PRODUCTION ENGINEERING (PRE206B) & PRODUCTION & AUTOMATION
ENGINEERING (PAA206B)
SURNAME & INITIALS
TSHIVULE G
RADZILANI V
MUKOSI M
MHLANGA MT
MOKGABUDI K
STUDENT NUMBERS
216256867
219119755
218555527
224591845
221652312
1
DECLARATION
We hereby declare that this report is entirely our own work.
SURNAME AND INITIALS
SIGNATURE
TSHIVULE G
_______________
RADZILANI V
_______________
MUKOSI M
_______________
MHLANGA MT
_______________
MOKGABUDI K
_______________
Date: 18 September 2023
2
Table of Contents
Define the problem
What problem are you trying to fix?
The problem we are trying to fix is the durability of the previous product. And so, the
product can be easy to use.
What is the problem or need?
The problem is that the current product does not last long and the other one is that is
not easy to walk around with
Who has the problem or need?
Carpenters or beings who are interested in doing their own woodwork.
What have you tried to do?
We have created a similar part but made of wood and we realized the wood was not the
best for manufacturing because it can crack overtime.
Why is it important to solve?
It is important because carpentry can be a tiring job and this product can make the work
easier and more efficient.
What would you do differently if you could do it again?
During our first designer could have first tested the product for a longer time to see the
potential problems that could occur and try to fix it before taking it to the customers
Is it achievable in the limited time?
Yes, our product is achievable in a limited time because we only change the type of
material, which is PVC plastic, but the process is the same.
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Existing jigs (door buddy):
Our jig product (door buddy)
Background research
In the context of carpentry and woodworking, a "jig" refers to a specialized tool or device
that assists carpenters in various tasks. These jigs are designed to ensure accuracy,
repeatability, and efficiency in woodworking operations. Here is some background
information on jigs in carpentry:
Origin and Purpose:
The use of jigs in carpentry dates back centuries, evolving alongside the craft itself.
Carpenters have always sought ways to streamline and improve their work.
Jigs serve several purposes, including guiding cutting tools, holding workpieces
securely, and helping carpenters achieve precise cuts, holes, or shapes.
Types of Jigs:
Crosscut Sled: A crosscut sled is a jig used with a table saw to make accurate
crosscuts. It provides better control and safety when cutting large or small workpieces.
Dovetail Jig: A dovetail jig is a tool used to guide a router to create dovetail joints, which
are commonly used in furniture making for their strength and In the context of carpentry
and woodworking, a "jig" refers to a specialized tool or device that assists carpenters in
various tasks. These jigs are designed to ensure accuracy, repeatability, and efficiency
in woodworking operations. Here is some background information on jigs in carpentry:
Mortise and Tenon Jig: This jig aids in creating mortise and tenon joints, which are
fundamental in woodworking for connecting pieces of wood securely.
Router Jig: Router jigs can be customized for various purposes, such as creating inlays,
dadoes, and grooves.
Drilling Jig: These jigs are used for drilling precise holes at specific angles or depths,
ensuring accuracy in furniture assembly.
Materials and Construction:
Carpentry jigs can be made from various materials, including wood, metal, or plastic,
depending on the specific task and the desired level of durability.
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Modern woodworking often involves the use of advanced materials like phenolic resin
for creating durable and long-lasting jigs.
Advantages:
Jigs in carpentry help woodworkers save time and reduce errors by ensuring consistent
and accurate results.
They improve safety by providing stable and controlled work environments, reducing the
risk of accidents.
Customization and Innovation:
Many carpenters create their own jigs, tailored to their specific needs or projects.
With advances in technology, CNC (computer numerical control) machines can be used
to create highly precise and complex jigs for specialized tasks.
Versatility:
Carpentry jigs are versatile tools used in a wide range of woodworking projects, from
cabinetry and furniture making to building structures like doors, windows, and stairs.
Summary
Carpentry jigs are essential tools that have a rich history in woodworking. They have
evolved to meet the demands of modern carpenters, allowing them to achieve higher
levels of precision and efficiency in their craft. Whether it is creating joinery, making
intricate cuts, or drilling holes, jigs play a crucial role in ensuring the quality and
accuracy of carpentry work.
joinery, making intricate cuts, or drilling holes, jigs play a crucial role in ensuring the
quality and accuracy of carpentry work.
Regenerate
room cabinetry and furniture making to building structures like doors, windows, and
stairs.
In summary, carpentry jigs are essential tools that have a rich history in woodworking.
They have evolved to meet the demands of modern carpenters, allowing them to
achieve higher levels of precision and efficiency in their craft. Whether it is creating
joinery, making intricate cuts, or drilling holes, jigs play a crucial role in ensuring the
quality and accuracy of carpentry work.
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Specify Requirements
PERFOMANCE
The product is a door buddy that helps with assisting carpenters with installing
specifically doors on cupboards. The carpenter doesn’t need to carry heavy doors trying
to align them with where they need to go, it makes the work easier by doing that and the
carpenter can work alone throughout the whole installation, with jig that is in the market
currently you cannot work alone u need someone to help you align the door, avoid
making mistakes like wrong holes when drilling.
Aesthetics
Our door buddy is made of polyvinyl chloride plastic, it can be manufactured in a wide
range of colours from transparent and translucent to solid and vibrant hues. Its texture
and surface are smooth. Metals and wood are used to make wood currently and it can
be expensive to add colors on metals.
Durability
The product can stay for an exceptionally long time it can survive for years because it is
made of plastic, plastic does not need maintenance so after buying it u will not spend
again unlike wood, which is expensive depending on the type, also some woods decay.
Steel/metal can experience corrosion.
Special features
The carpenter can work alone since our door buddy is able to align doors on cupboards
when installing, we added to sides on the door buddy to hold the door , with the jigs that
are on the market right now u can’t work alone because they can align or hold the door
and that increase costs because u must pay the person u are working with.
Reliability
The material is resistant to moisture, chemicals, and UV radiation making it suitable for
outdoor use. Currently in the market jigs are made of metals it will not be suitable to use
outdoors depending on seasons. Metals are rust and corrode.
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Brainstorming Solutions
Choose the best solution.
Door buddy


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
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We chose the door buddy because we only need plastic to produce it and the
material is polyvinyl chloride. also, affordable
The door buddy will make the work easier for the carpenter and save time
Save cost, easy to use, and less stress as the carpenter will be able to work
alone.
The material we are going to choose is of decent quality and cost less.
It is the permanent solution.
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Develop the solution
The purpose and the specific tasks or challenge are designed for jig carpentry.
Hinge Installation: Carpentry jigs can be designed to assist with the precise installation
of door hinges. They might include guides and templates to ensure that hinges are
positioned accurately and at the correct depth.
Lockset and Doorknob Installation: Some jigs are created to simplify the installation
of locksets, doorknobs, and other door hardware. They can help ensure that holes for
locksets and doorknobs are drilled accurately and consistently.
Hole Drilling: Jigs can be designed to aid in drilling holes for lock cylinders, deadbolts,
or other door components. These jigs can help maintain proper alignment and depth.
Mortising: Carpentry jigs may assist in creating mortises for strike plates and latch
mechanisms. These jigs can improve the accuracy and efficiency of mortising tasks.
Door Trimming: Some jigs are designed to help trim doors to the correct size or angle,
especially when dealing with non-standard doorframes.
Alignment and Squareness: Jigs can aid in ensuring that doors are hung squarely
within doorframes and are properly aligned. They may include leveling or alignment
features.
Repetition and Consistency: Jigs are often used for tasks that require repetitive
actions, such as installing multiple doors with identical specifications. They help
maintain consistency and accuracy across multiple installations.
Reducing Errors: The primary purpose of many jigs is to reduce human errors in
measurements and drilling. They provide a reliable guide, helping carpenters achieve
precise results.
Time Savings: By simplifying and expediting specific tasks, carpentry jigs can save
time during door installation and related carpentry work.
Test and redesign
Testing
Initially, we had set our product material using wood.
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After the first iteration we realized wood would not work in the long run looking at it in a
real-life perspective. We then conducted a 5-WHY root cause analysis trying to find out
if we should continue with it or find another suitable material to use.
5 WHY (Root cause analysis)
WHY: why will using wood be bad for the business in the long run?
⦁ Observantly, customers will stop buying the product all together
WHY: will customers stop buying our product?
⦁ Because they will be avoiding the admin of refurbishing or replacing the product just to
keep using it.
WHY: why will our product need to be refurbished or replaced?
⦁ Because wood is more susceptible to water damage, fire, decay, and termites.
WHY: why is that a factor that affects our product and business?
⦁ Because this will mean that our product will need to be maintained by each respective
customers that buys our product
WHY: why can’t we sell refurbishing products as well then?
⦁ Because it will be more costly for the customers and customers prefer going for the
cheaper things and it is not part of our business
From the 5-Why analysis we can deduce that the main causes of not using wood as a
material is because of its disadvantages that happen overtime.
Listed below are the main disadvantages of using wood:
DISADVANTAGES OF WOOD
Water damage
Fire
Decay
REASONING
When water gets into wooden fibers, the material
expands, and its structural properties become much
weaker causing it to deteriorate
Unless treated with chemicals, wood can easily
catch fire and is considered a combustible material
Moisture and environmental conditions can lead to
wood decay and that degrades the integrity of the
wood material
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Termites
Some pests, insects, and fungi can digest wood.
Termites can drill into the wood fibers which can
lead to significant deterioration of the wood material
Therefore, after analyzing the core causes of using wood, we were able to conclude that
we need to introduce a new material for our product.
Proposed solution
Our new solution is to use plastic material.
So, we keep the same design however, we change the material properties from wood to
plastic.
ADVANTAGES OF PLASTIC
Low manufacturing costs
Easy to mold
Lightweight
Durable & resistant to corrosion
Water resistant
REASONING
Plastic is already a commercial material,
so it is cheaper to make as machines and
molding machines are widely and readily
available
The process of molding plastic only
requires a short number of times and is
an automated process
Plastic is lightweight yet strong
Plastic is flexible, as well as it not being
an organic material which adds to its
durability and resistance to corrosion
Plastic does not get damaged by water
In conclusion plastic would be a better suited material to use when manufacturing the
door buddy as it has more advantages than using wood eventually, for example;

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
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Plastic has a lower manufacturing cost than wood and takes less time to
manufacture.
Plastic molding is easier and more cost effective than carving and/or CNC cutting
a piece of wood block. Multiple plastic molds can be poured/manufactured
simultaneously whereas with wood the process would have to be per individual
item.
As opposed to plastic wood which can easily be damaged with liquids such as
water, wood also develops splinters over periods of time.
Plastic is a lighter material than wood making it easier for the end user to use.
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
Other environmental and non-environmental factors can also negatively affect
wood such as insects, fire, fungi, shrinkage/swelling of wood and cracks from
dropping the item.
Redesign
Our first design
Picture
Challenges faced with the 1st design:
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

The design is one-directional meaning we must have two units, one for the left
door and one for the right door.
It needs a clamp to support and keep it in place which meant extra cost (buying
the clamp) and complexity of using the product.
The design is thin, has the possibilities of breaking under material load and
stress.
Measurements are out of scale.
Our second design
Picture
Complications with design two (Solution to design one)



This design solves design the limitations of one directional. This design is bidirectional meaning it can be used on the left and right door.
It needs a clamp to support and keep it in place which meant extra cost (buying
the clamp) and complexity of using the product.
The product has a thicker design.
PHASE ONE
Project Brief
Why are we considering building the product?
Since most carpenters and homeowners lack a suitable tool for balancing their materials
while installing doors and cupboards, we decided to design the product. The current
product indicates that two individuals are required to complete the task, one to install
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the product and the other to balance it. This procedure wastes time and reduces output.
Our jig will help you precisely balance the item at hand while also saving you time. This
implies that one person can install doors and cabinets by themselves while the other
person gets some job done.
Metals and wood are used to make the current jig. Wood is easily ignited, susceptible to
water damage, and some small insects, like termites, may drill and drive lines into the
wood fibers, which can cause serious degradation of the wood material before it is too
late. Metals can be heavy, rusted, and corroded. Customers can expect costs because
the wood and the metal will be damaged.
PVC material will be used to create our product. There is no need for additional
supporting materials like metal inside this plastic. It is a long-lasting substance that is
corrosion- and weather-resistant, as well as less expensive. People will not have to buy
it more frequently because of the damage
Consideration Values of the Product
The 4Ps
 Product
Carpenters will be the main users of the
product. It will assist them in maintaining
the stability and balance of the product
they are working on. In this manner, they
will only require one employee to work on
the product, as opposed to two.
 Place
The product will be sold in the stores that
sell building supplies. Everyone who
wants to utilize it will have easy access to
it. It can be put close to the tools used by
carpenters. The most popular means of
shopping is now online, where it may also
be found.
 Pricing
The product's cost will vary according to
the components, equipment, and tools
employed. For our product, the cost per
part ranged from R250 to R300.
 Promotion
Promotion of the product is possible on
social media sites like Facebook and
Instagram. These days, everyone uses
social media, so by making it known and
making it available for purchase,
everyone will be aware of it.
Project Objectives
 Simple working circumstances woodworkers (less bending)
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 One employee rather than two should be working on the doors and cabinets.
They can work on several projects at once in this fashion.
 The product will endure longer and will not need to be replaced as often
because it does not break or corrode.
Major Deliverables
Roles and Responsibilities
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Role
Sponsor
Responsibility
 They are accountable for a project's success and give the
project team and manager the required direction and
resources.
 Offer strong project sustainability, strategic planning, and
successful project goal implementation.
 Project alignment with organizational objectives, aims, and
strategies
 Making sure the project is launched and carried out
properly
 Keeping track of changes and risks while maintaining the
project's quality
Project Manager




Project Team
 By helping with the planning of project activities and
completing given tasks within the required quality
standards, they contribute to the overall project objectives
and specific team deliverables, ensuring the project's
success.
 Give technical or business knowledge to complete project
tasks.
 Contact stakeholders to make sure the project satisfies
business requirements
Customers




Plan and advance the project concept.
Tracking project development and deadlines
Address arising challenges and gauge project success
Make sure stakeholders are satisfied
The project's requirements are established by the client.
They oversee approving the project schedule.
Responsible for adjusting requests
They are also in charge of deciding whether to accept or
reject the finished product or service.
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Stakeholders
Name
Distributor of
PVC resin
Role
Suppliers
Responsibility
 Offer the components or raw resources that a
company requires to make its products.
 Abide by all applicable rules and regulations
and


Ms. Mokgabudi
Senior
Management

Ms. Mukosi
Project
manager


Ms. Radzilani
Accountant


Ms. Tshivule
Supervisor

Ms. Mhlanga
Team
members

Give all companies an equal chance to
conduct business with them.
To keep retailers' trust, promise them the
finest possible combination of price and
quality.
Accountable for managing the planning and
execution of a whole project, including the
creation of a budget, the recruiting of team
members and suppliers, and the scheduling of
the project's delivery.
Responsible for the project's success.
Manage each stakeholder's impact on the
project's requirements to produce the desired
results.
Analyze the results of the project
monitoring the project's financial elements as
it develops.
Control every part of a project from planning
through execution.
Contributing to the overall project goals,
participating in committees, aiding when
needed, and working with the team to achieve
the company's needs.
Assumptions
Below are the estimated costs for materials needed to produce our door buddy jig:
Rotational Molding machine (2.8m 3arm
Carousel
PVC granules
Labor cost
R990000.00
R37.69 per kg
R177.94 per day
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PHASE TWO
We are going to design a jig that will be able to balance the door when carpenter is
installing it/align the door of cupboard.
Diagram
PHASE THREE
Project requirements
We are asked to develop a product that can be used or applied to solve some of the
social and environmental challenges that society faces daily. We are asked to develop a
product using additive manufacturing technology. Our design is expected to meet the
following product design fundamentals:
⦁
Product must be authentic. Identify a clear purpose and make that
purpose apparent in its design.
⦁
Product must provide unique experiences.
⦁
Effective product design goes unnoticed.
⦁
Do one thing extremely well.
⦁
Solve pain points elegantly.
PROJECT SCOPE
Project Charter
Example: Imagine a project charter for a plastic manufacturing project:







Project Name: Door buddy
Project Manager: M Mukosi
Business Case: Increase production capacity to meet growing market demand.
Objectives: to develop a product that can be used or applied to solve some of the
social and environmental challenges that society faces daily.
Risks: Fluctuations in raw material prices, regulatory changes.
Assumptions: Availability of skilled workers and a stable supply chain.
Approval: Approved by the executive team.
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RISKS





Errors: In our manufacturing of the jig the potential risk can be error in printing of
the product
Delay in timeline: There may be delays and can cause us to reschedule the
project timeline.
Raw Material Price Volatility: Sudden increases in the cost of plastic resin
could impact profitability.
Supply Chain Disruption: Any disruptions in the supply chain for raw materials
could lead to production delays.
Raw Material Price Volatility: Sudden increases in the cost of plastic resin could
impact profitability.
Assumptions
The following assumptions can be made in the plastic production project:
Skilled workforce: assuming that there is a pool of qualified machine operators in the
labour market.
Stable Demand: market demand for plastic products will continue to grow steadily.
Supplier Reliability: If key suppliers will deliver raw materials on time and without
major disruptions.
Constraints
Constraints to the plastic production project could be as follows:
Budget Constraints: The project must operate within the allocated budget.
Time Constraints: there may be limited time in manufacturing of the product.
Resource Constraint: The availability of qualified machine operators may be restricted
in the project.
WORK BREAKDOWN STRUCTURE(WBS)
Diagram
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Manufacturing
2.1 Materials designed - Plastic injection molding process.
We will be molding our desired shape using a rigid mold. Our product will be
manufactured from plastic using raw polymer resin granules melted into a liquid and
injected into a mold, where the plastic will take our desired shape.
Plastic injection molding steps:
⦁
Plastic resin materials enter a barrel.
⦁
Heat melts the plastic, which is mixed.
⦁
Shot sizes are created, determining the volume of material to be injected into
each mold.
⦁
The mold closes.
⦁
The melted plastic is injected into the mold cavity.
⦁
While the material cools and solidifies, the rotational molding machine prepares
steps 1 to 3 for the next cycle.
⦁
The mold opens.
⦁
The part is ejected.
⦁
The process repeats when the mold closes again.
2.2 Materials procured.
⦁
Raw polymer granules
⦁
Resin
2.3 Frame complete
Design Concept
Picture
Parametric design
Picture
Analysis of Optimization
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As a method of analyzing optimization to improve the existing processes, we will use
the DMAIC method.
⦁ Define: We start by defining the problem, goal, process, parameters, and customers.
⦁ Measure: We gather data to serve as a control to compare changes to later.
⦁ Analyze: We use the measurable data to find probable causes for inefficiencies or
failures to reach the goals we defined at the start.
⦁ Improve: We produce strategies to solve for those inefficiencies or failures and
execute them, noting improvements against our measured baselines.
⦁ Control: We put those strategies into practice by integrating them into our process
going forward.
Creation of prototypes – we have one prototype that was created
Prototype testing & evaluation – all stakeholders tested the design and were happy with
it.
The evaluation observed was that it needed to be filed a little on the sides
Meet design criteria – yes, the design met the criteria
Final product – the final product is the Door Buddy
COMPONENTS
Components

Components procured is one solid body made from raw polymer resin
Components installed.

Plastic Granules
Components tested.

We tested wood theoretically and concluded that it would not be functional
overtime.
Schedule
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Construction Project Schedule
Project Name
Door buddy
Project Address
TUT Staatsartillerie Road, Pretoria West
Project Manager
MS M Mukosi
Project Start & End
Budget
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Manufacturing cost rate
Manufacturing cost
Production cost per day working 7-hour shift.
= R362.00*7
= R2534.00
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Production cost per week working 7-hour shift.
= R2534.00*5
= R12 670
Production cost per month working 7-hour shift.
= R12 670*4
= R50 680
NB: 1KG OF Polyvinyl Chloride (PVC or Vinyl) produces 5 buddy doors:
Therefore, we produce 25 products a shift.
Material cost per shift = (R15.00*5) *25
=R1875.00
Overall manufacturing cost per day
= R1875.00+ R2534.00
=R4 409
Production cost per week working 7-hour shift.
= R1875.00+R12 670
=R14 545
Manufacturing cost per month working 7-hour shift.
= R1875.00+ R50 680
=R52 555
UNITS PRODUCED IN A MONTH
= 25*5*4
= 500 units produced in a month
Production cost per unit
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= R52 555/500
=R105.11
Selling price
= R200.00
Profit per unit
= R200.00- R105.11
=94.89 UNIT SOLD
Calculations
It is assumed that you have a manual assembly line planned for an assembled product
with a work content time of 480 minutes. The production line will be operational for at
least 1000 hours per year. The product is expected to sell 6000 door buddies per year.
Based on previous assembly lines used by other companies in your field, the line's
uptime is expected to be 90%, line balancing efficiency will be at least 92 percent, and
repositioning time lost each cycle will be 0,7 seconds. The production line will have at
least one worker/station. Determine:
The line’s required hourly production rate
Rp = Da/50SwHsh
= 6000/50*5*7
= 3.43 units/hr.
Mitigate plans for loadshedding and absenteeism will include:
⦁
Cross-training workers to cover for each other during absences.
⦁
Implementing backup shifts or part-time workers to handle increased demand.
⦁
Regularly maintaining and servicing equipment to minimize downtime.
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The cycle time.
Tc = 60E/Rp
= 60*0.9/3.43
= 15.74 minutes
To avoid issues like not working as a team, working on too many things at the same
time, and working on too big increment, we will consider:



Implementing standard operating procedure
Providing training and guidance to workers on teamwork and task management.
Breaking down the assembly process into smaller, manageable steps Clear see
Mary and then see they are doing my number of required requests.
The ideal minimum number of required workers w* = minimum integer>=Twc/Tc
= 480/15.74
= 30.5
= 31 workers
The actual number of workers required is based on the efficiencies given.
Ts = Tc – Tr
= 15.74 – 0,7
= 15.05
Therefore:
w = Twc/Eb*Ts
= 480/0.92*15.05
= 34.7
= 35 workers
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Application of naive and moving average forecast tools. Show how you will apply them
in your company by means of a table.
Conclusion
Door Buddy represents an innovative solution that addresses specific challenges in
door installation and carpentry work. Its potential to improve precision, efficiency, safety,
and overall craftsmanship makes it a valuable addition to the toolkit of carpenters and
professionals in the field. As the tool is further refined and adopted, it has the potential
to enhance the quality of door installations and contribute to the efficiency of carpentry
projects.
The Door Buddy presents a promising solution for addressing specific challenges and
enhancing efficiency in door installation and related carpentry tasks. Through its
innovative design and features, it aims to simplify and streamline the process of
installing doors, ultimately benefiting carpenters and tradespeople. Here are some key
points to conclude the significance of the “Door Buddy":
Improved Precision: The "Door Buddy" is designed to offer precise measurements and
alignment, ensuring that doors are installed accurately and securely. This feature
contributes to the overall quality and functionality of the installed doors.
Time and Labor Savings: By automating and simplifying various steps of the door
installation process, this jig can significantly reduce the time and labor required for the
task. This efficiency can lead to increased productivity on job sites.
Enhanced Safety: Safety is a paramount concern in carpentry work. The "Door Buddy"
incorporates safety features that help prevent accidents or injuries during the installation
process, contributing to a safer work environment.
Ease of Use: User-friendliness is a crucial aspect of any tool. Carpenters can quickly
adapt to using the "Door Buddy" due to its intuitive design and clear instructions,
reducing the learning curve.
Versatility: The door buddy adaptability to different door sizes and types adds to its
versatility, making it suitable for a range of carpentry projects.
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Quality Assurance: The tool's precision and consistency ensure a high standard of
quality in door installations, meeting, or exceeding industry standards.
Cost Efficiency: While the initial investment may be a consideration, the "Door Buddy"
ultimately offers cost savings by reducing errors, rework, and labor costs associated
with door installation projects.
Environmental Considerations: The tool's design may also consider eco-friendly
materials or processes to align with sustainability goals in modern carpentry practices.
Reference
https://www.investopedia.com/terms/f/fourps.asp#:~:text=The%20four%20Ps%20are%20the,price%2C%20place%2C%20and%2
0promotion
https://www.dutchland.com/rotational-molding-for-beginners/
https://geminigroup.net/blog/rotational-molding-advantages-disadvantages/
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