Bailey Complete Folio_Bailey Cox

Working Drawings (Joining Methods)

Coach Screws (back to base)

65mm galvanised coach screws used to join
legs to body of the chair
Coach Screws (legs to main body)

150mm coach screws will be used to join the back
rest to the base of the chair creating a tight bond
between the two, the screws are galvanised steel and

should support the weight

These working drawings has helped us understand the workings behind the chair and how it is going to go tougher

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Working Drawings (3D Model)

These working drawings has helped us understand the workings behind the chair and how it is going to go tougher, as well
as help us gain a visual under standing of the chair and how its going to look

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Production Plan

The production plan consists of all of the steps taken to produce your product including the tools and safety measures to
do so as well as the time taken to compiled each step

Step No. Step Description Safety Measures Tool and Equipment Time Taken

1 Gather Source all Wear PPE and Compound Saw, 1 day
2 Materials timber and obey SOP’s table saw, 60 minutes
3 Cut timber materials when operation pencil, try 60 minutes
4 down to size required machinery square, tape 30 minutes
5 Biscuit measure 10 minutes
Mark out all Wear PPE and Biscuit cutter,
#53 Glue/Clamp cuts and follow SOP’s, biscuits, pencil, 18204962A
Make cut along preforms cuts in keep fingers try square
back end accordance with away for blade
cutting list Clamps, glue,
Mark out cuts Wear PPE, such scrap wood
and use biscuit as mask to
cutter to join reduce intake of Table saw,
timber to form toxic fumes protractor,
the seat Wear PPE, penile, tape
Smear glue Operate under measure
entirely over supervision,
seat pieces and follow SOP’s
tightly clamp

Measure and
cut back edge of
seat on a 15
angle

Production Plan

Step No. Step Description Safety Measures Tool and Equipment Time Taken

6 Drill and mark Using a drill Wear PPE, Drill press, 45 minutes
holes for dowels press, drill holes follow SOP’s, pencil, tape, try
7 into use machinery square, tape 30 minutes
8 Feed dowels components with care and measure 45 minutes
9 through back that will make clean up after. 45 minutes
10 rest up back rest Wear PPE, Wooden Mallet, 30 minutes
Join arm rest Hammer dowels Clamp down Scrap wood,
#54 and legs through the material, be clamps
Join back onto pieces that causes of hands
seat base make up back Wear PPE, Drill, impact
Connect body rest for support follow SOP’s driver, coach
onto arms and Attach legs and screws, drill bit,
legs arms of chair Wear PPE, penile, tape
using coach follow SOP’s Drill, 150mm
screws drill bit, 150mm
Using 150 mm Wear PPE, coach screws,
coach screws, follow SOP’s impact driver
screw back onto driver, coach
the seat base screws, drill bit,
penile, tape
With the use of
coach screws
join the entire
chair tougher

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Production Plan

Step No. Step Description Safety Measures Tool and Equipment Time Taken

11 Sand Using Wear PPE, Sand paper, 90 minutes
12 Finish sandpaper, sand operate in a orbital sander 60 minutes
back material ventilated area Paint brush,
slowing increase Exterior coat of
in git finish

Apply 3 coats Wear PPE such
onto final as a dust mask
product, with to reduce the
sanding in- intake of toxic
between coats fumes

The production plan allows for anybody to be able to recreate my product as each step taken is outlined allowing them to
follow the steps and produce the product as well

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Gannt Chart
The Gannt chart is a type of bar chart that illustrates a projects schedule, and the steps that are required to ensure the
project will be built to a high quality on time, it will also keep us on track, not allowing us to fall behind schedule, as we
know what needs to be completed by when

The Gannt chart has given us a in-depth understanding of all of the required tasks to produce this project and when they
need to be started and completed by, to ensure the product is completed on schedule

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Quality Measures
Quality Measures are actions and precautions taken to ensure the final product is of the highest quality possible, below
are some of the precautions we made to ensure the product is of high quality

Stage/Component Quality Measure Taken

Timber Cutting https://www.azweb.org/professi All timber was measured and marked prior to being cut.
Biscuit Joints onal-timber-cutting And material was cut on trusted and quality machinery
The biscuit machine was first tested on scrap wood to find
the suitable biscuit size and depth of the cut

https://thewoodwhisperer.com/

Gluing A strong reliable brand of Gorilla Glue was speared across
the entire face of the timber on both sides to create a large
https://www.diynetwork.com/ surface area of glue increasing the bond

Clamping Clamps were evenly applied on both sides after the gluing
stage to prevent the timber from bowing. Scrap wood was
https://hammersmith.worldsecuresystems/ also put in-between timber and clamp to deduce damage

Drilling Holes with Drill Press The machinery was first tested with scrap wood, and tape
was placed on the under side to prevent tear out once the
drill hand penetrated the timber

https://themostspruce.com/drill-press

Sanding Sanding will start will a more aggressive grit and continue
to work down to a finer grit, this is done to remove bowing
https://www.manmadediy.com/ in wood and ensure it’s smooth and of high quality

Finishing The finish will be applied after the material has been
sanded and will be applied in a number of thin layers, as
https://www.popularwoodworking.com/ well as sanding in-between coats

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Safe Operation Procedures
Each power tool that will be used in the production stage will be looked at and risk assessment will be preformed to
assess the dangers of using this tool, the Safe Operation procedures will gives us a better understanding on how to safely
operate the tool and machierny
Power Tool Purpose Safe Operation Risk Assessment
Procedures

Hand Drill The hand drill will be PPE including ear
used to drill pilot protection and eye
holes for screws protection will be
when joining the worn when operating
back rest onto the as stated in the SOP
seat base of the chair

Biscuit Joiner The biscuit joiner will When using
be used to join machinery keep
pieces of wood hands clear of
tougher when moving parts and
constructing the seat wear PPE as
base instructed

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Safe Operation Procedures

Power Tool Purpose Safe Operation Risk Assessment
Procedures Wear appropriate
PPE including Eye
Drill Press The drill press will be and ear protection
used to drill holes for and an apron, never
dowel in the back leave the machine
rest of the chair, as running unattended
it’s a accurate piece
of machinery

Orbital Sander The orbital sander Wear PPE including a
will be used in the dust mask to limit
final stages to sand the amount to dust
down the material to that’s inhaled,
create a smooth preform safety
finish and is ready to checks stated in SOP
be stained/varnished

We will refer back to the SOP before operating machinery to ensure that when the machinery is in use everything is done
is the safest manner possible
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Cutting and Pricing
The cutting list gives the end-user and designer a look at all of the material that’s required to construct the product as
well as the lengths that they need to be cut down to, and will serve as a guide when in the building stage and material
needs to be cut to length it will be clear as to what needs to cut down and the size of the cut

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Risk Matrix

The risk matrix is used to asses the risk of each tool and procedure, first the likelihood of something going wrong with the
tool or machinery is rated on a scale of one to five, then the potential consequence is rated on a scale of one to five.
These are then compared to understand the risk associated with using each tool

The risk matrix is going to help rate and evaluate the likely hood of the risk occurring and the potential hazard if the risk is
to occur. It’s a quick and easy way to grasp the risk of the situation weather it be a tool or procedure

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DATTA Victoria

Design and Technology Teachers Association (DATTA) with the help of the risk matrix has rated the risk of using a variety of
tools subdivided into category's, to help us understand the dangers and risk of using the tool

The tools matrix complied by DATTA Victoria allows us to look at a wide range of tools and understand the risk associated
with them, and if they can use them
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Tools Risks

All the tools and procedures that will be used in the construction of the final project have been listed below and we have
rated the likelihood of something going wrong and the consequences if it does in accordance with DATTA Victoria

This has given us an understand of the risk associated with each tool and process and the injury or harm they can cause,
as well as appropriate safety precautions to take to reduces these hazards. The SOP’s for each tool can be seen in the

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Area of Risk

Below are all the types of tools that will be used (hand, portable, fixed) in the construction stage of the product, as well as
the pre-existing control measures that will be used to ensure everything is conducted in a safe manner and reduces our
change of getting harmed using them

In this step we have looked at the types of tools we are going to use and the potential dangers that surround them, as
well as identify the control measures that are in place to limit risk

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- Material Testing #66-67
- Process and Machinery Testing #68
- Chosen Materials and Processes #69-70
- Manufacturing in the Industry #71-72

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Material Testing

In order to produce a product that lives up to the end-users expectations, the product needs to be made from high quality
materials to ensure it can hold the required weight and withstand various weather conditions. Material Tests will be
preformed to ensure the material chosen can live up to these expectations

Aim

The aim of these material test undertaken is to determine which of the chosen timbers is the most capable of holding
large amounts of weight with out bending or snapping, demonstrating its strength

Materials

The materials chosen where MDF, Merbau, Victorian Ash and Pine. These woods where chosen as they were all potential
timbers that could be used in the product as they match the end-users given environment. Further materials were need to

conduct the test, these materials included set squares, clamps, drill, weights, ruler, masking tape.

Method

A piece of each type of timber 800mm long and all 2mm tall and 50mm wide were clamped off the surface, and weights
were slowly applied to each type of timber with recordings at each new weight. The amount the timber was bending was

recorded

Results

The results show that Merbau was the strongest wood followed by Vic Ash and Pine with MDF being the weakest of the
woods tested. MDF was likely the weakest as it’s a engineered wood made up from softwood and hardwood fibres. Pine is
one of the weaker woods as it’s a soft wood and Merbau and Vic ash are both hardwoods which us likely why is so strong

Risk Management

PPE such as protective glasses were worn when the testing was done to ensure the safety of the observers, participants
also stood back from the testing to avoid falling weights or wood

#66 Results and Graph can been seen on next page 18204962A

Material Testing

Timber MDF Merbau Ash Pine 500 Materials Test (g)
Weight (g) 450
40 30 40 400 250 450 650 850 1050 1250 1650 2050 2500
0 65 60 55 75 350 MDF Merbau Ash Pine
250 120 100 75 120 300
450 180 130 115 150 250 18204962A
650 220 160 145 170 200
850 265 180 175 200 150
1050 290 200 205 220 100
1250 335 220 225 260
1650 390 240 285 280 50
2050 410 260 305 330 0
2500 430 0

The testing has assured us of the strength of
the woods tested and give us the confidence

that they can be used to construct the
required product with out compromising the

strength aspect

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Process and Material Testing
Here will list the tool and machinery we will use and well as there suitability and test we will conduct to ensure that that
machinery is working at its best, and how we are going to best manage that risk

Tool/Process Suitability Test Risk Management

Biscuit Joiner The biscuit joiner is a Scrap timber will first be PPE will be worn, Hands
Drill Press suitable tool to join the seat used to ensure the joiner is away from blade, follow
Sander base tougher working properly, and cut SOP’s
Clamps The drill press is the most are made in the right spot Follow SOP’s, check
accurate drill that’s capable First scrap bits of timber will machinery, wear PPE, clean
Panel Saw of drilling the required holes be drilled into to ensure work station
everything is well

The sander is the most The sander will be checked Wear PPE including dust
suitable tool to sand back to ensure sandpaper is mask, obey SOP’s,
material leaving a smooth properly attached Wear PPE, Keep hands clear
finish of clamping end
Wear PPE, follow SOP’s,
Clamps are the most suitable Scrap bits of wood will be restricted to teachers only
tool used to apply pressure put in-between the clamp use
to timber pulling them and timber to ensure the
tougher clamps don’t damage the
final product

The panel saw is the most The blade will be checked to
accurate way to make a long ensure it set at the right
precise cut angle and test cuts will be
made first

After this step we know the reasoning for the use of each tool and how we can best ensure that each tool is working to its
best, and what we have done to ensure its working at its best for both the quality of the product and our safety

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Justification of Material and Processes
Here will list all of the materials and processes we have chosen to use as well as explain why we have elected to go with
those materials and processes

Material/Process/Machinery Justification

Messmate Recycled Messmate was chosen to be used as the main timber
as sustainability was a factor the end-user wanted to
https://www.timberrevival.com.au/portfolio/feature-grade-messmate/ incorporate. Messmate is also a strong hardwood that can be
used in outdoor spaces as well as affordable that’s why it will
Tasmanian Oak be used
Tasmanian oak was the selected wood to be used in the dowel
https://trademaster.com.au/product/tasmanian-oak-std-mdf/ running along the back, the oak was chosen as it’s a strong
wood suitable outdoor, and its appearance complements the
Biscuit Joiner existing environment as well as serve as a contracting colour to
the messmate
https://www.bbta.com.au/dewalt-heavy-duty-biscuit-joiner-dw682k-xe/ The biscuit joiner will be used as it to join the seat base tougher
as its capable of creating a super strong bond between the
Clamps/Glue pieces of wood, the joiner also makes a quality cut as seen in
the test cut
https://www.capitalequipment.net.au/ The clamps will be used to apply large amounts of pressure to
hold the wood in place when using machinery or gluing
Drill Press The drill press will be used to drill holes for dowels in the back
rest section of the timber. The drill press will be used as its
https://www.tradetools.com/product-range/machinery- shown to be a super reliable and accurate drill in the given tests
An orbital sander will be used in order to sand down material
Sanding preparing for it to be finished. The orbital sander preformed
well in the tests and was able to smooth down the material
Panel Saw https://narangbatimbers.com.au/ The Panel saw will be used to cut timber down to size for the
#69 https://www.machines4u.com.au/view/advert/P product, the panel saw has shown to deliver an accurate cut
and there for will be used

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Justification of Material and Processes Justification

Material/Process/Machinery Coach screws will be used to adjoin the product as they are
capable of holding large amounts of weight due to them being
Coach Screws made from galvanised steel

https://www.allfasteners.com.au/coach-screw-galvanised-mild-steel-hex-head The dowel joint will be used to support the individual back
pieces holding them tougher, as well as providing a visual
Dowel Joint appeal to the chair with its contrasting colours

Finishing The product will be finished to provide that look the end-user is
going for as well as to protect the product from the weater
https://www.diynetwork.com/how-to/make-and-decorate/decorating/wood-
finishes-101

In this step we have identified why we are using the materials we have chosen and why we have chosen to use certain
processes through the production of the product

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Manufacturing in the Industry

Small changers can be made to my product in order for it to be produced on a small scale and then go on to be sold to a
wider customer base, although it will struggle to be mass produced as it requires complicated joining methods, that
machinery and average people might struggle with.

Step 1

The product can first be draw up in a CAD program to ensure its
of high quality, easily understood by a range of workers and
produced on a small scale

https://dedesigned.com/why-i-switched-to-fusion-360/

Step 2

The designs will need to be sent off to a factory or shop with
the capable machinery to produce it

https://www.pinterest.com.au/pin/450993350174362307/ 18204962A

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Manufacturing in the Industry

Step 3

Majority of the production can be done in a factor, this includes
cutting the wood down to size, the biscuit cut as well as the
dowel joint in the back, sanding and finishing. Most of these
procedures can be automated as well

https://www.huihefurniture.com/about.html

Step 4

The product can then be sent of in a flat pack like model to
the customer, this will reduce the carbon footprint, as well as

allow for cheaper transport cost

Step 5

The customer can then go about joining the final product
with coach screws provided, pilot holes will be predrilled for

customer ease

Although my product might not be able to be mass proceed, it might be able to be produced on a small scale or limited
run

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