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Effective Early Learning Furniture<\/p>\n
[\/vc_column_text][\/vc_column][\/vc_row][vc_row equal_height=”yes” el_class=”py-10″][vc_column css=”.vc_custom_1616419649473{padding-top: 0px !important;}”][vc_column_text]<\/p>\n
[\/vc_column_text][vc_column_text]The manufacturer of Childcraft furniture reaps 10 percent productivity gains after installing three Python XPR CNC routers from CNC Factory, all manned by one inexperienced worker.<\/i>[\/vc_column_text][vc_column_text]Bill Brugmann, director of manufacturing for Bird-in-Hand Woodworks, wasn\u2019t looking to buy a CNC router when he attended Wood Pro Expo Lancaster in October of 2018. Yet, less than nine months later, he found himself overseeing the delivery of not one, but three customized Python XPR CNC routers from CNC Factory.<\/p>\n
\u201cI really didn\u2019t do a lot of homework, but I had this idea in the back of my mind for improving our parts production,\u201d Brugmann recalls. \u201cWhen I saw the Python at the show with its automatic rear-loading capability and back-to-front cutting movement, I knew I was on to something. I don\u2019t know how else to say it, but it was the perfect machine for us.\u201d<\/p>\n
What especially made the Pythons an ideal fit for Bird-in-Hand\u2019s requirements was CNC Factory\u2019s willingness to manufacture the machines to handle 5 x 5 sheets of Baltic birch. \u201cMost nesting routers are built for 4 x 8 panels,\u201d Brugmann notes. \u201cThey customized the machines to our specifications \u2013 the load and unload tables, and the router table itself including vacuum hold-down placements.\u201d[\/vc_column_text][vc_column_text]3 driverless Pythons, 1 novice operator<\/strong>[\/vc_column_text][vc_row_inner equal_height=”yes”][vc_column_inner width=”1\/2″ offset=”vc_col-lg-6″][vc_column_text]Bird-in-Hand Woodworks is the furniture manufacturing arm of the publicly-traded School Specialty. The company\u2019s 75,000-square-foot factory in Lancaster, PA is dedicated to producing early learning furniture sold under the Childcraft name. Products include desks, tables and bookshelves.<\/p>\n Before the Pythons were installed, Bird-in-Hand produced parts by cutting 5 x 5 sheets of Baltic birch plywood to size on a panel saw and then processing them on CNC routers. It was a labor-intensive procedure that included multiple handlings of material from panel to final part.<\/p>\n \u201cThe majority of our parts don\u2019t need any type of edge work so it made sense to have equipment that could machine a full panel,\u201d Brugmann says. \u201cIn addition, because we are a seasonal business and hire a lot of temporary workers, we are always looking for equipment that\u2019s kind of a no-brainer for somebody to run.\u201d[\/vc_column_text][\/vc_column_inner][vc_column_inner width=”1\/2″ offset=”vc_col-lg-6″ css=”.vc_custom_1620839971183{padding-right: 0px !important;padding-left: 0px !important;}”][vc_single_image image=”1094″ img_size=”full”][\/vc_column_inner][\/vc_row_inner][vc_column_text]The Pythons, with their fifth generation, driverless technology, fit the bill. Once the job is entered on the touchscreen, the Python manages the entire production cycle without human intervention. This includes automatically loading a panel onto the table, selecting the correct tool, adjusting the height of the tool and robotic dust hood based on substrate thickness, and cleaning the table after removing all parts from the cut sheet.<\/p>\n Because of the Python\u2019s take-charge intelligence, one inexperienced worker is able to man all three of Bird-in-Hand Woodworks\u2019 Pythons, which stand side by side. Collectively, the routers process up to 275 panels per eight-hour shift.<\/p>\n \u201cUsually, all three Pythons are running the same pattern like a side or a shelf to maximize production,\u201d Brugmann says. \u201cThe cycle of each machine is alternating by a minute or two. This allows us to have a single temporary worker unload the parts from the three machines.\u201d<\/p>\n Brugmann estimates that when also taking into account the Python\u2019s impact on downstream processes, most notably assembly, they have helped increase the plant\u2019s overall productivity by 10 percent. That\u2019s equivalent to six full-time employees.<\/p>\n \u201cThe machines paid for themselves within 18 months,\u201d he adds.[\/vc_column_text][vc_column_text]<\/p>\n [\/vc_column_text][vc_column_text]Building on a successful partnership<\/strong><\/p>\n Brugmann says CNC Factory has been great to work with, including providing comprehensive onsite operator and maintenance training and dependable after-service support.[\/vc_column_text][vc_row_inner equal_height=”yes”][vc_column_inner width=”1\/2″ offset=”vc_col-lg-6″][vc_single_image image=”1100″ img_size=”full”][\/vc_column_inner][vc_column_inner width=”1\/2″ offset=”vc_col-lg-6″ css=”.vc_custom_1620839971183{padding-right: 0px !important;padding-left: 0px !important;}”][vc_column_text]Based on the positive experience with the Pythons, Brugmann is talking with CNC Factory about purchasing up to three Scorpion LDR insertion machines.<\/p>\n \u201cRight now, we do rabbet and dado construction, but we\u2019re planning to totally redesign our product line to use the Lockdowel connector system,\u201d Brugmann says. \u201cAssembly is currently 50 percent of our workforce. I\u2019d like to get that down to 35 percent.<\/p>\n \u201cWhat I particularly like about how the Scorpion is how it automatically measures parts and calibrates drill setup,\u201d Brugmann says. \u201cHaving the CNC Factory team as a backup, I think is super beneficial.\u201d<\/p>\n\u201c…when also taking into account the Python\u2019s impact on downstream processes, most notably assembly, they have helped increase the plant\u2019s overall productivity by 10 percent. T<\/span>hat\u2019s equivalent to six full-time employees.\u201d<\/h2>\n