Recently we’ve been elbow-deep in producing a sizable quantity of student desks for a private college. During the prototype phase, the client’s Executive Vice President, who has a 40 year background in manufacturing, suggested that doing this production run would help us improve our custom woodworking projects.
I was skeptical. Production runs require consistent quality over a series of identical pieces. Once you get a good system down, production becomes fairly rote after that. In contrast, custom pieces are unique and each requires independent planning and fabrication.
I was wrong. As it turns out, the guy with four decades of experience knew what he was talking about.
The experience we gained from our production runs have provided us valuable lessons that we have applied to enhance our custom woodworking projects. While custom and production woodworking differ in their objectives, the efficiency and precision we learned in production runs have contributed significantly to improving the quality and workflow of our custom projects. Here are some key lessons that we learned from production runs to elevate our custom woodworking:
Efficient Planning and Design Streamlining:
Lesson Learned: Production runs emphasize the importance of planning and design efficiency to achieve consistent results across multiple pieces.
Application to Custom Woodworking: Applying a structured planning process to custom projects can enhance efficiency without compromising creativity. Streamlining design elements and fabrication processes that can be replicated without sacrificing the uniqueness of the piece ensures a smoother workflow.
Effective Use of Jigs and Templates:
Lesson Learned: Jigs and templates are critical tools in production runs for achieving precision and uniformity.
Application to Custom Woodworking: Incorporating well-designed jigs and templates into custom projects can help replicate intricate details with accuracy. This ensures that custom pieces maintain a high level of craftsmanship while benefiting from the precision associated with production techniques.
Material Management for Consistency:
Lesson Learned: Production runs necessitate meticulous material management to ensure consistency across batches.
Application to Custom Woodworking: Adhering to best practices in material selection, storage, and preparation ensures that custom projects maintain a consistent quality. Understanding how different materials behave allows for better customization without compromising the overall integrity of the piece.
Embracing Adaptability in Problem-Solving:
Lesson Learned: Production runs teach the importance of adaptability in the face of unexpected challenges.
Application to Custom Woodworking: Custom projects often encounter unforeseen issues, and the ability to adapt and find creative solutions is crucial. The problem-solving skills honed during production runs can be applied to unique challenges in custom woodworking.
Balancing Speed with Quality:
Lesson Learned: Production runs require a delicate balance between speed and maintaining high-quality standards.
Application to Custom Woodworking: Striking a balance between efficiency and craftsmanship is essential in custom woodworking. While each project is unique, adopting efficient workflows learned from production runs ensures timely completion without compromising the quality of the final piece.
Thorough Quality Control:
Lesson Learned: Production runs emphasize stringent quality control processes to maintain consistency.
Application to Custom Woodworking: Implementing thorough quality control measures ensures that each custom piece meets the highest standards. This attention to detail not only satisfies clients but also establishes a reputation for excellence in custom woodworking.
By drawing on the lessons we have learned from production runs, we have enhanced our efficiency, precision, and problem-solving capabilities without sacrificing the unique and personalized aspects of our craft. The integration of these lessons allows us to deliver exceptional custom woodworking projects that combine individuality with the benefits of production-oriented practices.
Here are some photos of the process:
These are the Student Desk base cabinets.
These are the Pencil Drawer boxes and Leg Assemblies.
These three elements join to make the Student Desk Base.
Once we add the solid hardwood top and one of three hutch models, they come together like this:
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