining ...
Phill

Dropout,

Thanks for the response. I'll have to see if there is a way to program tabs without taking too much time on a drawing I import. Thanks for the tip.

9/20/17       #4: Furniture frame machining ...
Adam Member

Have you considered making the skin thicker than 0.5mm? Plywood does not always sit tight to the spoilboard, especially on the edges. If you tell router to come down to 0.5mm and the plywood is lifting up, it is possible you are cutting all the way through on the 1st pass.

9/20/17       #6: Furniture frame machining ...
Jerry Member

What software are you using to make your cut files.

9/20/17       #7: Furniture frame machining ...
Phill

Tanks Adam. That doesn't seem to be occurring though.
Jerry, we are using Biesseworks software. Both of our machines are Rover B's.
Dropout, before you switched techniques, what kind of loss, percentage wise, were you experiencing?

9/20/17       #8: Furniture frame machining ...
Dropout Member

I never kept track of how much I lost. Any amount of redo is bad.

My policy is in case or a lost part, the client pays for the material and I pay for the machine.

9/21/17       #9: Furniture frame machining ...
Adam Member

Phill, how big is your vacuum pump?

10/10/17       #10: Furniture frame machining ...
gregpeed Member

we had a supplier who couldn't give us 95% compliance, said he could do no better and would not credit defects. We increased hid pricing by 5% and then charged the rejects to his credits. Within 6 mouths he cut his defect rate in half. We gained production motion by having less rejects on the floor and were able to reduce over order supplying.


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