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<Title of work, centered. Use consistent capitalization
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In
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Peggy Gordon Miller
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Copyright 2011, FirstName LastName
Acknowledgments
This report recommends using thermally fused melamine, or TFM, to produce a new line
of furniture for our company. TFM is a very durable material that other businesses
closely related to ours, such as cabinet and display case makers, are beginning to use. It is
comparable to high-pressure laminate in scratch resistance and durability. TFM is also
water resistant, heat proof, and stain resistant.
In order to remain a leading producer of children’s furniture, it is necessary to begin
expanding our production capabilities. TFM will attract consumers that would not
normally purchase our furniture, and thus diversify our customer base. It is necessary for
Reynolds to capitalize on the strengths of TFM and begin using it in production.
TFM is manufactured and can therefore exactly match our specifications in terms of
appearance. It would be possible to produce furniture of a certain color, such as red or
blue, or maintain the traditional appearance of wood grain.
Table of Contents
Abstract
List of Tables
List of Figures
Chapter I
Title of Chapter I
Reynolds Manufacturing has made a solid reputation with schools, churches, and
daycares in the state of Texas as a maker of high quality children’s furniture. This
reputation and the quality of our furniture are built upon the precise methods which we
use in producing our products. Currently, Reynolds makes furniture out of two materials:
solid maple and three-quarter inch plywood. All pieces are hand crafted and carefully
inspected for quality. Reynolds has many repeat customers and continues to experience
substantial growth in the scope and amount of products produced.
However, while the current method of production has proven to be very reliable and
marketable, it is in the company’s best interests to start investigating alternative methods
of production. There are several ways that the current production method could be
streamlined, reducing costs by saving materials, time, and labor. By researching and
experimenting with new production methods and procedures, Reynolds will be able to
stay ahead of competitors and stay at the forefront of technological innovation.
This report analyzes the pros and cons of thermally fused melamine, explores the
feasibility of using this material in furniture production for our company, and examines
the potential benefits of capitalizing on this technology.
to work with the TFM.
This report deals with the four major topics: the advantages and disadvantages of using
TFM, the steps used in producing products made of TFM, the estimated effects that using
TFM will have on production and marketability, and the operation and cost of new
machinery.
Chapter II
Title of Chapter II
First-level subsection title for Chapter II
Many of the advantages TFM offers emerge from the unique use of melamine. Melamine
is a white crystalline powder, technically known as triamino-triazine, or C3N6H6, and is
composed of carbon, nitrogen, and hydrogen (DSM Melamine 1). The raw melamine
powder is condensed with formaldehyde to produce thermosetting resins, which harden
when heated. The heat and pressure that is applied to the melamine permanently adheres
it to the surface of the substrate, effectively sealing off the material from external contact
(Harbatkin 12).
The hardened melamine surface is highly resistant to physical damage, such as scratches
or depressions, as well as chemical degradation, including spills from substances that
would normally stain wood. Melamine totally covers the surface of the substrate,
fortifying the product against moisture (Miller 102). TFM is also extremely heat resistant,
withstanding temperatures of up to 300 degrees Celsius, or 572 degrees Fahrenheit (DSM
Melamine 1). This means that TFM is effectively heatproof and fire resistant.
Title for table
Name
Appearance
Job
Age
Turkey
florid, pursy
Copyist
same as narrator
Nippers
whiskered, sallow
Copyist
25
quick-witted
Office boy
12
Ginger Nut
TFM is manufactured and can therefore exactly match our specifications in terms of
appearance. It is possible to produce furniture of a certain color, such as red or blue, or
maintain the traditional appearance of wood grain. Using TFM would give Reynolds the
option of making and pioneering a radically new look for furniture by using patterns.
Along with wood grains, TFM comes in a staggering variety of patterns that can be
applied to furniture, allowing our products to be custom made to fit into a certain area of
a business, or to create an atmosphere desired by our clients (Lowry). In a room with no
natural colors our current products sometimes appear out of place and disjointed when
compared to the rest of the room. The patterns and colors that TFM offers would allow
our furniture to blend in with these rooms and become less of a distraction.
First-level subsection title for Chapter II
There are several drawbacks to using TFM. TFM it is heavier than plywood or maple,
and the resulting pieces would weigh more. However, most of our products are mounted
on casters, thus effectively negating the increased weight. Also, TFM cannot be cut using
traditional saws, and therefore requires two special pieces of equipment: a computercontrolled router, known as a CNC router, and an edge banding machine. These machines
have a very high initial cost, but they will save money by reducing time and labor and
will eventually pay for themselves.
First-level subsection title for Chapter II
Reynolds currently uses a finely detailed and very hands on production process, resulting
in a product that has been carefully worked on during every step. Although different
pieces require different steps of assembly, the basic method of production involves
approximately 9 steps:
NUMBERED LIST
Cut or rip plywood or maple boards to appropriate length and width.
Cut the resulting pieces to fit product specifications.
Assemble the pieces into the product.
Use Famo to fill in any voids.
This process creates the high quality product that customers appreciate. TFM furniture
will retain the hands on aspect of production and still guarantee a top quality product, but
in less time. Producing furniture using TFM requires only 5 steps:
NUMBERED LIST
Cut the melamine boards to fit product specifications.
Edge-band the rough or cut edges of the melamine.
Assemble the pieces into the product.
Inspect the product and add finishing touches.
Box the product.
Using TFM will save significant amounts of time in the construction process, primarily
by totally omitting the sanding phase, the spraying phase, and the drying phase. These
three phases account for approximately 75% of the man hours spent on any given piece
of furniture. Therefore, Reynolds will be able to create more than twice the amount of
TFM furniture as traditional furniture in any given time period. By using the unique
attributes of TFM, Reynolds will be able to maintain this increased production rate and
the current high standard of quality for all furniture produced.
Chapter III
Title of Chapter III
First-level subsection title for Chapter III
TFM will have varying effects on the production of furniture according to how long we
have been using it. When TFM furniture is first introduced, the overall production time
for a piece of furniture will take almost as long as it does now, including the time
necessary for spraying. This is largely due to the fact that the methods used in working
with the material are still new and production personnel will be unused to the process
(Lowry). However, the longer the workers use TFM, the faster the process will become.
After several months of use, it is estimated that a piece of TFM furniture can be made and
boxed in about half the time as a traditional piece (Lowry). The workers will become
used to the routine of milling and assembling the new furniture, and the overall time
necessary to produce a piece of furniture will drop drastically. The workers will also
become more familiar the new machinery, and the more proficient they become, the
faster they will be able to produce.
First-levelsubsection title for chapter III
One of the great benefits of TFM is its diversity. There are many options associated with
TFM that allow almost limitless combinations of colors, patterns, wood grains, and
finishes (Miller 102).
2nd Level subsection for Chapter III
The two machines that will be needed to manufacture furniture using TFM are an edge
bander and a CNC router. The CNC router is a computer controlled, fully automated
router that will cut, rabbet, and dado the TFM according to our specifications. A rabbet is
an “L” shaped joint cut along the edge of the wood to recess panels, or distribute weight
across a larger surface area, therefore increasing strength. A dado is a groove cut into the
surface of the wood panel; usually a shelf or support goes into this groove to add stability
and strength to the furniture.
Title for image
The CNC router has a movable computer console attached to the rest of the machine by a
large plastic bundle of wires and cords. Through this console the router can be directed to
execute different programs and make different cuts to the TFM. The program used to
control the router is very customizable, and once the information is entered into the
software the router does everything needed to finish the part. In order to operate the
router, it will be necessary for one or two employees to learn the programming language
needed to program the router’s software (Lowry).
2nd Level subsection for Chapter III
The cost of the edge bander and the CNC router is approximately $250,000. This cost
includes the machines, the training materials necessary to use the machines, a six
compartment dust collector that services both machines, and a week long tutorial by an
expert from the company.
Chapter IV
Title of Chapter IV
In order to remain a leading producer of children’s furniture, it is necessary to begin
expanding our production capabilities. TFM will also attract consumers that would not
normally purchase our furniture, and thus diversify our customer base. It is necessary for
Reynolds to capitalize on the strengths of TFM and begin using it in production.
TFM is a very durable material that other businesses closely related to ours, such as
cabinet and display case makers, are beginning to use. It is comparable to high-pressure
laminate in scratch resistance and durability. TFM is also water resistant, heat proof, and
stain resistant.
TFM is manufactured and can therefore exactly match our specifications in terms of
appearance. It would be possible to produce furniture of a certain color, such as red or
blue, or it could maintain the traditional appearance of wood grain.
Works Cited
“DSM Melamine.” DSM Melamine Online. 01 Nov. 2003.
<http://www5.dsm.com/en_US/html/dmm/melamine_home.htm>
“What is Melamine?” DSM Melamine Online. 01 Nov. 2003.
<http://www5.dsm.com/en_US/html/dmm/description.htm>
Harbatkin, Lisa. “Creating Images.” Wood Digest May 2001: 12-13.
Lowry, Jon. Production Worker for Counter Tops of Amarillo, Inc. Personal interview.
Brothers, TX. 20 Nov., 2003.
Miller, Hannah. “Engineered Wood Adds Value to Store Fixtures.” Wood & Wood
Products Mar. 2001: 102.
Appendix A
Title for Appendix A
Appendix B
Title for Appendix B