2015 HSC Timber paper

C

A

B

C

B

A

D

B

C

To test that all joints fit accurately before gluing (and to set the cramps and rehearse the glue-up).

Memorise pack: notes 3.9

• Provides a relevant purpose of dry cramping 1

NESA sample answer

Dry cramping is used as part of the test fitting process to ensure all joints fit neatly prior to
gluing.

Answers could include

• Test joints for accurate fit
• To set all cramps in position prior to gluing
• Check for square/flatness
• To familiarise yourself with the order and processes required for efficient gluing
 operations.

Timber moves as its moisture content changes, and back-sawn boards tend to cup. If all the boards are laid with their rings the same way, the cupping adds up across the whole top, causing a large curve. By alternating the growth rings, each board cups in the opposite direction to its neighbour, so the movement is balanced. The top stays flatter and can be fastened securely to the frame.

Memorise pack: T9

• Provides a detailed description of why timber may distort AND how the
 3
 alternation of boards in a widening joint can minimise distortion
 • Provides a sound description of why timber may distort OR outlines how
 the alternation of boards in a widening joint may minimise distortion
 OR 2
 • Provides a limited description of why timber may distort AND how the
 alternation of boards in a widening joint can minimise distortion
 • Provides a basic outline or lists a reason to alternate boards in a widening
 joint
 1
 OR
 • Limited understanding of how it limits distortion evident

NESA sample answer

Timber is prone to movement (cupping or distortion). When creating a widening jointed
board such as a table top, failure to alternate the boards’ grain direction can exacerbate
cupping or distortion of the timbers. In the case of a table top this could create effective
cupping across the entire width of the jointed boards. By alternating the grain the possibility
of cupping is balanced out by flipping the direction of cupping between each board and thus
providing a flatter top, which can be more securely fastened.

The Festool Domino loose-tenon joint. First, it is much faster than a hand-cut mortise and tenon: a machine cuts matching mortises and a ready-made domino is glued in. Second, it is accurate and repeatable, and the large gluing area gives strength similar to a traditional mortise and tenon, reducing production time and cost.

Memorise pack: T7

• Identifies an appropriate new joint technology AND provides relevant
 3
 examples
 • Identifies an appropriate new joint technology AND provides a relevant
 advantage
 OR
 • Demonstrates a sound understanding of some of the characteristics and 2
 features that make new joint technologies advantageous
 OR
 • Provides two partially accurate advantages
 • Provides an advantage of new joint technologies
 OR 1
 • Lists an example of a joint

NESA sample answer

An alternative joint to a traditional mortise and tenon is the festo domino joint. The domino
has two advantages: firstly it is quick to produce, replacing hand cut joint members with a
machine cut mortise into which dominos (tenons) are glued. The large gluing area maintains
the joint strength offered by a mortise and tenon. The domino is secondly fast and accurate to
produce, significantly reducing production time while providing accurate, quality joints.

Answers could include

• Knock down fitting
• Brackets and clip lock fittings
• Domino joints
• Flat packing – distribution advantages
• Increased efficiency in production therefore lower costs to both manufacturer and
 consumer
• Similar strengths and joint integrity achieved at significantly lower cost and less time,
 making products cheaper.

Quarter-sawn timber has its growth rings close to 90° to the face, so it shrinks less in width and is much less likely to cup or warp. This keeps panels and joints stable. It also shows attractive ray figure and wears evenly, making it worth its higher cost for fine furniture.

Memorise pack: T3

• Provides a detailed understanding of quarter sawn timber characteristics
 3
 appropriate for quality furniture production
 • Provides an understanding of quarter sawn timber characteristics
 2
 appropriate for quality furniture production
 • Provides a basic understanding of quarter sawn timber 1

NESA sample answer

Quarter sawn timber while slower to convert provides several advantages to the
designer/manufacturer. Quarter sawn timber has growth rings parallel to the short face, which
typically shows the best grain on the face, provides better resistance to collapse and has better
wear. It has lower shrinkage and less cupping and warping than other cuts thus providing
stable, attractive material.

Answers could include

• Best grain on face
• Good wear resistance
• Lower shrinkage
• Less warping and cupping
• High stability
• Visually appealing.

Select the veneers and a suitable adhesive (urea-formaldehyde) and make a mould or jig of the stool's shape. Cut the veneers to size, allowing for waste. Lay up the veneers with glue between each layer and press them over the mould, using cramps or a vacuum bag and press. Leave the glue to cure fully, then remove the moulding. Trim the edges to final shape and cut the handholds with a router and template. Sand all surfaces and apply a suitable finish.

Memorise pack: T6

• Provides a detailed range of steps applicable to the construction of the
 5
 laminated stool. All processes outlined are logical and correctly sequenced
• Provides a range of steps applicable to the construction of the laminated
 3–4
 stool. All processes outlined are logical and correctly sequenced
• Provides a basic outline of some possible steps applicable to the
 construction of the laminated stool. Limited detail provided or limited 1–2
 logic evident in process

NESA sample answer

Select materials: laminates, glues, etc
 ↓
Obtain suitable tools: cramps
 ↓
Mark/cut out allowing for waste
 ↓
Lay, apply glue and cramp laminate over jig/mould
 ↓
Repeat step 4 as necessary
 ↓
Remove from jig/mould
 ↓
Trim as required
 ↓
Shape handles and base: router
 ↓
Apple suitable finish

Answers could include

• Vacuum press over a mould or jig
• Vacuum bag and mould
Section III

Restructuring means changing a business's personnel, management levels, systems, processes or physical layout, and it can affect quality control both negatively and positively.

Restructuring and quality control: restructuring (changing roles, teams, machinery or layout) can first lower quality because workers moved to new tasks lack skills and morale drops. With retraining, specialised teams and new machinery such as CNC, it can then improve accuracy and consistency, raising quality.

For example, a furniture factory that restructures into specialised teams (machining, assembly, finishing) with a dedicated quality inspector can catch defects at each stage. New workers may also bring fresh attitudes and less complacency. However, staff anxiety about job losses during a restructure can lower care and quality until roles are settled, so communication and retraining are essential.

Memorise pack: S10

• Detailed understanding of the causes and effects of restructuring a
 5
 business on quality control
• Provides characteristics and features of the causes and effects of
 3–4
 restructuring a business on quality control
• Indicates the main features of restructuring and/or quality control 1–2

Answers could include

• Restructuring can involve personnel, systems, processes, physical environment
• Effects can be positive and negative
• Restructuring can cause stress/anxiety on workers, causing a lowering of the quality of the
 product/services
• Workers moved during a restructure may initially lack the skills to perform new tasks,
 retraining must be under taken to provide knowledge to overcome lack of experience. This
 can lead to a short drop in quality of the product/services.
• New workers can provide a fresh attitude and show less complacency, possibly improving
 the quality of product/services
• The introduction of new machinery can improve the quality of products through increased
 accuracy, precision and output
• Restructuring personnel into specific teams with designated roles can help to improve
 product quality through skill specialisation

New technology has had a very positive effect on production and efficiency in the timber products and furniture industry, although its high cost and effect on jobs reduce its value for some businesses.

CAD allows designs to be drawn, changed and reused quickly from libraries of standard parts, and sent electronically to clients and factories, saving drafting time and delivery costs.

Parts are designed in CAD, and CAM nesting software arranges them on the sheet with the least waste. The machine then cuts, drills and grooves whole sheets of board automatically, with vacuum hold-down and automatic tool changes. This improves the industry by increasing accuracy and repeatability, cutting material waste and labour time, and allowing custom-sized kitchen and wardrobe cabinets to be produced quickly at mass-production cost.

3D printing and CAD renders allow rapid prototypes that clients can approve before production, reducing costly changes later.

Impact on quality and waste: automation removes human error, so every part is identical and joints fit, improving quality control. CAM nesting software minimises offcuts, reducing material costs and environmental impact.

Impact on the workforce: automation reduces demand for unskilled machine operators and traditional hand skills, causing job losses and resistance. It also creates new skilled roles in CNC programming, CAD design and machine maintenance, and removes workers from dangerous tasks at saws, improving WHS.

Limitations: automated lines are very expensive for small businesses, and mass production suits standard products rather than one-off pieces. Small workshops survive by making bespoke solid-timber furniture.

Overall, the value of new technology is high: it greatly increases productivity, accuracy and material efficiency and makes custom furniture affordable, provided businesses can fund it and retrain workers.

Memorise pack: S4, S5

• Provides a detailed judgement of the value of new technology with an
 10
 explanation of its effects on production and efficiency in the industry
• Provides an effective judgement of the value of new technology with a
 8–9
 description of its effects on production and efficiency in the industry
• Provides some measure of the value of new technology with features of its
 5–7
 effects on production and efficiency in the industry
• Attempts to provide an assessment of the effect of new technology on
 3–4
 production and/or efficiency in the industry
• Lists aspects of new technology or production or efficiency in the industry 1–2

NESA sample answer

There are ways to determine the value of new technology improving production and
efficiency. CAD drawings have allowed faster production due to reduced time in planning and
drawing. These drawings are able to have elements such as a library of parts, which can be
reused and save time for the business, therefore increasing efficiency in the production of
drawings. For example, if you consistently use one component of a drawing, eg a particular
cog, then you can save complex drawings and reuse and edit them. CAD drawings allow for
electronic distribution of drawings around the world via the internet (even attached to emails).
This could previously not have been done with hand drawings, as the drawings would have to
be physically sent. This fast method of distribution is a significant cost saving, which is more
efficient due to the time and cost saved by not having down time when waiting for delivery.
With electronic distribution, there are no postal costs and no flying workers around the world
with drawings/plans to attend meetings. In addition, if you were sending physical drawings,
these may be lost. CAD allows for multiple backups to be made so the work will be able to be
sent again reducing duplication of effort. As this globalisation has been made so much easier
by the introduction of new technologies, you also have access to a global work force, and
companies can get more qualified and experienced staff which are then likely to work more
efficiently, thus increasing the amount of drawings produced in a set time.
3D printing allows rapid prototyping in the early stages of production. It allows concept
sketches to be produced quickly, and then tested as a physical prototype to scale. This
physical prototype is faster to generate than previous methods such as creating cardboard
models thus reducing money the company may have spent on labour costs and freeing up this
capital for re-investment. This model can then be shown to clients and feedback given which
is then applied to the model. The time within the design process in preparing for production is
then minimised, as changes can be made quickly and easily to the model based on feedback.
This is a more efficient process, as previously, feedback would be received, drawing would
have to be modified then new drawings printed, or perhaps new models created. This can all
be done in the one process now with the model that is used for the prototype can then be
repurposed and sent out for production, thus saving time in making a separate prototype and
product, therefore being more efficient. Some 3D printers also print in different resins that can
be used for things such as moulding and casting of multiple copies of objects. This is time and
cost efficient and allows smaller businesses that do not have access to large budgets to be
competitive in the market.
2015 HSC Industrial Technology
Timber Products and Furniture Technologies