Assembly Supervisor Department Highlight
Each department is vital to the manufacturing process of a custom HDPOCKETDOORS frame. Here's an inside look into the Assembly Supervisor's department as we go in depth in explaining the process.
Describe the steps you do in the manufacturing process.
I often start with filling racks with common size door frame headers 36/32/30/28, taking 22' laminated veneer lumber (LVL) and cutting them to size. Later, as needed, they will be run through the planer to smooth track side surface, then top & bottom side edges are routered with a 1/8" router bit to achieve smooth edges.
Our most used track also has to be cut down to our common sizes and then handed off to someone to have an access hole routered in the end for hardware removal if needed.
Once the materials are stocked, I can now move forward to start a work order. Working from the cut list I make sure all the items are put together ready for me or someone else to begin assembly.
In the assembly process, the LVL header is laid down on the work bench and marked for a specific track and hardware. The track is then fastened to the LVL and then laid out for hardware (soft close/open, stops & size of door).
Then hardware is installed and tested. When everything checks out 100%, track covers are installed and then post brackets for the header and floor are attached to the header.
Floor brackets with designated stickers are attached temporarily for removal during the installation process. Hardware mounting brackets are placed in a tab with wrenches and instructions and a t-guide attached with instructions on the frame.
From there, it is sent over to the shipping department. Custom frames have a little more cutting and a lot more measuring. This would include making the track covers which are sized according to order. Depending on the size of the order, I will manufacture a pallet custom made for length & width to ship freight.
There is always clean up and odd & end things to take care of along with expedited orders that will have jump to the front depending on when the customer expects the order to arrive.
Are there any issues you might run into when manufacturing the frames and if so, how do you mitigate these issues?
Custom frames are usually a challenge, so I need to pay close attention to all the details and make the adjustments needed.
What kinds of tools and why are they used when manufacturing the frames?
Mitter box: Used for cutting LVL's & aluminum tracks
Table saw: Used for ripping down lumber to size
Planer: Used to smooth & size lumber
Router: Used to round over edges to avoid splinters during manufacturing & installation
Screw Gun: Used to install all the fasteners
Staple Gun/Nail Gun: Manufacturing pallets & shipping crates
Sander: Detail work
Framing Square: Laying out and marking for layout on track and soft close/open mechanisms
What's the most important part of the process?
Quality first, Customer satisfaction.