Issue 152 - June 2006
Page 22

Linkwood goes nesting with Biesse.

Linkwood software and Biesse machining technology are proving the ideal combination for 'true nested manufacturing' at Bespoke Kitchen Company, which produces top quality made-to-order furniture that is competitive at all levels of trade and retail markets

Among the displays in Bespoke Kitchen Company’s showroom there is a semi-circular island unit that seats five comfortably around the curved edge. Along the straight edge the wood surface has an inset of granite, in the centre of which is a flat circular metal plate. Turning a control heats the plate…causing it to deform into a 'Wok' for that authentic Oriental 'cooking at the table' experience.

So far, several customers have ordered this optional appliance for the island unit - but that isn't the point. Like other gadgets hidden among the displays (such as the plasma TV screen that rises through a worktop), the purpose is to excite and inspire visitors.

Since the company was founded six years ago at the factory in Stonehouse, Gloucestershire, the drive has been to offer 'high-end' bespoke fitted kitchen furniture to all levels of the market - trade as well as retail.

It's a successful formula that sets Bespoke Kitchen Company (BKC) apart and has led to significant growth from customers nationwide - most from recommendations and ranging from £4,000 installations to £80,000 projects. But with rising demand, the challenge of increasing production whilst maintaining quality and reasonable lead times became more acute.

"We needed to find extra capacity by speeding up the entire process from design and site survey to manufacture and

 installation", said production director Brian Burt. "The key to this has been investment in manufacturing software from Linkwood and Biesse's Rover B CNC machining centre, both of which have transformed our way of working".

A key feature of BKC's investment is that it allows true nested manufacturing, with seamless integration between the Linkwood software and BiesseNest, which optimises components for nested production and creates the machining program that is downloaded to the Rover B.

Initial designs for customers are prepared on a laptop, after which a BKC surveyor visits the site and draws up a detailed plan. Back in the production office, the information is input to Linkwood's Product Planner - a catalogue-based parametric bill of materials program which can be configured exactly to the user's method of construction on a product-by-product basis.

Dimensions and configurations - including width, height, depth, back void space, number of shelves, drawer front height, drawer box type - are applied to the product. The software then calculates 100% accurate lists of cut parts, hardware, accessories, doors, drawers etc, by product or job.
 

Drilling patterns are created on the fly using Linkwood's Drill Mate, which works in conjunction with Product Planner. Each component is linked to a parametric drilling template in Drill Mate, so when a dimensional change is made to a product, all associated parts are recalculated and revised drilling, routing and grooving patterns are produced.

Linkwood's software expert Adam Bumpsteed wrote a unique sub-routine that merges the cut parts and appropriate drilling patterns from Product Planner and Drill Mate into a set of data files by job, which can be read into the BiesseNest software.

“Working out the cut list for a typical kitchen of 20 standard and custom units used to take more than a day”, said Mr Burt. "Now it can take less than 30 minutes, and that includes creating drilling programs for the parts and the nesting pattern".

Labels are produced for each individual component, which include manufacturing information, a drawing of the part and a letter that identifies the part on the hard copy printout of the nested board.
"Previously, we had four operators using panel saws to cut components", said Mr Burt. "Now, everything is produced by a single operator using the nested machining capability of the flat bed Rover B.

"This machine was chosen because it offered the best value-for-money - with a number of standard features that were optional on other manufacturers' machines - and because it has one of the smallest footprints for the size of panel it can handle (3m x 1.2m), which was a big consideration as space in the factory is tight.

"In addition to nested parts we also use the Rover for other products, such as TG&V panels that were previously bought in at a cost of £100 per sheet".

Using a range of raw materials including hardwood, MDF, high-grade chipboard, plastics and acrylics, BKC now manufactures everything in-house, including cabinet doors.

"I am more than impressed by the technology", said Mr Burt. "The quality of components is superb and accuracy is spot on. When cutting manually on panel saws we used to have variations in tolerances and our installation teams had to make adjustments for a perfect fit, but that is no longer necessary.

"Our aim is to be No 1 by offering top quality furniture made to order for trade and retail customers. It's a very competitive market but we have 10-week order books.

"With the combination of Linkwood and Biesse we have probably doubled the volume of kitchens we produce. We also have the capacity to design and manufacture more shaped work and to embark on our next stage of expansion: bespoke bedroom furniture".