11/14/2018 INERWOOD MOBEL

REPORT

Jalil Ahmad
Supervisor CNC Operations
ACKNOWLEDGMENT

The opportunity I had with Interwood mobel pvt. ltd. was a great chance for learning and
professional development. Therefore, I consider myself as a very lucky individual as I was
provided with an opportunity to be a part of it. I am also grateful for having a chance to meet so
many wonderful people and professionals who led me through this period.

I express my deepest thanks to management, for taking part in useful decision & giving
necessary advices and guidance and arranged all facilities to make life easier. I choose this
moment to acknowledge their contribution gratefully.

It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to all
management and crew members of Interwood mobel especially to Mr. Akhtar Riaz (General
Manager Operations) for their careful and precious guidance which were extremely valuable for
my learning practically. In the light of his wisdom and vast area of experience he is running the
firm successfully.

Mr. M Kashif Ashiq who is the Production Manager Board and Press of INTERWOOD MOBEL
(Pvt.) Ltd and the source of guidance to all of the employs in organization. I want to thank him
for his support during gathering and analyzing information and guided in the period of my stay
with advice, despite his busy schedule.

I also want to thank my colleagues for helping and guiding us in different aspects of training,
named as Mr. Arshad, Mr. Yasir Mushtaq, Mr. Safdar, Mr. Adnan Mughal and Mr. Amir Hussain.

I perceive as this opportunity as a big milestone in my career development. I will strive to use
gained skills and knowledge in the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives. Hope to continue cooperation with
all of you in the future.

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PREFACE

Engineering education is always completed by the fusion of theoretical knowledge and Practical
field experience. Regarding this reason, field experience plays a vital role in polishing an
Engineer’s qualities.

As Technical and management skills are very important for Engineer graduates, field related
experience provide a golden opportunity to enhance, practice, groom and develop all these
skills.

The purpose of writing this report is to express the knowledge, experience and skills, which I
assimilated at INTERWOOD MOBEL PVT. LTD. during my six months of probation. The content
of the report depicts the major components and operations performed at INTERWOOD MOBEL
PVT. LTD.

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ABOUT
INTERWOOD MOBEL is Pakistan’s leading furniture, appliances & accessories brand that covers
a wide array of product categories, namely: Office Furniture, Home Furniture, Kids Furniture,
Kitchens, Doors, Wardrobes, Flooring and Lifewares.

We believe in providing one-window solutions that save you the hassle of building your living
space piece by piece. Catering to each and every aspect of our client’s needs, our corporate &
domestic ranges both are above par from the industry’s standards.

At INTERWOOD MOBEL, we stay abreast of the latest technologies to make sure your homes &
offices are beautiful and stand the test of time. Our broad experience enables us to recommend
the best for you, depending upon location, use and personal taste.

We design living spaces the “Interwood Way”; a professional approach to manufacturing that
has grown from its quality origins into a wider, near-obsessive; devotion to customer
satisfaction. The culture of the company is wholly focused around delivering living solutions
that are 100%, both in terms of quality and in meeting customer requirements. The
INTERWOOD MOBEL culture means staying on top of your game, from R&D and marketing to
sales and operations.

We are the market leader due to one reason, that is, commitment to what we do. Our high
quality products and our diverse ranges are the result of state-of-the-art machinery and the
skill, motivation and dedication of the INTERWOOD MOBEL workforce. We are furnishing the
needs of illustrious clients such as Allied Bank, Barclays Bank, HSBC Bank, Marriot Hotel, Avari
Hotel, Park Lane Towers, Haidri Villas, Civil Aviation Authority, McDonald’s, PepsiCo, Nestle,
CNBC, British Council, Bahria Town and many more.

INTERWOOD MOBEL is also serving the education system of Pakistan by providing an extensive
range of education furniture. We provide furniture for Classrooms, Laboratories, Offices,
Libraries, Hostels, etc. We have furnished some of the renowned educational institutes like IBA,
LUMS, The Staff College, LSE, CBM, Karachi University, F.C College, and GIFT University.

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Besides the local sale of our products through our tastefully displayed showrooms at Lahore,
Karachi, and Islamabad, we also export our product ranges to the UK, Norway, Spain, Africa, the
Middle East and India. Furthermore, we have executed woodwork, interior design,
refurbishment and furnishing projects for many prestigious local and multi-national
organizations such as Parliament Building of Maldives, Lahore Airport, Multan Airport and
Karachi Airport.

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Table of Contents

WORK SECTIONS: .................................................................................................................. 1

Figure 01 ........................................................................................................................... 1
Materials: ......................................................................................................................... 1
Machines layout .................................................................................................................... 2
Figure 02 ........................................................................................................................... 2
Details of layout ................................................................................................................ 2
DETAILS OF MACHINES: ......................................................................................................... 3
Beam saw: ........................................................................................................................ 3
Lipping Machine: ............................................................................................................... 3
Rover C9.65:...................................................................................................................... 4
Weeke Venture 159: ......................................................................................................... 5
Rover Aft 1836 .................................................................................................................. 6
Skipper 100: ...................................................................................................................... 6
Automatic Press Machine: ................................................................................................. 7
Calibration Machine: ......................................................................................................... 7
PROCESS LAYOUT .................................................................................................................. 8
Figure 03 ........................................................................................................................... 8
Time study ............................................................................................................................ 9
Comments: ..................................................................................................................... 10
Improvements: ............................................................................................................... 11
PRODUCTION PROBLEMS & SOLUTIONS: ............................................................................. 11
Maintenance ................................................................................................................... 11
Blowers........................................................................................................................... 11
Breathing problems......................................................................................................... 11
Solution: ......................................................................................................................... 12
MATERIAL HANDLING PROBLEMS & SOLUTIONS: ................................................................. 12

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 Unorganized material processing..................................................................................... 12
Availability of space ........................................................................................................ 12
Transfer of material ........................................................................................................ 12
PROJECTS: ........................................................................................................................... 13
SUGGESTED LAYOUT:........................................................................................................... 14
Figure 04 ......................................................................................................................... 14
Figure 05 ......................................................................................................................... 15
Figure 06 ......................................................................................................................... 16

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WORK SECTIONS:
 Board section
 Veneer section
 Corian section
 Drawer section

Figure 01

Materials:

 Mdf
 Plywood
 lamination
 Corian
 Chipboard
 Formica
 Acrylic

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 Board section
Machines layout

Figure 02

Details of layout
1. BEAM SAW SELCO
2. BEAM SAW 792
3. EDGE BANDING M/C 143
4. BRANDIT
5. ROVER C9
6. ACKRON 1400 (Edging M/C)
7. WEEKE 159
8. ROVER AFT 1836
9. SKIPPER 100

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DETAILS OF MACHINES:
Beam saw:
 Drawing is fed into the system through IMOS
 Material is loaded from backside of machine through conveyor system
 Scoring cutting check, Size, Variation, Chipping
 After this the material is finally obtained in the required dimensions and required
number of parts.
 After this the material is moved through manual conveyer system for lipping process to
the PVC lipping machine.
BEAM SAW SELCO 750
 Length of bed is 3000mm
 6 sheets of 18mm can be cut at one time
 sheets of 25mm can be cut at one time
Tools No. of T Store Code
Main saw 01 TO-04-2306
Securing saw 01 To-04-2308
BEAM SAW
 Less efficient than SELCO
 Capacity is less
 It can cut 3 sheets of 18mm at a time
 It can cut 2 sheets of 25mm at a time
Tools No. of T Store Code
Main Saw 01 TO-04-1478
Securing Saw 01 TO-04-1479R

Lipping Machine:
 It is used for edging(lipping)
 One or more sided lipping
 Material fed is of : 16,18,25 mm thickness
 Lipping thickness: 0.8 or 2mm

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 ACKRON 1400 (EDGING M/C)

Tools No. of Tools Store Code

SKAPPER UNIT 02 TO-04-0435
CLIP UNIT 02+02 TO-04-0433+34
CLIP UNIT 02 TO-04-0432
CUTTER 02 TO-04-0425
CORNER ROUNDING 04 TO-04-0431
CORNER ROUNDING 04 TO-04-0430
CORNER TRIMMER 05 TO-04-0427+29
PRE-MILLING 02 TO-04-0424
KNIFE 02 TO-11-0103
BUFFING UNIT 01

EDGE BANDING M/C 143

ROUTER TOOL 04 TO-04-1441

Rover C9.65:
 Work capacity is most among all CNC machines
 It has 8 beds, 6 beds are active.
 Different drawings can be operated at a time
 If the length of the sheet is less than 1000mm than it can accommodate 4 sheets at a
time
 And if the length of the sheet is more than 1000mm than it can accommodate 2 sheets
at a time.
Tools No. of Tools Store Code
HEAD CUTTER 01 TL-04-5001
CUTTER OVVO 01 TO-04-0288
FLAT TOOL 01 TO-04-1482
ROUTER TOOL 01 TO-04-1441
ROUTER TOOL 01 TO-04-0138B
ROUTER KNIFE 01 TO-04-1445
ROUTER KNIFE 02 TO-04-1485+86
DIAMOND TOOL 01 TO-04-1440
SPINDLE 01 TO-04-1433+34
SPINDLE 04 TO-04-1584+85

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 SPINDLE 01 TO-04-1586+87
SPINDLE 01 TO-04-1588+89
SPINDLE 01 TO-04-1681+82
SPINDLE 02 TO-04-1433+34
V-SHAPE 01 SP-06-0929
SUNSET
PROFILE TOOL
ANGLE ADJUSTMENT TOOL
AGGREGATE TOOL

Weeke Venture 159:

 It is more efficient than Skipper machine

 Two different drawings can be operated on two different jobs
 Can perform: 1) Grooving 2) Drilling
 Maximum thickness of the sheet 45m

Tools No. of Tools Store Code

WEEKE JIGS 02 SP-07-0811
WEEKE JIGS 02 SP-07-0812
ROUTER KNIFE 01 TO-04-1485+86
KNIFE 01 TO-04-149
BIT DOWEL DRILL 02 TO-04-1588+89
BIT HING BORING 01 TO-04-1654
BIT TOOL HING 01 TO-04-0144B
BIT TOOL 01 TO-04-1655
BIT TURN BLADE 01 TO-04-1445
BLADE SAW 02 TO-04-1645
KNIFE

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Rover Aft 1836

Tools No. of Tools Store Code

ROUTER KNIFE 01 TO-04-1445
ROUTER KNIFE 01 TO-04-1485+86
DIAMOND TOOL 01 TO-04-1440
KD BIT 02 TO-04-1654+55
SPINDLE 02 TO-04-1433+34
SPINDLE 02 TO-04-1584+85
SPINDLE 02 TO-04-1586+87
SPINDLE 02 TO-04-1588+89
SPINDLE 02 TO-04-1681+82
SPINDLE 02 TO-04-1683+84
HINGS TOOL BIT 02 TO-04-0144B
DIAMOND TOOL 01 TO-04-0275
DIAMOND TOOL 01 TO-04-0277
ROUTER TOOL 01 5MM
PRE-SETTER
V-SHAPE 01 SP-06-0929
PROFILE
SUNSET

Skipper 100:
 Used for 1) Doweling 2) Grooving 3) KD
 Same job can be done on two pieces using mirror command
 It’s capacity is 8x4ft
 Job is fixed on bed using vacuum
 Head moves and job remains fixed

Tools No. of Tools Store Code

ROUTER KNIFE 01 TO-04-1445
KD BIT 01 TO-04-1441
KD BIT 01 TO-04-0282+83
SPINDLE 02 TO-04-1433+34
SPINDLE 05 TO-04-1584+85
SPINDLE 02 TO-04-1681+82
SPINDLE 02 TO-04-1683+84
DIAMOND TOOL 02 TO-04-0275
SPINDLE 02 6MM

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Automatic Press Machine:
 The material is loaded on the automatic conveyer system of the machine.
 Normally veneer pressing is done on this machine sometimes Formica pressing is also
done on this machine.
 The pressing time of this machine is 5min.
 The total size of the bed of the machine is 3000x1300mm.
 8x4feet is normally pressed in this machine.
 Pieces of smaller dimensions are also pressed in this machine.
 Different pressures are applied according to the dimensions of the material.
 170bar pressure is mostly used. 50bar, 200bar, 300bar pressures are also used
according to requirement.
 The material from the manual conveyer system is loaded onto the automatic conveyer
system.
 The material is then forth into the machine for pressing for the required time.
 After pressing the material is sent to the next machine through manual conveyer
system.

Calibration Machine:

 The material is again brought to this machine through manual conveyer system from
wood lipping machine.
 The machine is used to surface finish the material.
 The sand papers are used in this machine.
 Sand papers of different sizes are used i.e. 24, 26, 40, 50, 60, 80, 100, 120, 150, 180 etc.
 Sand papers of size 60, 100, 150 are commonly used.
 The current used ranges from 20-30 ampere.
 The material is fed on the conveyer of the machine manually.
 The material takes 4min to be finished according to the required dimensions (on both
sides).
 The material is collected on the other side of the machine on the conveyer system.
 The sand papers are changed according to the requirement of the finishing on the job.
 Time for changing sand paper: 8min
 Total times sand paper changed: 15-20 times (depending on the work load)
 Total time for changing sand paper in one shift: 2hours-2hours 40min.
 The material is then moved to the press machine through manual conveyer system.

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PROCESS LAYOUT

Figure 03

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Time study
CAPACITY CALCULATIONS FOR SKILL 1224GFT
Time required to complete one job of DHA DOOR is given as,

NO. Machining Time Setting Time

s s
1 283 124
2 296 188

3 307 225

4 276 205

5 300 325

6 300 264

NOTE: THESE CALULATATIONS MAY VARY ACORDING TO THE RPM OF MACHINE. IN THIS CASE
THE MACHINE WAS WORKING ON 60 RPM.

Calculating average time,

tave = ∑ 𝒕/n
𝟑𝟖𝟑+𝟐𝟗𝟔+𝟑𝟎𝟕+𝟐𝟕𝟔+𝟑𝟎𝟎+𝟑𝟎𝟎
=
𝟔
= 293.667sec
Average time = 4min & 53 sec
This is the time which each product takes to get in final shape.

Now calculating average setting time,

tave = ∑ 𝒕/n
𝟏𝟐𝟒+𝟏𝟖+𝟐𝟐𝟓+𝟐𝟎𝟓+𝟑𝟐𝟓+𝟐𝟔𝟒
=
𝟔
= 221.3sec
Average setting time = 3min 42 sec
This is the idle time when work piece is being checked and loaded. Also the dimensions are
verified in this time.

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CAPACITY CALCULATIONS FOR SKIPPER 100.
For JOB No.3164, time for sides

No. Machining Time Setting time

(s) (s)
1 71 28
2 72 32
3 70 31
4 71 33

NOTE: THESE CALULATATIONS MAY VARY ACORDING TO THE RPM AND FEED OF THE MACHINE.
Calculating average time,
tave = ∑ 𝒕/n
𝟕𝟏+𝟕𝟐+𝟕𝟎+𝟕𝟏
=
𝟒
= 71sec
Average time = 1min & 11 sec
This is the time which each side takes to get in final shape.
Now calculating average setting time,
tave = ∑ 𝒕/n
𝟐𝟖+𝟑𝟐+𝟑𝟏+𝟑𝟑
=
𝟒
= 31sec
Average setting time = 3min 42 sec
This is the idle time when work piece is being checked and loaded. Also the dimensions are
verified in this time.

Comments:
1. Time depends upon type of material being used as well as on lamination.
2. If material is hard we can use higher RPM.
3. Chipping occurs if material is not rigid.
4. The time noted for both left and right side was almost same.
5. Considering the dimension of work piece we were restricted to use only one work piece
at a time.

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Improvements:
1. Tool must be changed during setting time in order to save time.
2. To minimize the setting time work piece being loaded must be checked before sending
to production line.

Automatic feed should be used to save setting time.

PRODUCTION PROBLEMS & SOLUTIONS:

There are some common problems that are being faced due to some obvious reasons.
 Before time maintenance
 Blowers
 Breathing problems

Maintenance
It has been seen that machines are requiring maintenance before their schedule. The
reason is because as we are dealing with chipboards, Mdf and other material that
produces dust. This dust then causes malfunctioning of sensors consequently the
machine requires maintenance ahead of time. Hence production is effected by this
unplanned maintenance.

Blowers
Blower are being used as the waste material handling during the machining process.
These blower suck the major amount of dust. Sometimes due to absence of hood or the
process that do not allow the hood to function or damaged hood the waste material is
not properly managed which is one of the reason for dusty work environment.

Breathing problems
The particles coming out from the machines although are very minute on the particulate
level but are causing breathing problems as they are entering directly in lungs of the
workers. These particles do not only cause the breathing problem but also causes the
itching to the eyes of the worker. This all results in decreasing efficiency of worker
leading towards the slow production.

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Solution:
To overcome these problem we can use dust collectors with required calculated
capacity. Proper checkup plans should be made to check the quantity of the dust particulates in
the work environment.

Note: there are some problems related to drawings and cams. These are queer problems that
occur very seldom.

MATERIAL HANDLING PROBLEMS & SOLUTIONS:

Proper handling the material is one of the most important job as this is the core component of
a production process. If a material is not organized then a lot of time is wasted to organize on
machines.
 Unorganized material processing
 Availability of space
 Transfer of material

Unorganized material processing

Starting from the beam sawing of material as their first process. The material should be
handled according to item wise. A lot of jobs consist of different units but while cutting
their required parts they just cut the required pieces and place them randomly in the
stack of material. Which causes trouble while machining or edging.

Availability of space
The space is very confined in the given layout as there is no management. Machines are
placed in a confined space thus creating problem in working. Also, the raw material is
placed on conveyors causing hindrance in seeing the workers and their working.

Transfer of material
Basically it is the reason for the availability of space. The material should be transfer
according to the machining on the required machine. Also if the machining is done the
material should be dispatched right away.

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PROJECTS:
From the date of joining this company, a journey of adding new skills to my personality has begun.
After each passing day at this company I feel more confident and motivated.
I have started at this company as a novice and now I have been assigned the planning and process
control. By the grace of Allah Almighty and valuable supervision of Mr.Kashif I have successfully
completed number of projects and few of them are:

Job No. Client Product description

2049 PAKISTAN SERVICE FIRE RATED DOOR ZAG
2513 EMAAR GIGA GROOVED DOORS
2726 A A TRADERS CARCUS+WANGY+SHUTTER
2707 GLOBAL ARTS LECTURE DESK
2827 SIGMA SYSTEM BUDGET BASE FILING CABINET
3029 SHIRAZI INVESTMENT LAMINATION KITCHEN
2920 ABL FULL HIGHT FILING CABINET
3031 SINDH BANK MANAGER SIDE RACK
2788+2796 ATLAS COFEE TABLE
3164 MCB BANK LTD OFFICE DESK
2406 AGA KHAN OFFICE
2340 WAREHOUSE CREDENZA
3369 ROOMI WARDROBE
3206 RAUMPLUS WARDROBE
3165 RIZWAN ANWAR SHUTTER FREE

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SUGGESTED LAYOUT:
Thinking about the work process, material administration and dispatch stockpiling if there
should be an occurrence of much number of items of the jobs the accompanying format is
being proposed. The old lipping machine (Brandit) is not giving us any creation and ought to be
removed from the area.
The movement of material in the current layout is shown as below,

Figure 04

Steps Lipping Rover C9 Weeke 159 Rover Aft Skipper 100 Total (ft.)
1 10 0 0 0 0 10
2 60 0 0 0 0 60
3 0 10 20 35 90 155
4 0 10 70 80 100 260
480

Hence the total movement is of 480ft.

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Now considering the suggested layout.

Figure 05

Steps Lipping Rover C9 Weeke 159 Rover Aft Skipper 100 Total (ft.)
1 10 0 0 0 0 10
2 60 0 0 0 0 60
3 0 10 20 35 20 85
4 0 10 70 80 10 170
325

Hence total movement of material is 325 ft.

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Clearly the suggested layout has less movement of material which can save time and increase
the production of the company. In addition it will provide extra space for the dispatch area.

Figure 06

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