MASTERWOOD PROVES PERFECT FOR ALL SEASONS

Switching from traditional manufacturing methods to a Masterwood CNC machining centre is bringing huge benefits to All Seasons, a small joinery business in Sheerness, Kent.

The family-owned and run firm, with a staff of seven, concentrates on making bespoke conservatories, external doors and windows for domestic customers and building contractors.

Owner Daryl Yates's story is a familiar one to hard-pressed owner-managers of small and medium sized joinery businesses.

“Until I bought the Masterwood we were often working seven days a week, up to 16 hours a day, to get the work out on time. As it produces as much as three people working traditionally, it has made my life so much easier. I can now produce in a day what previously took three days.”

Daryl Yates (left) and Masterwood area manager Dave Kennard with the Project 415 at All Seasons.

He has been able to cut out almost all of the overtime that was worked, which will transform the business's profitability.

The Masterwood Project 415 features a C axis, a 12 tool carousel, plus an additional two tool box at other end, together with a drilling head, pneumatic clamps and standard vacuum pods. It has a 14Kw motor for the large diameter tooling, up to 220mm in diameter, which is used for long tenons on windows and doors.

The suite of easy-to-use software supplied with the machine is Masterwood's own Masterworks, MasterWindow and Master Traditional Door.

A window produced by All Seasons on the Masterwood Project 415.

Said Daryl: “It's a very versatile machine and I use it to produce all of our hardwood doors and windows, including those needed for conservatories. It's early days yet but I also intend to make the conservatory roofs with it.”

By using the MasterWindow specialist software he designs casement and storm proof type windows in various styles and dimensions, including gable versions.

“The software takes all the worry out of the job. It cuts down on mistakes, even giving me a cutting list and the required glass sizes.”

It's just as efficient on door production. Where it used to take half an hour to make a door stile with traditional tools, the CNC can produce two in around 10-12 minutes.

Said Daryl; “It took one man around three hours to make a complete door by hand and with the Masterwood this has been reduced to 30-40 minutes, including cutting out all the holes for the hinges and locks. We have also used it to make a rebate in a 2.8m length of timber measuring 200mm x 70mm, something we would have struggled to do on a spindle.”

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Daryl Yates shows off the Masterwood Project 415 to two visitors.

As well as processing joinery components the Project had proved ideal for panel work, including making fielded panels for doors.

Using the software's CAD/CAM facilities Daryl does all the design work on a PC in his office, saving the machining programs on a USB stick which he puts into the machine.

“It's far more accurate than doing things by hand and I am not reliant any more on recruiting highly skilled and expensive staff. Because it's so versatile I can start the day by putting doors through it, then windows, then switch back to doors if necessary. And while it's doing all the processing, I am free to do other work.”

Its purchase resulted from an initial cold call to the company last year by Masterwood's area manager, Dave Kennard.

Said Daryl: “Out of interest I asked him for the rough cost of a machine and when I found out my face hit the floor. But after reading the literature I decided to take a closer look.”

He went out to the Masterwood factory in Italy where he saw machines in action and came away extremely impressed.

“I talked to existing Masterwood users in the group and when I got back home I went to see one at a local company and spoke to the owner. As a result of all the excellent feedback I received I was happy to place the order.”

What impressed him more than anything else about Masterwood was the fact that it could provide the total package of machine plus specialist software.

“I was very green when it came to CNC operation. A few months ago I would not have even known how to turn on a computer. I needed to know that I would be looked after if anything went wrong..

“The machine has helped increase production substantially in the few months we have had it, which will result in increased profits once I have gone through the initial learning curve. I can also now take on work I would not have attempted before, like producing fire doors with apertures in them.”

The Masterwood's purchase has not led to a reduction in staffing levels as the former machinists are now out on site doing installation work.

“Basically, it has given me more time to think about the business and where it's going in the future, something I could not do before as I was always working flat out,” said Daryl.

“We are now all working at a much easier pace, which is better for everyone as we do have lives away from the job."


All enquiries to Masterwood (UK) Ltd, Telephone 01436 675000, Fax 01436 678999, Email masterwooduk@aol.com.

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