We first started off by moving all CNC equipment out of the old CNC room, which was a small room that came right after the making room and main hallway. We then started by extending the main hallway to the old engraving and packaging area. After we laid out the hallway we made plans for a laser engraving room and new tuning room on the north side of the hallway. Across from the new tuning area we built a separate packaging areas where every call would be packaged before taken to the warehouse, while still keeping intact the washing station and break area. Glass windows were put in all walls facing the hallway, so that touring visitors could still be able to watch every step involved in making the calls. A drop in ceiling was added throughout these areas. The hallway extended the wood flooring from the original hall, and all remaining concrete floors were painted to allow for a cleaner look inside work areas.
The new engraving room has really been a nice addition. It has allowed for customers to come up to the sliding glass window and visit with the engraver about any ideas he or she may have about custom engraving. It also allows the customer to be able to view the design and engraving process.
The CNC room was a much needed upgrade. We were getting cramped in our old CNC room and limited to what new equipment we could add. We removed all old shelves and packaging materials out of this room and built a small room to house our table saw with its own dust collection system to help contain the dust from the old making room. New dust collection duct work along with air hoses were ran and dropped at each new machine location. Next the floors were painted and after a week of drying we moved all the CNC equipment in its new home. Now we have a designated CNC area that is neat, organized, and clean, which in turn makes production much more efficient.
Our total production process has also been streamlined by these renovations as well. It is a single flow through process as you progress through the shop. At the back room, raw material is kept and cut, then carried to the CNC room. Next turned parts go to making room were finished, then passed on to the dipping room if wood, if acrylic the dipping room is bypassed and sent straight to the engraver. After the engraver is finished it is sent back to the making room to be polished and painted. The tuning room is the next stop. Following the tuning the calls are packaged in the new packaging room and sent to the warehouse.