Download Chapter 1 Introduction to Cabinetmaking.Pdf

CHAPTER 1 Introduction to Cabinetmaking

Objectives on chairs and sleep on beds supported by wooden frames. We select goods from store fixtures, work After studying this chapter, you should beableto: at desks, prepare food on counters, and pull books • Identify the needs and desires for cabinets in from shelves. All of these storage areas, work sur- everyday living. faces, and decorative products might be made from • Discuss the importance of function and form wood, Figure 1-1. for furniture and cabinetry. Every product you see is the result of a need that • Explain the decision-making process for an individual set out to meet. Ideas first put on paper cabinetry production. later became a design that had to be developed. Decisions were made. Problems, such as acquiring • Describe the production process and use of materials and operating tools or machines, were technology as a tool to manage production. solved. Processes for cutting, shaping, assembling, and finishing were chosen to bring the design idea Technical Terms to reality. Cabinetmaking is both an art and a science. You architectural woodwork function can seethe artistic and creative talents of the cabinet- Architectural material decisions maker in subtle curves, precise joints, suitable color- Woodwork Institute organizing ing, and flawless finish of a product. This text covers (AWI) planning the decision-making practices for producing fine Architectural cabinetry, furniture, and architectural woodwork, post-processing Woodwork including doors, trim, and wall, floor, and ceiling Manufacturers preprocessing treatments. The topics focus on the methods, mate- Association of processing rials, and machines used to create these products. Canada (AWMAC) production decisions This chapter presents an overview of cabinetmaking and identifies the relationships between various combining quality steps, including design, materials, production, and computer numerically ready-to-assemble (RTA) management. controlled (CNC) separating controlling quality tooling design decisions 1.1 Design Decisions veneer form Woodwork Institute Consider yourself a designer. Your responsibil- forming (WI) ity is to help people choose furniture and cabinets that meet their needs and desires, Figure 1-2. The designs you create might be original or influenced Throughout history, wood has been used to cre- by an existing style. ate many products. Even with the advent of plas- Design decisions are conclusions made about tics, wood continues to play an important role in the product design before work begins. Making our everyday lives. We store food, utensils, and decisions about a product’s size, shape, and over- personal belongings in or on wood cabinets. We sit all design while work is in process is very costly.

/ 4 Section 1 Industry Overview

KraftMaid Cabinetry, Inc. Figure 1-1. Left—Wooden cabinetry in the home can be practical, functional, and beautiful. Right—Wood is used in cabinetry, on floors, and for other amenities, such as the range hood spice shelf, to personalize a kitchen.

Without a documented plan of procedure, time and Needs and desires materials will likely be wasted. All design decisions are based on two factors: function and form. Consider these factors as you Design generate ideas for a product. decisions 1.1.1 Function and Form Function Form Function describes the purpose for having a cabinet or piece of furniture. Refer to the cabinets Ideas designed and manufactured for use in a dentist’s office in Figure 1-3 and Figure 1-4. A dentist must have many tools within reach of the patient. These Variables Standards cabinets provide storage for supplies and support for lighting, equipment, and trays. The sink cabinet provides for cleanup and solid waste disposal, through Sketching the hole in the countertop. This represents efficient planning and production. Material Another example of function is a home library, considerations Figure 1-5. Adjustable shelving makes this shelv- Working ing unit flexible enough to display taller items. As a drawings designer, you must ensure that every product meets Goodheart-Willcox Publisher the needs and wants of the user. Figure 1-2. A series of decisions and considerations are Form is the appearance of the cabinet. What made during the design stage. will the piece look like? Is there a particular style

/ Chapter 1 Introduction to Cabinetmaking 5

A B C

Adec Figure 1-3. Cabinets for a dentist’s office. A—When closed, this base cabinet has an attractive appearance, yet provides access to frequently used latex gloves. B—Upper cabinet provides access to paper cups and towels through opening in the bottom and latex gloves through the door. C—A variation that provides glove access through the side.

Adec Chuck Davis Cabinets Figure 1-4. Careful arrangement of cabinets and furniture Figure 1-5. Home library shelving displays the owner’s provides an attractive and efficient work facility for both collection of memorabilia. Low voltage lighting with the dentist and the assistant. dimmer switches adds to their enjoyment.

/ 6 Section 1 Industry Overview you want to copy, such as French Provincial, Early American, or Scandinavian? The appearance of the product must fit with the surrounding furniture. Designers often say, “form follows function,” meaning the cabinetry must first serve a purpose. If the product is not functional, even careful styling will not make it useful.

1.1.2 Design Ideas Once the form and function of a product are considered, sketch your ideas. Use your sketches to document your thoughts and to compare alternate designs. Production cabinet shops often create their designs with a computer-aided design (CAD) system, Figure 1-6.

1.1.3 Design Variables Patrick A. Molzahn Figure 1-6. Computer-aided design systems help cabinet Products vary in size depending on their intended designers determine the size and layout of cabinetry. use. A trophy casewith 12″ (305mm) between shelves obviously will not hold a 14″ (356 mm) trophy. You must take into account the size of objects 3′ (1 m). Most metric units have been rounded off to be stored. Furthermore, there are human factors to whole units, such as meters or millimeters. Only to consider. For example, a child’s chair will have where more precise measuring is necessary, is a different dimensions than an adult’s chair. A table decimal point used. For example, 1″ is equivalent to or counter designed for a person in a wheelchair exactly 25.4 mm. must be a different height than standard cabinets Another measurement standard, the 32mm and furniture. System, applies to case construction and hardware installation. Holes are drilled 32 mm on center and 37 mm from the edge of the cabinet front. European 1.1.4 Design Standards hardware is designed to fit this system, making the Many types of cabinetry are designed and pro- hinge mounting plate, drawer slide, or fastener eas- duced based on standards. Kitchen cabinets are ier to install. one example. There are standards for countertop heights, distances between base and wall units, and unit sizes. Widths for mass produced cabinets Green Note are standardized in modules of 3″ (76 mm). Refer The practice of forestry has irreversibly dam- to Chapter 46 for a more detailed discussion of aged some of our forests. Several organizations measurement standards for kitchens. When mak- now exist to monitor and regulate every step of ing a custom cabinet, dimensions may be adjusted forestry in order to sustain forests. The Forest to meet the customer’s needs. Stewardship Council (FSC) is an organization Most of the world uses the International (SI) Met- that has created standards meant to lessen the ric System of measurement. Familiar units include environmental impact of practicing forestry. The millimeters, centimeters, grams, and liters. In the FSC certifies specific forests to be used to create United States, the standard system of measurement wood products and paper. is known as the US customary system. The US customary system developed from English units used in the British Empire before American indepen- dence. For cabinetmaking, feet and inches are used 1.1.5 Ready-to-Assemble (RTA) for measurement, ounces and pounds for weight, and fluid ounces and gallons for volume. Design In this text, the metric units are in parenthe- Another design concept is ready-to-assemble (RTA) sis. For example, you may encounter 1″ (25 mm) or cabinets and furniture. Ready-to-assemble (RTA)

/ Chapter 1 Introduction to Cabinetmaking 7 products are purchased unassembled in a neatly meet the demand for furniture. They began replac- packaged carton and then assembled by the con- ing solid wood with newly introduced panel prod- sumer, using special RTA fasteners. The pack- ucts and plastic laminates. This decreased the cost aged cartons allow even large furniture items to per item, making their products affordable for the be moved through small doors and narrow stair- average consumer. However, because plywood, par- ways. The assembled product often looks no dif- ticleboard, and other panel products held nails and ferent than preassembled-and-finished furniture, screws poorly, manufacturers needed to design new Figure 1-7. assembly methods. This led to the introduction of Ready-to-assemble cabinets and furniture were frameless construction methods and RTA fasteners. developed after World War II, when Europe was RTA fasteners do not create a permanent joint. They faced with a severe shortage of home furnishings. are designed to connect and disconnect with ease. Large furniture companies rapidly appeared to These fasteners make assembly much easier and they hold with great strength in both solid wood and composite materials. RTA fasteners are discussed in greater detail in Chapter 20. With the introduction of RTA cabinets, European 5′-10″ manufacturers learned two important lessons about

3′-1″ consumers: • Becausemoving large furniture was so difficult, consumers appreciated being able to disassemble furniture and reassemble it in a new location. 2′-2″ • Consumers did not mind buying furniture

6′ disassembled and assembling it themselves, provided easy-to-follow instructions were included.

1.2 Material Decisions

2′-10″ There are many materials available for produc- 5′-¹¹¹⁄″ ing cabinets and fine furniture. Carefully consider which materials to use throughout the design and production process. Materials you might consider include wood, veneer, manufactured panel products, plastic laminates, plastic, ceramic, metal, stone, and glass. To assemble these materials, you will need to make choices about adhesives, mechanical fasteners, or joinery. You will also need to choose a finish for your product and when it will be applied. Hardware, such as hinges, pulls, and knobs, add the final touches to the product. Wood can be either softwood or hardwood. Soft- wood identifies lumber from cone-bearing trees and is typically used as a construction material. Hard- wood describes wood from broadleaf trees and is usually selected for making cabinets and furniture. Each species has unique properties affecting appearance and workability. Wood is also made into products such as plywood, particleboard, and veneer. Veneer is a sheet of thinly sliced wood used to cover poor quality

Sauder Woodworking Co. lumber or manufactured panel products. Veneer Figure 1-7. This ready-to-assemble computer console is especially effective when inlaying or overlaying can be assembled by the consumer. decorative designs.

/ 8 Section 1 Industry Overview

Manufactured panel products play an important role in cabinetmaking today. Medium density fiber- Product demands board (MDF) and particleboard have become popular for kitchen cabinets, bath vanities, closets, and Analyzing RTA products. These may be covered with enamel, current plastic laminate, or veneer for appearance purposes. practices MDF is easily shaped into almost any pattern and is available in lengths up to 20′ (6 m). Because of this, MDF is widely used for finished interior molding. Production Managing work Glass, plastic, and ceramic materials create durable surfaces. They are often applied to tabletops, coun- Planning Preprocessing tertops, and edges. Plastic laminates are extremely production popular for their durable, nonfading surfaces. Some have patterns that look exactly like wood grain. Cane, a form of grass, is woven to provide pat- Organizing terns and texture. A cane seat can be more comfort- Processing material, people, able and lighter than solid wood. Cane is also used machinery on cabinet door fronts and other surfaces. Once cabinet components have been cut to size, they are assembled with adhesives or mechanical Overseeing fasteners. Select the proper type of adhesive, cement, Post-processing process workflow glue, or mastic for bonding similar and dissimilar materials. Carefully choose mechanical fasteners as well. A wood screw holds well in solid wood, but poorly in particleboard. Select hardware based on Quality the design and materials being used. control At some point in the cabinetmaking process, components are sanded. Sanding is done before assembly on components that will be hard to reach after assem- Quality products bly, such as chair parts or cabinet backs. Exterior sur- ready for use faces are typically sanded after assembly. Goodheart-Willcox Publisher Finishing materials are coatings that provide Figure 1-8. A series of factors are involved with color and protection for the wood. Natural and syn- producing a product. thetic products are available. Some finishes build up on the wood surface while others penetrate into the grain. Carefully select and apply the finish. A poor finish can ruin hours or days of production time. 1.3.1 Tools There are many types of tools used in cabinet- 1.3 Production Decisions making. Most cutting, shaping, and sanding is done with stationary power tools, such as belt sanders, Production decisions relate to making any table saws, planers, and shapers. These reduce heavy product become a reality. They include choosing the and bulky materials, such as long lengths of lum- tools, tooling, and procedures necessary to build the ber and plywood, into component sizes, Figure 1-9. product in the most efficient manner, Figure 1-8. Portable power tools, such as orbital sanders, screw Design and material decisions impact production guns, and saber saws, are easy to handle and are decisions. Material decisions are choices regarding often more appropriate than stationary tools for use which products to use. on small parts. Hand tools are generally used for A piece of furniture designed with many minor operations, where set up time for a stationary curves will likely be more difficult to produce machine may be too time consuming. than one with only straight surfaces. A cabinet that includes stained glass doors is more difficult to create than one with solid wood doors. Make 1.3.2 Tooling decisions in an organized manner. It is important Replaceable parts of tools that perform cutting to plan each step. operations, such as router bits, shaper cutters, drill

/ Chapter 1 Introduction to Cabinetmaking 9

Patrick A. Molzahn Patrick A. Molzahn Figure 1-10. Computer numerically controlled (CNC) Figure 1-9. Reducing sheets of plywood to component machines reduce the amount of human labor needed sizes with a sliding panel saw. to process a part. bits, and planer blades, are commonly referred to as tooling. Proper selection of these items helps control costs and improves production and quality. Choosing the wrong tooling for the operation can adversely affect the safety, efficiency, and quality of the machining operation.

1.3.3 Processes Material processing for cabinetmaking fits into the three categories. These categories include separating, forming, and combining. Separating refers to cutting or removing material. Cutting stock on a table saw, sanding, or turning a spindle on a lathe are separating operations. Some Patrick A. Molzahn machines are automated, or controlled by a com- Figure 1-11. Forming wood using a mold and vacuum bag. puter. Figure 1-10 shows a computer numerically controlled (CNC) dowelling machine. The move- is mass-produced by cabinet manufacturers using ment of the machine is controlled by the numerical sophisticated machinery. Regardless of the size of data output from a computer. the shop, there are many decisions to be made. First, Forming includes all operations where material the equipment must be selected and set up. This is is bent, or formed, into a shape using a mold or form, known as preprocessing. Then, processing opera- Figure 1-11. tions are performed, including sawing, shaping, Combining includes bonding, mechanical fas- sanding, assembling, and finishing. Finally, the fin- tening, and coating, Figure 1-12. Each of these com- ished product is transported and installed during bining operations involves assembling or joining the post-processing phase. two materials. 1.4.1 Preprocessing 1.4 Producing Cabinetry Preprocessing includes all activities that take Planning for production involves making effi- place prior to building a product. Designs are fin- cient and effective decisions related to materials, ished and mock-ups may be built. Mock-ups are tools, tooling, and processes. Today, most cabinetry three-dimensional, full-size models of the product

/ 10 Section 1 Industry Overview 1.4.2 Processing Processing includes all tasks from cutting standard stock to finishing the product. You need to cut components, such as cabinet doors, drawers, legs, bases, cases, shelves, and tops. Work progresses by cutting and shaping parts to size. Joints are then made to create assemblies. Holes may be drilled and bored for various mechanical fasteners and the components are sanded. A sampling of these processes is found in Figure 1-13. Once cut to size and smoothed, parts are bonded together to give strength and structure to the product. Finally, a topcoat is applied by brushing, dipping, rolling, spraying, or wiping on the coating. This coating protects the product from moisture and wear. Patrick A. Molzahn Figure 1-12. Assembling components with adhesive is one form of combining. 1.4.3 Post-Processing Post-processing includes the transport, installation, and maintenance of products. For example, to be built. They help you decide if the product will desks built in a workshop are boxed and trans- be functional and have a pleasing appearance. ported to an office. Installation refers to setting up Materials are bought as standard stock items. the product, such as putting store fixtures in place or This includes full lengths of lumber, sheets of ply- attaching cabinets to floors and walls, Figure 1-14. wood, boxes of screws, and containers of finish. They Maintenance keeps cabinets and furniture looking have to be received, stored, and marked as inven- good and operating properly. For example, applying tory. Storing materials in specific locations helps you a coat of wax periodically and repairing scratches work more efficiently. can restore a product’s appearance.

Resawing Drilling Sanding

Patrick A. Molzahn Goodheart-Willcox Publisher Figure 1-13. Typical processes in cabinetmaking.

/ Chapter 1 Introduction to Cabinetmaking 11 1.5 Managing Work 1.5.4 Controlling Quality

Work has to be planned, organized, directed, and Controlling quality involves comparing pro- controlled to progress smoothly and safely. These cessed products to design and quality specifications. activities are management responsibilities. An indi- Suppose you cut all joints to size, but later find they vidual at home or school must make the same kinds do not fit. What should you have done? Trying a test of decisions as a business manager. joint could have prevented this problem. Quality is ultimately measured by how well the product meets the requirements and expectations 1.5.1 Planning of the consumer. Quality may be specified by the Planning involves establishing goals and decid- designer or the person who uses it. Quality standards also have been established and documented. ing how they will be accomplished. Study alternative designs and processesto learn how others have solved The Architectural Woodwork Institute (AWI), the similar problems. Experience with various functions, Woodwork Institute (WI), and the Architectural Woodwork Manufacturers Association of Canada forms, materials, tools, tooling, and processes allows you to make sound management decisions. (AWMAC) are all associations that create and enforce standards. These three organizations have worked jointly to create the Architectural Woodwork Stan- 1.5.2 Organizing for Efficiency dards. Many different aspects of quality are defined and presented in this manual. Standards, or speci- and Safety fication requirements, address lumber grades, ply- Organizing involves the four rights: having the wood grades, interior woodwork and stairs, wood right information and the right material in the right and manufactured panel casework, plastic covered place, at the right time. Schedule work properly to casework, countertops, doors, finishing, and instal- prevent waste of material and time. Progress may be lation requirements. slowed by supply delays, machines that do not oper- The documentation provides manufacturers ate properly, or poor process flow. with a level playing field when bidding work. This ensures that one manufacturer does not have an advantage over another. The expectations for mate- 1.5.3 Directing Daily Activities rial quality and construction methods are clearly Supervisors in industry see that planned and explained. When applied to cabinetry and millwork, organized tasks are performed on schedule. When these standards are defined as premium, custom, working alone, you still need to have a schedule. and economy. When a designer specifies custom, Guidelines are also helpful when people face diffi- and the product meets the custom standards, a cult decisions. specific level of quality is ensured.

1.5.5 Quality and Productivity Quality also involves productivity. When work falls short of the goals, corrective action must be taken. Reports and schedules are made to assist in monitoring work activities. In industry, all management decisions should show concern for and involve employees. This helps build decision-making abilities and self-confidence. In every cabinetmaking shop, workers risk exposure to chemicals, accidents, and injuries. Some individu- als may be allergic to dust or finishing materials. Some solvents are toxic and flammable. Remember that hazardous conditions exist everywhere. Read labels and follow directions carefully when using Patrick A. Molzahn machines and materials. More in-depth safety infor- Figure 1-14. Installing cabinets is a post-processing task mation is provided in Chapter 2. you can do yourself.

/ 12 Section 1 Industry Overview Summary 3. Adapting cabinetry for children and adults involves _____. • The responsibility of a designer is to create fur- A. size charts niture and cabinet designs that meet the needs B. human factors and desires of their clients. C. disabling injuries • Design decisions are choices made about the D. identifying needs product design before work begins. 4. Many types of cabinetry are designed and pro- • All design decisions are based on two factors: duced based on _____. function and form. 5. European hardware is based on a(n) _____ mm • Function describes the purpose for having a module. cabinet or piece of furniture. 6. RTA stands for _____. • Form is the appearance of the cabinet. What 7. Major decisions about production relate to will the piece look like? _____, _____, and _____. • Sketches document design ideas and can be 8. Planning involves what two steps? used to compare alternate designs. 9. _____ involves having the right information • Cabinetry is designed and produced based on and the right material in the right place, at the standards. right time. • Carefully consider which materials to use 10. The _____ of a product is how well it meets the throughout the design and production process. requirements and expectations of the consumer. • Production decisions include choosing the tools, tooling, and procedures necessary to Suggested Activities build the product in the most efficient manner. • Planning for production involves making effi- 1. Make a list of three to five places you find cabi- cient and effective decisions related to materi- nets. What are these cabinets used for? For als, tools, tooling, and processes. example, dental offices are mentioned in this chapter. Dentists use cabinets to store supplies. • Work has to be planned, organized, directed, Can you identify any special features for the and controlled to progress smoothly and safely. cabinets on your list? • Reports and schedules are made to assist in 2. Measure the cabinets in your home or class- monitoring work productivity. room. How tall are they? How deep are the countertops? Do the cabinets differ in dimen- Test Your Knowledge sion based on use? Are the widths standardized in 3″ modules? Answer the following questionsusing the information provided in this chapter. 3. Many different tools and machines are required to manufacture cabinets. Make a list of as many 1. Cabinetry should meet the _____ and _____ of of these tools and machines as you can think those who use it. of. Put an X before all that you have previously 2. Design for _____ first, then for _____. used and comment on your experience with them.