Specialist Joiners Mumford & Wood Turn to Homag

Premier timber window and door manufacturer, Mumford & Wood, recently broke with tradition and bought its first machine from Homag UK. The company chose a Homag BOF 311 CNC router as part of an extensive improvement project at its Essex-based factories. The aim of the project was to significantly reduce production costs and lead times to preserve the company's competitive position.

Established in 1954, Mumford & Wood has always produced joinery using traditional craftsmanship with the emphasis on quality and attention to detail. In 2008, Operations Director, Michael Scarfe,led a project team whose goal was to develop a strategy that would enable the business to maintain a long-term competitive pricing structure in a tough economic climate. "Sourcing a reliable, high quality CNC machining centre was a key element in the development of an innovative and sustainable assembly process for the business.

"Although we, as a company, had never bought from Homag before their product range and track record made them a serious contender on our short list of potential suppliers. The machine we were replacing was ten years old and whilst it had served the business well, it was no match for modern equipment in terms of either quality or productivity," explains Scarfe.

The Versatile and Reliable Homag BOF 311 CNC Router

"When it came to a final purchase decision," Scarfe enthuses, "the task was made very easy because of Homag's superb service support. We wanted a reliable, flexible machine that was capable of maintaining consistently high levels of productivity. The Homag BOF 311 was, with a few additional bespoke features, ideal for our needs. We saw the machine both in the UK, at Castle Donington, and in Germany where we specified the tailored options including a 6m long bed with a unique clamping system.

"The woodWOP software that comes free with the machine is fantastic. Its ease of use and functionality have enabled us to be totally self-sufficient in our manufacturing process. Previously we had to send out to get the design programmes converted into machine code; with woodWOP, however, it is a seamless in-house process. The design work is carried out on PCs in the design office and then the programme is converted automatically into machine code to run the machine on tthe factory floor."

Dramatically Reduced Cycle Times

One of the biggest benefits to the business has been the reduced cycle times. "We are seeing very significant reductions in cycle times," continues Scarfe, "thanks in no small part to the BOF 311's 30 station tool changer. Not only are tool changes made in two to three seconds, but also they run in parallel with the machine head, so downtime is minimal.

"The operator's time is also more fully utilised with the Homag machine. He doesn't spend time waiting for the
machine to carry out certain operations; he can get on with other tasks.

"In terms of training, the software training was carried out at Castle Donington prior to the machine being delivered to our Tiptree plant. The operator training took place on-site the first week the machine was up and running. Homag trained our two team leaders who have then been able to train the relevant operators.

"As far as the actual installation of the machine went, that too bore the hallmark of typical German efficiency. We wanted to hit the ground running in the first week of 2009. To achieve this Homag said they would deliver our machine on 15th December and have it operational by the 5th January which, with Christmas and New Year in between, left little room for manoeuvre. Nevertheless, true to their word the machine arrived on the 15th December and they had it ready to go on the 5th January, just as they said."

Rapid Return on Investment

Mumford & Wood claim that they will achieve a return on investment within a short time frame which, given the expected ten year life of the machine, will leave them plenty of ‘free' years machine life. Scarfe again, "Our cost analysis was based on life-time value of the machine rather than initial cost. We have insured the machine with Homag to cover malicious or accidental damage and have taken out a comprehensive service contract. These support packages give us absolute peace of mind and, coupled with the online diagnosis facility and excellent service support, mean downtime is minimal.

"There is no doubt that the Homag CNC centre has enabled us to maintain a very competitive offering in an extremely tough market place. And, because it works just as efficiently for small batches as large runs, the savings are gained across the entire production range.

"The performance of both the machine and of Homag UK has surpassed our expectations and whilst the BOF 311 is the first machine we have bought from Homag, it certainly won't be the last. We couldn't ask for better service from them," concludes Scarfe.