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Industrial arts

WOODJIG.com

The economic problem 
wasn’t isolated, the solution was isolated...

Grasping manufacturing principles and concepts have always been a challenge. Now we have robotics, CAD design, lean and even rapid manufacturing. Much of these new processes needlessly cause the student to be disillusioned. But it is not that complicated. "Automation, at least the basic process begins with a passion, some machines, an organized shop, focused goals, but most of all;  understanding duplication.

Tools are a means to profit and duplication is a means to reach a surplus.  To do anything less than employ our tools to their greatest potential is considered a waste to a machinist,  an ambitious leader or engineer. We can't compete for long raising a nation out of the loop,  with little ownership of economic methods or ability to compete can we?  Financial specialists and politicians might become a stepping stone to great things, if they knew more about mechanics, especially the age old techniques.  What an economy of scale might need is for the ambitious to be introduced to the past as well as the future. 

"Hindsight is when we are informed afterwards about the consequences of being shortsighted."

Many of these economic  "abundance/surplus" concepts are concepts which have been unnecessarily guarded over the ages, causing a shortage of advanced skills in many trades.  I know this because I have been in numerous woodworking shops in the U.S. and Canada, and have been in numerous manufacturing plants.  This science, and these proven organizational methods and ideas have been around and improved upon throughout the ages resulting from the need for an economic surplus. These techniques, mostly waste saving originate from the desire for a surplus, trade, and  economic security. 

When we communicate automation concepts we scare some people, but when we get the point across that we only need to grasp the basics, we give a glimpse of what is possible. All that some people need is an insight as to how basic the requirements really are to automate. It was done thousands of years ago. The Egyptians understood, and used a primitive type of automation by making molds, pouring the materials into the molds, and stacking the bricks in a certain sequence. It’s fairly certain that they didn’t make each brick a different size. 

The average person with a few machines on his premises, especially a table saw can automate. He can build jigs relatively cost free, and then produce components which can be routinely assembled the same way, and duplicate the initial project. Then the projects can be sold at fairs, markets, through clubs and holiday events. The basics soon develop into more openings and more ways to cut down waste and become more efficient. Soon, we have someone making all sorts of goods, furniture and a variety of profitable products from inexpensive hobbyist machinery. 

A hobby horse goes from one to the other....

I have seen many tool retailers go out of business for lack of productive enterprise. The majority of people who own machines, even trade schools become what is called a "latest trend crafter" bouncing from one unfinished pursuit, never settling into, or even becoming familiar with a system of automation or replication. America is unlike most foreign countries in that we have a surplus of machinery and information, but a drought of basic clarity about automation methods. Knowing more about jigs and about automation would eventually spark a huge demand for supplies, new machinery, and more available automation related hardware from tool suppliers. 

First, those unaware of duplication techniques need to make a clear connection. Ask a woodworker, and you will likely find out that most woodworkers either don’t use their machines, or they fumble through custom, one at a time projects over and over, often abandoning their hobby. Often it was a hobby which was begun to explore the possibility of a small business, a limited volume operation, but the information was never available, and schools didn’t cover such topics. 

"It takes years of thinking and reflection to discover some things. Recently MG motors, (and numerous other manufacturers) having developed enormous technical processes held privy since there inception were sold to China (and in MG’s case) along with the plant manager and much of it’s technical information. These are the things that keep politicians and tool suppliers running for help, asking why these operations failed, and what happens to those trained to build and operate such an organization. 

The actual skills required to build jigs and fixtures have been neglected, trapped in a vacuum and utilized only by a few attracted to the principles and concepts of duplication. Many times these principles and skills are trapped within or shared only within family generations, or within the old "inherited" manufacturing circles who will naturally educate too few.  Then there is a risk that they insulate these unique skills often to only one or two key individuals. 

Tool builders and suppliers suffer when we don't get the word out. Sure, a business angle is the obvious tone of this story.  I have written extensively about how the business side has been replaced by the "Hobby-Pastime" tone that woodworking has been.  This is because writers are careful not to mis-inform some who might run out and start a business over the weekend.  A business is a process, and, like the stock broker,  to comply with full exclosure, I, as well as everyone in my city and my state has an interest in a business result, or goal for every talent.  

This drought of knowledge about basic automation, about jigs, fixtures and duplication techniques can only present a scarcity of skills, it duels with the economy, worries or does worse to the tool suppliers, and even restrains future economic growth. We can't isolate this knowledge and not expect our manufacturing and tax base to wither. It needs to be encouraged and fostered, not conditionally isolated from the remainder, or entrusted only to a few privy people, possibly about to retire, start their own business, or work in research somewhere. 

I have worked in numerous production plants, and visited woodworking shops, and I can attest that merely a few know, or even have the ability to explain secondary operations requiring jigs and fixtures. Most people don't know much about push-type toggle clamps, air cylinders, and stock fixtures and production parts. These are the operations that are done isolated from production, many times in other divisions which involve the final manufacturing operations, the tapping, welding, drilling, assembling and riveting of the production made parts. 

In woodworking these secondary operations might be drilling, assembling, gluing, and all with the use of jigs and fixtures. The majority can produce a part, but because of various reasons only another few know what to do to complete the processes required for a mass produced, quality built finished product. 

I have written a book, "Northirst County" which is a story about an Old Man, injured in a snowstorm and about to retire. He is responsible for his friends care, and he is successful trying to teach his nephew vital, basic skills needed to go beyond plain woodworking. He needs to teach him secondary operations, jigs, and fixtures, in order to produce furniture on a mid to high volume scale. In the process, he teaches Northirst County enthusiasts how to prosper from similar concepts. He becomes a symbolic figure, industry is restored, taxes get paid, and roads repaired. The Old Man Zack has a nephew who then becomes instrumental in helping the whole county back in the economic loop. 

Students need to read things that aren’t so institutionalized about the real challenges they confront: real life situations that relate to their interests with the crafts and with machines. Just basic skills with a machine are not enough. They often need great stories, and they need to know the things they might confront, which helps drive them to hone their skills, be more efficient, disciplined and competent, and to face the challenges of enterprise. They need someone to turn riddles into rhythm and rhyme. 

They always see it when they believe it! Mascut 1.0

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About George?
Developed the woodjig.com website, and in 2001 had over 2,500 email subscribers. I have written 4 books that are used by teachers and students alike. One book describes the basics of automation, Jigs for Beginners, and another tells about the history of machines and productivity. IMM, Ingenious Machine and Methods. Another E-book, called "The Firty Giants of Industry" has been used by trade school teachers. Tags: making furniture ,  industrial arts , furniture.