Chapter 3

Overview of the Production system

3.1 Brief Description of the Product:

Brother Furniture Ltd. in Bangladesh is a company that specializes in designing and

manufacturing a wide range of furniture products. Their offerings include office furniture, home
furniture, and customized solutions, emphasizing durability, comfort, and modern design. They
use quality materials and offer products like desks, chairs, cabinets, wardrobes, and storage
solutions, catering to both residential and commercial needs. The company aims to combine
functionality with aesthetic appeal, providing stylish and practical furniture for various spaces.
Factory has manufactured steel furniture like oven rack, office room chair, waiting room chair.
Steel furniture is mainly used in the medical sector such as hospital beds, gynecology beds,
patient ,examination beds, patient trolley, saline stands, over bed stand, ECG trolley etc. Pillows,
different shape of mattress, comfort mattress also prepared in mattress & Ton section. Tissue
boxes, trays, showpiece racks, magazine racks, mirrors were also produced as customization.
Accessory furnishings are smaller subsidiary items such as clocks, mirrors, tapestries, fireplaces,
paneling ,and other items complementary to an interior scheme .Almost this company has 300
variety of designed product.

3.2 Brief Description of the Production System:

In order to create furniture that is flawlessly shaped, functional, and comfortable, Brothers
Furniture combines artisanal craftsmanship, mechanical activity, and suitable raw materials, all
of which guarantee high-quality goods. It all begins with the creation of a specific product
concept, followed by design that takes material selection, functionality, and aesthetics into
account. The BOM was then produced by the product development department and supplied to
the appropriate section. The first step in production is the processing of raw materials, primarily
utilised board or wood. Processing involves cutting, shaping, and joining raw materials. Before
being dispatched for additional processing to take on the correct shape, beams and panels were
first cut with the desired shape using various pieces of equipment. Saws, CNC machines, or
lasers are used to precisely cut raw materials to size. raw timber that has been chopped or laser
cutting .The machinery and sawmill division receives raw cut wood board for various machining
operations, including moulding, routing, pasting, shaping, joining, and sanding. Products with
uneven shapes must be pasted. Particle board joint veneer for edging machines. After machining
operation, different types of furniture parts are produced.

Individual components are joined together to form the furniture piece. Sanding and finishing are

important for a better surface. Emery paper is also used for smoothing the surface. Some
products were sent to the upholstery section as per demand. After using siller and sanding, color
is applied as per customer need. Lacquer is used as topcoat for shining and glaze. Self-Inspection
is applied in every section to check finished products for defects and ensure they meet design
specifications and quality standards. The finished furniture is carefully packaged to prevent
damage during transport and delivered.
3.3 Layout of the Plant:

Figure 3.1: Plant layout

In building 1, there are several sections like logistics, store, machine section, PDQMS, carpentry,

admin office, IT office, finished goods store. In building 2, there is a sawmill section and

upholstery section. Seasoning plant and office chair section are in building 3.
3.3.1 Process Layout : A process layout is a type of production layout where similar
machines or operations are grouped together based on the type of tasks they perform. It’s
designed to handle a variety of products that require similar processes, which is often the case in
job shops or for companies like Brothers Furniture Ltd, where furniture manufacturing could
involve customized or low-volume production.

For Brothers Furniture Ltd, here's how a process layout working as far,

1. Woodworking Department:

 Machines: Saws, lathes, routers, sanders, jointers.

 Tasks: Cutting raw wood to required dimensions, shaping, and sanding.
 Arrangement: Machines that handle similar wood processing functions are grouped
together, enabling efficient workflow. For example, all the saws are in one section, all
lathes in another.

2. Upholstery Department:

 Machines: Sewing machines, cutting tables, fabric stretchers, tackers.

 Tasks: Cutting and sewing fabrics, attaching upholstery to furniture frames.
 Arrangement: This department focuses on working with fabrics, so machines that handle
cutting, stitching, and fitting upholstery materials are grouped here.

3. Assembly Department:

 Machines: Screwdrivers, drills, presses, pneumatic tools.

 Tasks: Assembling parts like legs, armrests, backs, and frames into finished furniture
pieces.
 Arrangement: All equipment needed for assembly, including tools and fastening
systems, would be placed in a central area where finished parts are brought together for
assembly.

4. Finishing Department:
  Machines: Spray booths, sanders, drying ovens.
 Tasks: Applying stains, paints, and finishes to wooden furniture, and drying them.
 Arrangement: Equipment for staining, finishing, and curing the furniture would be in
one zone to streamline the finishing process.

5. Quality Control:

 Machines/Tools: Measurement tools, inspection tables.

 Tasks: Inspecting finished furniture for defects, verifying dimensions and quality.
 Arrangement: A space where all final products go for inspection and testing before
being sent to the warehouse or dispatched to customers.

6. Storage/Warehousing:

 Materials: Raw wood, hardware, fabrics.

 Finished goods: Completed furniture, ready for shipment.
 Arrangement: Raw materials are stored near the corresponding departments for quick
access, and finished products are stored in a separate, organized area for dispatch.

General Workflow for Brothers Furniture Ltd:

 Step 1: Raw materials (wood, fabric, metal components) are brought into the plant and
sorted based on their respective uses.
 Step 2: The raw materials go to the appropriate department (woodworking, upholstery, or
metalworking) depending on the type of product being produced.
 Step 3: In each department, tasks are performed (cutting, sewing, shaping) to create the
individual parts of the furniture.
 Step 4: The parts are moved to the assembly department, where they are put together.
 Step 5: The assembled pieces are sent to the finishing department for painting, staining,
and drying.
 Step 6: After finishing, the furniture pieces undergo quality control to ensure they meet
the company’s standards.
  Step 7: Finally, the finished products are stored in the warehouse for final shipment to
customers.

3.4 List of machinery:

3.4.1 Machine section Machinery:

Beam Saw and Panel Saw:

In the furniture industry, a beam saw plays a crucial role in optimizing production efficiency and
ensuring precise cuts for large panels of materials like plywood, MDF, particleboard, or
laminate. Here it’s typically used:

1. Panel Cutting: Beam saws are used to cut large sheets of material into smaller,
standardized pieces that will be used in furniture manufacturing. These materials are
often pre-laminated or veneered, so precision cutting is essential to maintain the quality
of the surfaces.
2. High-Volume Production: Beam saws are highly efficient, allowing furniture
manufacturers to cut large volumes of panels quickly, making them ideal for mass
production. They can handle multiple cuts in a single pass, which significantly reduces
the time and labor involved in cutting.
3. Precision and Accuracy: One of the key advantages of a beam saw is its ability to make
precise, straight cuts with minimal errors. This is crucial in the furniture industry where
even a slight misalignment can affect the overall quality and fitting of the final product.
4. Customization and Flexibility: Some beam saws allow for automated or programmable
cutting patterns, which helps manufacturers cut various shapes and sizes based on
specific design requirements for custom furniture pieces.
5. Material Efficiency: The beam saw reduces waste by optimizing the cutting process,
ensuring that as much material as possible is used, and excess scrap is minimized. This is
important in the furniture industry to keep production costs down.
Multi Boring:

A multi boring machine is a type of machine that can be used to create multiple bores or holes in
a piece of wood, particle board, MDF board or plywood. The machine is used for enlarging a
hole with a single cutting tool and also used different size of double point cutting tool. The
primary purpose of a boring machine is to create a hole for butt joint and lap joint between wood
or board.

Router:

Router, portable electric power tool used in carpentry and furniture making that consists of an
electric motor, a base, two handle knobs, and bits (cutting tools) [3]. It is most frequently used to
give details to frames and patterns, round off the edges of worktops, and create a variety of other
designs in wood. The spindle may be driven by an electric motor or by a pneumatic motor.
Routers are used most often in woodworking, especially Routing a decorative groove into the
front of any wooden furniture is the perfect way to create a framed look.

Molder:

A molder machine in the furniture industry is a woodworking machine used to shape and profile
wood or wood-based materials into specific designs and profiles. It’s an essential tool for
creating intricate, detailed edges, grooves, and shapes on furniture components like moldings,
panels, and frame parts.

1. Shaping Edges and Profiles: The molder is commonly used to create decorative edges or
profiles on furniture parts, such as table tops, cabinet doors, and trim. It can produce detailed
designs like rounded, beveled, or fluted edges that enhance the aesthetic appeal of the furniture.

[Link] Panels and Moldings: Molder machines are especially valuable for producing
moldings and paneling that require consistent and accurate profiles. These components are often
used in doors, windows, and cabinetry.
3. High-Speed Production: Molders are designed for high-volume production. They can quickly
process long runs of wood or MDF, making them ideal for mass-producing furniture pieces,
especially for parts that require repetitive shaping.

CNC Machine:

A CNC (Computer Numerical Control) machine is a type of automated machine tool controlled
by a computer program, allowing for precise and repeatable movements to shape or modify
materials like wood, metal, plastic, and more. In simpler terms, CNC machines take digital
designs (often CAD files) and convert them into physical products by controlling the movements
of tools like routers, mills, lathes, or lasers.

Key Features of CNC Machines:

1. Automation: CNC machines operate automatically based on pre-programmed

instructions, reducing the need for manual operation and increasing efficiency.
2. Precision and Accuracy: They are capable of performing highly precise and intricate
tasks, making them ideal for tasks that require exact measurements, such as in furniture
making or metalworking.
3. Repeatability: Once a CNC machine is programmed, it can repeat the same operation
thousands of times with consistent results, making it perfect for mass production.
4. Versatility: CNC machines come in various forms, including CNC routers, CNC lathes,
CNC mills, and CNC laser cutters, each designed to perform specific tasks like cutting,
carving, drilling, and engraving.

Band Saw:

Band saws are mostly used to cut hardwood and create precise cuts using a variety of blade
designs detailed scrolling cuts because it spins quickly enough.
Drill:

Woodworking drill machines involve the technique of drilling round holes in a stationary
workpiece using a revolving cutting tool . Typically, the holes are drilled to accommodate
machine screws or bolts for assembly.

Jigsaw:

A Jig saw is a one type of a saw, which cut the wood in different shape [5]. A jigsaw is ideal for
curves and complex shapes in wood. They also work well for making short crosscuts on anboard
and finishing inside corner cuts that start with a circular saw.

Hinge Boring:

A hinge boring machine is a specialized drill press designed to precisely create the holes required
for installing cabinet door hinges. These machines are particularly useful for cabinet makers and
woodworkers who need to ensure accurate and consistent hinge placement during furniture
assembly. Many hinges boring machines are adjustable, allowing them to accommodate various

hinge sizes and types. This versatility makes them suitable for a wide range of furniture

Straight Edging Machine:

The straight edging machine plays a vital role in achieving a clean, finished look for furniture
pieces, conceals the unfinished core material of the furniture panel. Edging protects the core
from moisture damage, chipping, and wear. These machines apply edging material, typically
made from wood veneer and PVC to the raw edges of panels.

Round Edging Machine:

Round Edging Machine play a crucial role in creating smooth, finished edges on furniture
involves applying a pre-rounded edging material, like PVC or veneer etc.
Cold Press:

Cold presses apply uniform pressure across the entire work surface, ensuring a tight and durable
bond between wood components. Cold presses are instrumental in applying thin wood layers
toncore materials, creating a visually appealing and durable surface for furniture pieces. cold
presses are essential for ensuring a strong and seamless joint in furniture parts constructed from
glued wood panels.

Hot Press:

Hot presses can bend and shape wood veneers to core materials like MDF or plywood. The heat
activates adhesives, forming a strong, permanent bond that creates the final surface of furniture
panels. By applying heat and pressure over molds, the machine can create curved shapes for
furniture components like chair backs or table legs

Figure: Machine section Machinery

3.4.2 Sawmill Section Machinery

Sawmill:

A sawmill is a facility where logs are cut into lumber. Factories generally deal with processed
wood that has already been cut into planks, boards, and other usable shapes.

Chain Saw:

In the furniture industry, a chainsaw machine can be used primarily for rough wood processing,
particularly in the initial stages of woodworking or in the production of large, custom furniture
pieces. While chainsaws are more commonly associated with logging and forestry work, their
use in furniture production, though less common, can be quite useful for certain tasks.

Tenon:

A tenon refers to a type of joint that is commonly used in woodworking to connect two pieces
of wood. It is an essential part of creating strong, durable furniture pieces, especially in
traditional carpentry and joinery. The tenon is typically a projection or "tongue" at the end of
one piece of wood that fits into a corresponding hole or slot, known as a mortise, in another
piece of wood. Together, the mortise and tenon joint is considered one of the strongest and
most reliable joints in woodworking.

Mortise:

A mortising machine creates rectangular or square holes in wood pieces. The mortise can be
either a square or an elongated rectangle [4]. These mortises interlock with corresponding
projections with tenons, on other pieces to form strong and secure joints.

Lathe:

A lathe machine is an essential tool primarily used for shaping wood, metal, or plastic by rotating
the workpiece against a cutting tool. It is particularly useful for creating symmetrical, round, or
cylindrical shapes, making it a crucial machine in the production of decorative and functional
furniture parts.

Key Functions of a Lathe Machine in the Furniture Industry:

1. Turning and Shaping: A lathe machine is primarily used for turning wood. This means
it can shape a piece of wood into circular or cylindrical forms. For instance, it’s
commonly used to create legs for chairs, tables, and cabinets, and for making spindles for
furniture like bed frames and balusters for staircases.
2. Sculpting Decorative Features: Lathe machines are also used for carving intricate
decorative details into furniture pieces. Craftsmen use them to add turning patterns,
grooves, and spirals to furniture legs, armrests, or columns, giving the pieces a refined
and decorative finish.
3. Creating Dowel Pins and Round Components: Lathe machines can make dowels,
which are used in joinery (e.g., in mortise and tenon joints or for reinforcing joints in flat-
pack furniture). The ability to create precision dowels or round components is
particularly valuable in high-quality furniture construction.
4. Smoothing and Finishing: The lathe can smooth rough surfaces by gradually trimming
material away from the workpiece. This is crucial in achieving even, smooth, and
polished surfaces on wooden parts of furniture, which enhances the overall finish and
quality of the piece.
5. Making Handles and Other Small Parts: Lathe machines are also used for making
smaller cylindrical parts, such as handles for drawers, cabinet knobs, legs for stools, or
knobs for chairs. These parts need to be symmetrical and uniform, which the lathe can
produce efficiently.
Radial Saw:

A radial arm saw is a powerful and versatile machine that cuts downward, either with or against
the wood grain in furniture factory. The saw arm can be raised and lowered and swung from side
to side to adjust the depth and horizontal angle of the cut. The blade can also be replaced with
shaping cutters, disks, or drum sanders and other accessories. Radial saws have features that
make them more versatile than other saws.

Finger Joint:

A finger joint is a woodworking joint made by cutting a set of complementary, interlocking

profiles in two pieces of wood, which are then glued. The cross-section of the joint resembles the
interlocking of wood between two parts.

Figure: Sawmill section Machinery

3.4.3 Sanding Machinery

Table Sander:

A table sanding machine is an electrical tool that makes the surfaces apply smoother and
smoother in the wood factory. Sanding serves to remove imperfections on walls, ceilings,
furniture, floors,etc. It is also used to roughen surfaces too glossy for paint or filling compound
to adhere easily. Different types of Sandpapers are the most commonly used abrasive materials
for this purpose .For different types finishing different no. grit is used. In medium finishing
80,120,180 is used and 220,240 is used for fine finishing. For more smoothness ultra-fine fining
is used with 320 and 400 grit paper.

Edge Sander:

An edge sander utilizes a sanding belt or platen to precisely sand the edges of furniture
pieces ,ensuring a uniform and polished finish. It can handle various materials like wood,
plywood, MDF, and even veneered surfaces. portable power tool used for smoothing, polishing,
or cleaning a surface, as of wood, board edge.

Wide Belt Sander:

The wide belt sander is used to achieve smooth, spotless surfaces with the proper thickness for
finishing on MDF, plywood, and board. The material is placed between the sander table and the
sanding belt for sanding and suitable for flat panels.

Brush Sander:

A brush sander helps manufacturers prepare their products for finishing, wood items of burrs and
marks. During the sanding and brushing process, sanding and deburring brushes rotate around an
axis to clean wood by removing imperfections and residual material left from sawing, or shaping
wood component.
Fig: Sanding Machineries
3.4.4 Color Machinery

Lacquer Spray Booth:

A lacquer spray booth in a furniture factory is an enclosed space designed specifically for
applying lacquer finishes to furniture items. The primary function of the spray booth is to
provide a controlled environment where furniture can be sprayed with lacquer or other finishes
to achieve a smooth, high-quality surface.

Figure : Colour Section Machinery

3.4.5 Mattress Machinery

Mattress Tape Edging Machine:

A mattress tape edging machine, also known as a mattress sewing machine, is used to create a
clean, finished edge on mattresses, upholstered furniture pieces, and other similar items.

3.4.6 Upholstery Machinery

CNC Sewing Machine

CNC Sewing Machine is a computer-controlled tool that uses a needle and thread to create
intricate designs on fabric, leather or other materials. These machines use digital designs, created
either by the user or obtained from a database, to generate the code that will guide the needle and
thread to reproduce the design. It can handle intricate stitching patterns for unique design
elements, customized furniture pieces and ensures immaculate stitch accuracy, reducing human
error and rework.

Single Needle Machine

A single needle sewing machine is a workhorse for furniture factories, providing the essential
stitching capabilities needed to assemble upholstered furniture, cushions, drapes, and other soft
components.

Double Needle Machine:

The double needle sewing machine is a crucial piece of equipment for furniture factories. It
creates strong, reliable seams by stitching with two needles simultaneously. The double stitch
creates a more robust seam to withstand wear and tear and creates a clean, finished look on
seams, adding a touch of quality to furniture pieces.

Overlock Machine:

The overlock stitch is used for construction and edge finishes most often but can be used for
rolled them edge finishing hems and giving them a clean, seamless look to delicate fabric, leather
and can be used to create wire edged ribbon. These machines pack a punch with high-
performance motors to ensure smooth stitching through multiple layers of fabric

Figure : Upholstery section machinery

3.5 Production flowchart:
.