MANUFACTURING SYSTEM

FIELD

The present invention relates to a system for manufacturing, and in particular for manufacturing of cabinetry and furniture.

BACKGROUND

Existing systems for furniture and cabinetry manufacture, including those with Computer Numerical Control (CNC) cutting and boring machines, require control by a highly-skilled user. For example, controlling a mechanical saw or a CNC machine directly requires experience with joinery and a developed understanding of the specific machine's controls. Other systems allow for CNC machine control via command computer-aided design (CAD) packages, which generate data that can be interpreted to provide commands for the CNC machine; however, generating an appropriate CAD drawing also requires a considerable period of time and a high level of skill, and therefore training. If a new design is an adaptation of an existing design, it may be very time-consuming and costly to create the new CAD drawings, even when the changes are minor. If a number of furniture designs are related but slightly different (e.g. cabinets with intentionally non-matching shelf heights), the differences may be very difficult to observe in CAD drawings.

If a client wishes to order a manufactured item, such as a cabinet, existing manufacturing systems require a manual ordering process, which is time consuming and prone to errors. This is followed by re-processing of the order to produce a design that can be manufactured. This re-processing requires skilled staff and is also prone to errors.

CAD tools may also generate slightly inaccurate manufacturing data from drawings of single or multiple items in projects of various sizes, e.g. drill holes may be located incorrectly in drawings of an entire kitchen, or incorrect colours may be applied to surfaces.

It is desired to address the above, or at least provide a useful alternative to existing manufacturing systems.

SUMMARY

In accordance with the present invention there is provided a manufacturing system for controlling manufacture of a project on at least one machine, including: a user module for generating design data for the project based on a user's selection of one or more design options, represented by design options data, of a design template for at least one product in the project; and a translator module for generating machining data for said at least one machine to shape at least one component of the at least one product based on the design data.

The present invention also provides manufacturing system, including: a customer module accessible remotely for use in selecting a furniture or cabinetry product, selecting parameters, from a predetermined set of parameters, and values for the selected parameters to define the selected product, and submitting design data representing the selected parameters and values for the product; and a translation system for processing the design data and generating manufacturing commands for at least one machine to automatically produce components for said product.

The present invention also provides a manufacturing process for controlling manufacture of a project on at least one machine, including: generating design data for the project based on a user's selection of one or more design options, represented by design options data, of a design template for at least one product in the project; and generating machining data for said at least one machine to shape at least one component of the at least one product based on the design data.

The present invention also provides a manufacturing process, including:

receiving a selection of a furniture or cabinetry product, parameters, from a predetermined set of parameters, and values for the selected parameters to define the selected product; and generating design data representing the selected parameters and values for the product to enable manufacturing commands to be generated, based on the design data, for at least one machine to produce components for said product.

DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are further described, by way of example only, with reference to the accompanying drawings, wherein:

Figure 1 is a schematic diagram of hardware of a preferred embodiment of a manufacturing system;

Figure 2 is a block diagram of functional modules of the manufacturing system; Figure 3 is a screen shot of a user interface generated by the manufacturing system;

Figure 4 is a flow chart of a production process performed by a production system of the manufacturing system;

Figure 5 is a flow chart of an ordering process in the production process;

Figure 6 is a flow chart of a translation process in the production process; Figure 7 is a flow chart of a scheduling process in the production process; and

Figure 8 is a flow chart of a manufacturing process in the production process.

DETAILED DESCRIPTION

A manufacturing system 100, as shown in Figure 1, includes a production system 102, which generates manufacturing commands to a factory 104 based on design options selected by a user of a user system 106. The manufacturing system 100 allows a customer to selectively design specific items and have the items produced by the factory 104, such as furniture or cabinetry products, without any drawings of the products or components being produced. The manufacturing system 100 is able to handle a number of projects (or jobs), such as a whole kitchen fit-out, or a single machined item. A project includes one or

more products (e.g. cabinets, cupboards, glass-frame doors, coffins etc), and each product includes one or more components (e.g. cut wooden/acrylic/glass/stone panels, moulded acrylics, shaped metal, hinges, handles etc.).

The production system 102 includes a front end server 108 for providing rapid high- capacity access to a master server 110 and one or more slave servers 112 which generate a Web-accessible application for the user system 106 via the Internet 114. The front end server 108 is a Squid server which acts as a reverse proxy to accelerate access to the master server 110. The slave servers 112 provide high-capacity access to the master server 110 and high fault tolerance. The master server 110 provides the Web application using data in a database server 116. The servers may be SME servers based on Linux with database management provided by PostgreSQL and dynamic web access provided by stored computer code written using a language such as PHP (URL: http://php.net/). The production system 102 is connected to the Internet 114 via an intranet 118 and a router 120 which includes a firewall.

The production system 102 is administered by an administrative system 122 through which an administrator can monitor and adapt the production system 102 as required. Also connected to the intranet 118 are a test system 124 and a development system 126. The test system 124 provides an environment which is as close as possible to that of the environment of the production system 102; and the test system 124 is used by the administrator to test configurations of the production system 102. The development system 126 provides an environment which is largely similar to the environment of the production system 102, except that the administrator may use the development system 126 to adapt and test configurations without altering the ongoing external environment provided to the user system 106. The development system 126 incorporates version control to allow for comparison of functionality between different versions of the environment in the development system 126, and the possibility of roll-back to a previous version.

Disaster recovery is provided for by a disaster recovery system 128 connected to the router 120 via the Internet 114. The disaster recovery system 128 is preferably at a site distant from that of the production system 102, and may therefore be used to recover data and system parameters if the site of the production system 102 is damaged. The production system 102 also includes a local non-live mirror (not shown) which is a mirror of the configuration of the master server 110 and is used for disaster recovery on a local scale.

The production system 102 integrates selection of design options by the user, automated manufacturing in the factory 104, and automated ordering of supplies from a supplier system 130. Ordering supplies and shipping completed furniture may also require the services of one or more transporters which use at least one transporter system 132 to exchange shipping/transport data with the production system 102.

The Internet connections are in the form of secure tunnels, e.g. SSL or SSH, providing secure encrypted communication between the systems.

The user system 106 is a personal computer of a user having an Internet connection, and/or one or more Internet-enabled computing devices (e.g. a laptop, a PDA, and/or a mobile phone).

The factory system 104 includes manufacturing, labelling, handling and tracking systems to produce cabinetry, furniture etc. in accordance with the furniture manufacturing commands generated by the production system 102. A typical factory 104 includes one or more of the following machines: a cutting machine, a boring machine, an edging machine, a painting system, a drying system and/or a routing machine. These machines may be for example Computer Numerical Control (CNC) machines produced by Altendorf (URL: http://www.altendorf.de/ ) or Biesse (URL: http://www.biesse.it/ ). The factory 104 also includes units for handling the materials which are to be machined, including a hardware picking system, a hardware packaging system, a loading/unloading robot, an automated

handling device, a transport loading system, a dispatch holding system, a dispatch releasing system, and a wrapping system. For tracking purposes, the factory 104 includes a label printer for printing labels for the components of each project (or 'job') being manufactured (e.g. barcodes or serial numbers printed onto cut panels, or onto stickers/labels for other components). The factory 104 includes a scheduling and tracking system for displaying a schedule for each project and tracking the progress of each project through the factory (e.g. once a project or component is completed, it is marked off the list of items to complete). The factory 104 includes a quality assurance PC (personal computer) and remake software for initiating machining and repairing of damaged or missing components on the factory 104 floor (e.g. if a panel is damaged during manufacture, the remake system allows an operator in the factory to generate a fresh copy of the component). The capabilities of the factory 104 may be located in one physical location, or distributed across a plurality of locations, e.g. to provide flexibility and/or a greater scale of production. Production of the furniture project at a site remote from the production system 102 may provide for reduced costs for supply of materials, shipping of finished products, and/or labour. Furthermore, large projects or jobs may be distributed among a number of factory sites, e.g. a plurality of factories 104.

The user interacts with the production system 102 via a client 202 in the form of a Web client (e.g. a Web browser) in the user system 106 and an interface module 204 in the form of a web application (e.g. stored computer code written in PHP) in the production system

102 (Figure 2). The interface module 204 includes a user module 206 configured to communicate with the client 202. The interface module 204 also includes a supply module

208 and a transport module 210 to interface with the supply system 130 and the transporter system 132 respectively. The user module 206 provides user interface data to the client

202 which displays a user interface, for example as shown in the screenshot of Figure 3.

The interface module 204 and other modules 250, 252, 254 and 256 are coordinated and controlled by a system controller 212 of the production system 102 (e.g. a main procedure). The system controller 212 provides access to a data store 214 (e.g. one or

more databases). The data store 214 has user contact data 216 relating to the user. The user data 216 may include names, contact details, billing details, authentication data, saved projects, delivery information, quoting margin, payment information and user specific notes (e.g. existing product templates related to the particular user, i.e. customer). The data store 214 also includes similar information for suppliers, in the form of supplier contact data 218, and for transporters in the form of transporter contact data 220. The user contact data 216, the suppler contact data 218 and the transporter contact data 220 allows these parties to access at least part of the production system 102 via the interface module 204, to receive relevant data (e.g. orders, bills, etc.) from project orders, bills, and transmit relevant data (e.g. material availability, etc.) to the production system 102.

The interface module 204 enables the user to select and configure a project to be manufactured by selecting available design options in design options data 222 in the data store 214 of the production system 102. The design options are provided to the interface module 204 via the system controller 212.

The design options are parameters and values selected to specify a design. For example, Table 1 shows a list of design options (by title) representing parameters relating to cabinet manufacture, and a list of corresponding values for the parameters (e.g. 'yes ¹ , 'no', '2mm', etc.).

The design options data 222 include design options titles data 224 with user-readable titles for each design option (e.g. as in Table 1), material used data 226 relating to the materials required for each design option, and machine commands data 228 relating to machine- specific control commands (for machines in the factory 104) corresponding to the design options.

The data store 214 also includes material availability data 230 relating to the availability (e.g. current raw panels available in the factory 104, or availability and lead-time of materials from a supplier), and material cost (e.g. cost per square metre of a given sheet of material, or cost per unit of a hinge). The material availability data 230 is used by the system controller 212 to generate a cost for the components of each project selected by the user (e.g. 'cost per item' 304 in Figure 3). The material availability data 230 is updated during tracking and purchasing processes as described below.

The data store 214 also includes project data 232 which indicates the details selected by the user for each project. Project data 232 may describe the selected design options relating to a particular project, e.g. each component of the project can be a particular panel, or item of hardware such as a hinge or a handle. A project (e.g. a kitchen fitout) typically includes a plurality of products (e.g. cabinets), each of which are made of components (e.g. panels and hardware). The project data 232 is stored in the data store 214 for each user, and allows the user to re-use old projects, to adapt old projects without having to re-specify all relevant design options and to save and transfer the project data 232 to other users. The project data 214 may also include pre-defined components or products defined by the administrator, forming a library of products for users to select and configure (e.g. the 'base standard height cabinet ¹ ). This library of products enables users to adapt the design options with ease and rapidity, at least for common projects (e.g. shelves or two-door cabinets).

The project data 232 for each project includes design data 234 which represents the design options selected for this particular project by the user, and delivery data 236 which

represents delivery requests and specifications selected by the user relating to this particular project (e.g. an urgency level reflecting the urgency of elements of the project). The project data 232 also includes machining data 238 representing machine commands which enable machines (in the factory 104) to manufacture the products in this particular project. Project data 232 also has hardware list data 240 representing a list of hardware components required for the project (e.g. hinges, handles etc.). The project data 232 may include optimised machining data 242 representing optimised machining patterns for machines to efficiently cut components (e.g. panels) from the raw materials (e.g. sheets of material) with minimum waste. The machining data 238, the hardware list data 240 and the optimised machining data 242 is generated by the production system 102 from the design data 234 of each project. The project data 232 further includes priority rank data 244 representing the current rank of the components in this project in the work flows of the factory 104. The priority rank data 244 for each project is generated in accordance with a user-specified urgency level for the project and the schedule of other jobs and availability of each factory 104. The project data 232 also includes supply- transport data 246 representing selected suppliers and transporters for the materials and finished products in the project. The suppliers may be selected in accordance with the material availability data 230 by the system controller 212, and/or by the user when specifying the design options. The project data 232 also includes tracking data 248 representing an up-to-date status of the project, including the location(s) of the component(s), the estimated time to completion, and/or the estimated time of delivery. Tracking data 248 is generated in accordance with a tracking and scheduling module 250 of the production system 102 and may be viewed by the user to determine the status of their project (e.g. over the Internet).

The production system 102 includes a translator module 252 which translates the design data 234 for each project into the machining data 238. The translator module 252 carries out a translation process 404, described below, using the machine commands data 228 for each design option.

An optimisation module 254 optimises the use of raw materials by optimally spacing the

various cuts that need to be made for each component to be cut: e.g. each panel of a selected material, across all products in the project, will be cut at the same time, laid out in a pattern on the raw sheet of material such that there is minimal waste of the material. An example panel optimisation module 230 is the cutting optimisation software provided by ARDIS Information Systems NV (URL: http://www.ardis.be ).

The production system 102 includes a drawing module 256 for generating graphical representations of each project, relying on the design data 234 and/or design options data 222, as it is selected by the user during a design process. The graphical representation of a project, and/or of each product, may be displayed in the user interface (e.g. 'product picture' 302 in Figure 3), or displayed to the administrator, and/or the supplier to visualise each project/product, which assists with the manufacturing process. The production system 102 can, on request from the user system, generate graphical representation input data for a user's visualisation system (not shown), e.g. a third-party CAD package, which will allow a user to generate detailed visual representations that display all the design options selected for a given product (e.g. cabinet) or for an entire project (e.g. a kitchen).

Administration of the production system 102 is provided to the administrator via an administrator module 258 in the administrative system 122. The administrator module 258 is in communication with the system controller 210 of the production system 102.

The modules 204, 250, 252, 254 and 256 and the system controller 212 of the production system 102 are preferably implemented by computer program code (written in a language such as PHP, Ruby or Microsoft .Net) stored in computer readable storage memory of the production system 102 or the database server 116. Alternatively, to enhance the speed of processing, the modules can at least in part be implemented using dedicated hardware circuits, such as ASICs of FPGAs. The same applies for the administrator module 258 with respect to the administrative system 122 and a machine controller 260 with respect to the factory 104. The data store 214 is provided by the database server 116 with the data of

the data store 214 being stored on computer readable storage memory of the data server 116.

The production system 102 communicates (e.g. via the Internet 114) with at least one machine controller 260 of a manufacturing machine 262 in the factory 104. The machine controller 260 controls its corresponding machine 262 (e.g. a CNC routing machine) and provides information to an operator via a machine display. The machine controller 260 receives the machining data 238 of each project from the production system 102 and generates corresponding commands for the machine 240. The machining data 238 utilises OEM commands 264, which are commands for the specific machine 262 provided by its manufacturer, and custom commands 266 which are commands for the specific machine 262 custom-generated by the administrator in accordance with the available design options 206. An OEM command 246 includes those commands which are part of a standard machine, e.g. how to perform drill or routing actions. A custom program 248 may be routines or programs developed for performing actions, or series of actions, to fulfil the available design options.

The design options data 222, including the material used data 226 and the machine commands data 228, provides a link between the design options selected by the user (e.g. "a microwave panel") and the selected parts of the machine commands data 228 which are used to generate the machining data 238 for each project. The machine commands data 228 includes references to machine sub-routines which must be defined for each machine 262 in the form of the custom commands 266. For example, a machine sub-routine called "BSEND L" may refer to one of the custom commands 266 which controls the machine 262 to machine a base standard end on the left side of a panel. The machine commands data 228 also include the values for each design option, including particularly the sizes and lengths of each component.

The available design options include options with a one-to-one correspondence to the

machine commands, which include the OEM commands 264 and the custom commands 266 associated with each machine controller 260. The design options and the machine commands are maintained in a data structure having this one-to-one correspondence in the data store 214.

The production system 102 performs a production process 400 (Figure 4), commencing with an ordering process (step 402) in which the user, using the client 202, views available design options (from the design options data 222) and selects design options and delivery options to create one or more projects (thereby generating project data 232 in the form of design data 234 and delivery data 236). Once the order is finalised, the production system 102 performs a translation process 404, using the design data 234 to generate the machining data 238 and the hardware list data 240 that will be used in the manufacture of this project's components. The production system 102 also performs a scheduling process 406 which generates purchase orders for any required materials, and generates the priority rank for the project (in priority rank data 244). The production system 102 performs a manufacturing process 408 when this project has the highest priority rank on the relevant machines in the factory 104 that are able to produce the project's components. At the end of the manufacturing process 408, the components and products in the project (i.e. the job) are shipped to the user's selected delivery address. The production system 102 also performs a tracking process 410 from when the project is ordered (in the ordering process 402) until the project is completed (in the manufacturing process 408). The tracking process updates the tracking data 248 to indicate the current status of the project (e.g. "scheduled for delivery in four weeks", "in factory", or "shipping").

At least some elements of the tracking status of the project (e.g. estimated arrival times) are accessible to the user via the interface module 204 (e.g. over the Internet). The tracking process may generate an initial estimated finishing date when the project order is first generated, and then a more accurate delivery date when the order is nearing completion (e.g. after manufacture of all components). The tracking status is also accessible by the transporter system 132 (via transport module 210) to allow transport to

be pre-booked at the estimated delivery date, and confirmed when the order is nearing completion.

Tracking of completed products can be improved by printing identifying data (e.g. a barcode, or serial number) on the product (e.g. onto a cut cabinet door). Printing may be performed directly onto the product, activated depending on material/colour of the board, or onto an adhesive sticker that is attached to the product. A printing unit is fitted onto the machine 262 and controlled by the machine controller 260.

In the ordering process 402 (Figure 5), a connection is established between the client 202 and the production system 102 (e.g. an encrypted Internet session) and the production system 102 requests credentials of the user (e.g. user name and password) and determines whether these are existing user credentials in the user contact data 216 (step 502). If the user credentials do not exist, a new user account is generated (step 504). New account creation (step 504) may require approval from the administrator (for full account access) or may be at least partially automated (for limited account access, e.g. only to view designs, or access simplified design templates). Once the user credentials exist, and the user is logged in, the production system 102 transmits relevant current user contact data 216, and identifying details of any project data 232 for the user, to the client 202 for display to the user. The production system 102 allows the user to view, change and update the user contact data 216 and the project data 232, including user details, reports of user and project details, and project tracking details (step 506). The user contact data 216, the design options data 222 and any project data 232, are presented to the user in the form of a user interface by the interface module 204.

The user interface, an example screenshot of which is shown in Figure 3, allows the user to provide the production system 102 with their order details, billing details, delivery details, selected profit margin, project (i.e. 'job') details, currently available raw materials and hardware, expected lead-times for delivery of additional raw materials and hardware, etc.

The user interface is populated with data from the data store 214, including available design options, user contact data 216 corresponding to the logged-in user, and project data 232 of relevant projects (e.g. past saved projects, or available pre-prepared templates). The production system 102 allows the user to select design options for a new project (step 508), which may include adaptation of a previously saved project (either for the same user or saved by a different user), a previously saved project template (which allows further selection of details), or any saved project and/or product in the data store 208 with access permissions set for the user. Some saved template projects may allow only limited adaptation, e.g. for ordering by an unskilled user (e.g. a home owner wanting a standard corner cabinet need only select external colour, external dimensions and number of shelves), while others allow a broader adaptation (e.g. a skilled tradesman installed a custom-designed kitchen). Generally, the user may select design options relating to the physical design of cabinets. For example, for the product shown in Figure 3, the user has selected a design option entitled "Base Cabinet Standard Height" from the category of "Base" products. The user has also selected design options corresponding to this particular product, including the external materials, the internal materials, the cabinet size, the number of cabinets, and specific arrangements for this product (e.g. hinge side and shelving type). During selection of the design and delivery options, the production system 102 allows the user to delete projects/products, to print projects/products and to save projects/products for future use. The user may also select design options relating to the urgency of each project/product, stored in the delivery data 236 for the project.

Having received the selected project options from the client 202, the production system 102 generates pricing, availability and prioritisation data for the selected design options, and transmits the pricing and availability data to the client 202 (step 510). The user interface displays the pricing (or quote) data (e.g. 'cost per item' 304 and 'total order price' 306), a representation of the project or product (e.g. 'product picture' 302) and/or the expected lead time for delivery of this product (e.g. dependent on availability of raw materials and factory availability). The pricing data is generated by the production system 102 using the material availability data 230. Once the user is satisfied with the order, the production system 102 receives order confirmation data from the user (step 512) and

generates the design data 234 and the delivery data 236 for the project (step 514).

Following establishment of the project data 232 for a new project, the production system 102 generates the machining data 238 from the design data 234 of each project in the translation process 404 (Figure 6) performed by the translator module 252 and the panel optimisation module 254. In the translation process 404, the translator module 252 first receives the project design data 234 from the data store 214 via the system controller 212 (step 602). The translator module 252 then separates the project's design into individual products (step 604). Then, for each product in the project, the translator module 252 iteratively generates the corresponding machining data 238 and hardware list data 240 for each component using the design data 234 and the machine commands data 228 for each selected design option (step 606). Each design option is represented by one or more parameters, each having a value selected by the user (e.g. as shown in Table 1). The translator module 252 accesses a database (in the design options data 222) which has an array of machine commands for each of the available design options; these machine commands include calls to machine subroutines for a machine in the factory 104, pre-set values to be send for carrying out the subroutines (i.e. standard numbers/values for a selected parameter, e.g. the value of edging depth is dependant on the type of product selected and is not independently selected in the ordering process 404), and methods/equations for generating values for the subroutines based on values in the design data 234. For example, a certain product may be defined by a collection of parameters, e.g. the cabinet type = 'Base Cabinet', the client = 1 (each registered client has a different default set of parameters and values for their base cabinet), and values, e.g. height, width, depth etc. The translator module 252 searches for a match in the database for this collection of parameters using an SQL query (or similar). A matching record for this collection of parameters contains the relevant machine subroutines, pre-set values and equations/relations. The translator module 252 then generates machine parameter values for the machining data 238, using the design values, in accordance with the equations/relations in the matching record retrieved from the database. The translator module 252 formats the matching retrieved data of machine subroutines calls and generated machine values into a file or data structure for eventual transmission to the

optimisation module 254; an example of such an output file is shown in Appendix A.

Following generation of the machining data 238, repeated for each product in the project, the raw machining data 238 is transmitted to the panel optimisation module 254 which performs a cutting optimisation process (step 608) to optimise the cutting layout of all products in the project and generate optimised machining data 242. The panel optimisation module 254 sends the optimised machining data 242 to the data store 214 (step 610). An example print-out of optimised machining data 242 as generated by a panel optimisation module 254 (in this case the ARDIS Cutting Optimiser program) is shown in Appendix B. In certain circumstances, such as when the design includes only whole boards of material (e.g. an uncut granite bench top), the machining data 238 can applied directly to the manufacturing process 408 without optimisation by the optimisation module 254.

Scheduling and prioritisation of the projects (and in some cases products) represented in the project data 232 is performed in a scheduling process 406 (Figure 7) performed by the scheduling and tracking module 250. The scheduling process 406 commences with the scheduling and tracking module 250 receiving updated project status data (step 702) from the system controller 212 indicative of the delivery data 236 (including e.g. user urgency) a new project in the project data 232 or updated tracking information e.g. generated by completion of production in the factory 104, or delays in availability of materials (e.g. generated by the supply module 208 or transport module 210). When the project status is updated, the scheduling and tracking module 250 retrieves available project data 232 including the delivery data 236, tracking data 248 detailing the current status of all of the products in the project, and material availability data 230 (step 704). If the materials data is current (i.e. if all raw materials are available in the factory 104, or at least that definite delivery times are available for the relevant materials in the material availability data 230), determined at step 706, the scheduling and tracking module 250 generates priority rank data 244 for the project, and sends it to the data store 214 where it is associated with project data 232 of the relevant project (step 708). If the material availability data 230 is

not current (as determined at step 706) the scheduling and tracking module 250, in communication with the supplier module 208 (and using the supplier contact data 218) generates a purchase order for the relevant materials, including material parameter files in the materials data 216 (e.g. part and serial numbers for the materials required, e.g. handles, hinges, fittings, sheets of wood/board, etc.) in step 710. Following generation of the purchase order, the purchase order is sent to the supplier system 130, via the supply module 208 (step 712) and in return availability data is received from the supply system 130 (step 714) which enables the scheduling and tracking module 232 to update the materials data 216 to indicate at least the expected lead time for the relevant materials, and therefore proceed to generation of the priority rank data 244 in step 708.

The priority rank data 244 (generated in step 708) takes into account at least one of the following priority factors associated with each project/product:

(i) a due date of the project/product (represented in the delivery data 236); the number of raw sheets of material required in the project (extracted from the design data 234);

(ii) the number of processes required to generate each product, defined according to a number associated with each product in the design data 234 and corresponding to the selected design option for each product (e.g. flat bed = 3 processes, edging = 1.5 processes, hardware = 0.5 processes, poly paint = 3 processes, veneer paint = 2.4 processes, sanding = 3 processes, check vinyl = 1 process and wrap = 0.5 processes);

(iii) a user urgency level as selected by the user in the delivery data 236 (e.g. low = 1 priority point, medium = 2 priority points and high = 3 priority points);

(iv) the type of material for the product, also found in the project's design data 234 (e.g. melamine = 1 point, vinyl = 2 points, veneer = 4 points, and polyurethane = 8 points); and

(v) the number of days between today's date and the due date (in the delivery data 236) selected by the user, and represented in the delivery data 236, or alternatively a value of 0.1 if the project is overdue.

In an example production system 102, the priority rank data 244 is represented by a number generated in accordance with the following equation: priority rank=(A+B+C+D)*E, where A is the number of sheets, B is the number of processes, C is the number of priority points, D is the number of type points and E is the number of days or 0.1 if overdue. The projects may then be arranged by the scheduling and tracking module 250 in order of their priority rank in the priority rank data 244 associated with each project.

Once machining data 238 (and any appropriate optimised machining data 242) has been generated for each project, the production system 102 commences the manufacturing process 408 (Figure 8) of one or more products when the system controller 212 receives machined status update from the factory 104, indicating that the machine 262 is available for use (step 1002). When the machine 262 is idle, the system controller 212 sends the machining data 238 or the optimised machining data 242 of the project with the highest ranked priority rank that matches the available machine 262, e.g. for a product requiring routing, a routing machine is required (step 1004). The machine controller 260 carries out the machining process in accordance with the machining data 238 or the optimised machining data 242, and the production system 102 subsequently receives a machine service update indicating completion from the factory 104 (step 1006). Accordingly, the tracking data 248 is updated, indicating that one or more products of the project are now complete (step 1008). If further machining is required to complete all products in the order (tested in step 1009), the production system 102 sends the next highest ranked set of machining data to the factory 104 (repeat step 1004). On the other hand, if all products and components in the project/job are complete (step 1009), the production system 102 commences a shipping/billing process in communication with the transporter system 132 and the user system 106 to send a completed project to the user, and to invoice them accordingly (step 1010).

The production system 102 provides editable default templates, which enables the user to

order a slightly different cabinet with a minimum of redesign work (only the selection of different parameters, e.g. material used, height, colour, is required). The production system 102 also provides for more rapid and accurate manufacturing than existing methods; the very nature of the production system 102 is parameter and value based, rather than visually based (as in CAD design), thus unintentional generation of manufacturing instructions (e.g. hole locations, colours, etc) is far less likely to occur.

Many modifications will be apparent to those skilled in the art without departing from the scope of the present invention as herein described with reference to the accompanying drawings.

APPENDIX A

Cabinet Type - Base - Base Cabinet Standard Height. Cabinet Number: 1 Cabinet Dimensions - Height: 780 - Width: 900 - Depth: 560 - Quantity: 1 |BSEND_L|l|l|780|543.5|16.5mm WhtBrdMan WHITE HMR Particle Board|0|I||||PRNT=l HAND=I TRCH=I TRO=2 TRSP=21 TRMT=19 STYP=2 ASSP=65 ASEP=50 NUMH=6 NASH=I ASMT=I 6.5 HDIS=32 CCTP=O CNRB=O YHNG=37 BHNG=IOO THNG=103 HTYP=I HNGM=700 BOTS=60 BOTE=60 BMT=16.5 BTYP=I BMX=300 HDIA=5||l|Left End|7127|NSW1234 |BSEND_R|l|l|780|543.5|16.5mm WhtBrdMan WHITE HMR Particle Board|0||I|||PRNT=l HAND=2 TRCH=I TRO=2 TRSP=21 TRMT=19 STYP=2 ASSP=65 ASEP=50 NUMH=6 NASH=I ASMT=16.5 HDIS=32 CCTP=O CNRB=O YHNG=37 BHNG=IOO THNG=I 03 HTYP=I HNGM=700 BOTS=60 BOTE=OO BMT=16.5 BTYP=I BMX=300 HDIA=5||2|Right End|7128|NSW1234 |BSTOP|l|l|867|42|42xl9mm White Vinyl Rail|0|||||PRNT=0||3|Top Rail|7129|NSW1234 |BSBOTT|l|l|867|543.5|16.5mm WhtBrdMan WHITE HMR Particle Board|0||I|||PRNT=l AFFI=54.5 AFSI=16 AFBI=18 AFW=64 AFD=64 ADIA=IO AFCH=883 FSSO=30 AFTP=2||4|Bottom|7130|NSW1234

|BSBACK| 1111780|899| 16.5mm WhtBrdMan WHITE HMR Particle Board|0|||||PRNT=l BACS=60 BACE=60 BMT=16.5 BCTP=I BCMX=300 LMT=16.5 LSP=60 LEP=60

LTYP=I LMX=300 RMT=16.5 RSP=60 REP=60 RTYP=I RMX=300 STYP=2

NUMH=6 NASH=I ASMT=16.5 HDIS=32 HDIA=5||5|Back|7131|NSW1234

|BSASH|l|l|865|528.5|16.5mm WhtBrdMan WHITE HMR Particle

Board|0||I|||PRNT=l||6|Adjustable Shelfl7132|NSW1234 |BSDOOR_L|l|l|777|447|18mm Laminex WHITE SATIN BOARD Satin|O|||||PRNT=l HAND=I HIN=22 HSP=IOO HEP=IOO HTYP=I HMX=700||7|Left Door|7133 INSWl 234

|BSDOOR_R|l|l|777|447|18mm Laminex WHITE SATIN BOARD Satin|O|||||PRNT=l HAND=2 HIN=22 HSP=IOO HEP=IOO HTYP=I HMX=700||8|Right Door|7134|NSW1234

|BSFILL_L|l|l|780|140|18mm Laminex WHITE SATIN BOARD

Satin|4|||||PRNT=l||9|Left Filler|7135|NSW1234

Cabinet Type - Base - Corner Cabinet (Lazy Susan). Cabinet Number: 2 Cabinet Dimensions - Height: 780 - Width: 900 - Depth: 560 - Quantity: 1

|BSEND_L|2|l|780|560| 16.5mm WhtBrdMan WHITE HMR Particle Board|0|I||||PRNT=l

HAND=I TRCH=I TRO2 TRSP=21 TRMT=I 9 STYP=2 ASSP=I 50 ASEP=66.5

NUMH=6 NASH=I ASMT=I 6.5 HDIS=32 CCTP=O CNRB=I BACS=60 BACE=60

BCTP=I BCNH=2 BCMX=350 BCMT=16.5 BCVD=16 YHNG=37 BHNG=IOO THNG=103 HTYP=I HNGM=690 BOTS=60|BOTE=60 BMT=16.5 BTYP=I

BMX=350 HDLA=5|10|Left End|7136|NSW1234

|BSEND_R|2|l|780|560| 16.5mm WhtBrdMan WHITE HMR Particle Board|0||I|||PRNT=l

HAND=4 TRCH=I TRO=2 TRSP=21 TRMT=I 9 STYP=2 ASSP=I 50 ASEP=66.5

NUMH=6 NASH=I ASMT=I 6.5 HDIS=32 CCTP=O CNRB=I BACS=60 BACE=60 BCTP=I BCNH=2 BCMX=350 BCMT=16.5 BCVD=16 BOTS=60 BOTE=60

BMT=16.5 BTYP=I BMX=350 HDIA=5||l l|Right End|7137|NSW1234 |BSTOP|2|l|843|42|42xl9mm White Vinyl Rail|0|||||PRNT=0||12|Top Rail|7138|NSW1234 |BSTOP|2|l|323.5|42|42xl9mm White Vinyl Rail|0|||||PRNT=0||13|Top

Rail|7139|NSW1234 |BCBOTT|2|l|851|843|16.5mm WhtBrdMan WHITE HMR Particle Board|0|||||PRNT=l

AFTP=O LCS=527.5 RCS=527.5 EDG5=-l||14|Bottom|7140|NSW1234

|BCBACK_L|2|l|780|850| 16.5mm WhtBrdMan WHITE HMR Particle Board|0|||||PRNT=l

BACS=60 BACE=60 BMT=16.5 BCTP=I BCMX=350 LMT=16.5 LSP=80 LEP=80

LTYP=I LMX=350 RMT=16.5 RSP=80 REP=80 RTYP=I RMX=350 STYP=2 NUMH=6 NASH=I ASMT=I 6.5 HDIS=32 ASMW=850 TRDI=534 TRDD=21

CNRB=I HDIA=5 TRVR=I ||15|Back|7141|NSW1234

|BCBACK_R|2|l|780|858.5|16.5mm WhtBrdMan WHITE HMR Particle

Board|0|||||PRNT=l BACS=60 BACE=60 BMT=16.5 BCTP=I BCMX=35O LMT=16.5

LSP=80 LEP=80 LTYP=I LMX=350 RMT=16.5 RSP=80 REP=80 RTYP=I RMX=350 STYP=2 NUMH=6 NASH=I ASMT=16.5 HDIS=32 ASMW=850

CNRB=I HDIA=5 TRVR=l||16|Back|7142|NSW1234

|BC_SHLF|2|l|849|841|16.5mm WhtBrdMan WHITE HMR Particle Board|0|||||PRNT=l

LCS=427.5 RCS=427.5 EDG5=-1 SHR=100||17|Adjustable Shelfl7143|NSW1234 |BCCDOORL|2|l|777|316.5|18mm Laminex WHITE SATIN BOARD Satin|O|||||PRNT=l

HAND=I HIN=22 HSP=IOO HEP=IOO HTYP=I HMX=690||18|Left Door|7144|NSW1234

|BCCDOORR|2|l|777|308.5|18mm Laminex WHITE SATIN BOARD Satin|O|||||PRNT=l

HAND=4 HIN=22 HSP=IOO HEP=IOO HTYP=I HMX=690||19|Right

Door|7145 INSWl 234

Cabinet Type - Base - Sink Cabinet. Cabinet Number: 3

Cabinet Dimensions - Height: 780 - Width: 865 - Depth: 560 - Quantity: 1

|BSEND_L|3|l|780|543.5|16.5mm WhtBrdMan WHITE HMR Particle

Board|0|I||||PRNT=l HAND=I TRCH=I TRO=2 TRSP=21 TRMT=19 STYP=2

ASSP=65 ASEP=50 NUMH=6 NASH=I ASMT=I 6.5 HDIS=32 CCTP=O CNRB=O YHNG=37 BHNG=IOO THNG=I 03 HTYP=I HNGM=700 BOTS=60 BOTE=60

BMT=16.5 BTYP=I BMX=300 HDIA=5||20|Left End|7146|NSW1234

|BSEND_R|3|l|780|543.5|16.5mm WhtBrdMan WHITE HMR Particle

Board|0||I|||PRNT=l HAND=2 TRCH=I TRO=2 TRSP=21 TRMT=19 STYP=2

ASSP=65 ASEP=50 NUMH=6 NASH=I ASMT=I 6.5 HDIS=32 CCTP=O CNRB=O YHNG=37 BHNG=IOO THNG=103 HTYP=I HNGM=700 BOTS=60 BOTE=OO

BMT=16.5 BTYP=I BMX=300 HDIA=5||21|Right End|7147|NSW1234 |BSTOP|3|l|832|42|42xl9mm White Vinyl Rail|0|||||PRNT=0||22|Top Rail|7148|NSW1234 |BSBOTT|3|l|832|543.5|16.5mm WhtBrdMan WHITE HMR Particle Board|0||I|||PRNT=l AFFI=54.5 AFSI=16 AFBI=18 AFW=64 AFD=64 ADIA=IO AFCH=883 FSSO=30 AFTP=2||23|Bottom|7149|NSW1234

|BSBACK|3|l|780|864|16.5mm WhtBrdMan WHITE HMR Particle Board|0|||||PRNT=l BACS=60 BACE=60 BMT=I 6.5 BCTP=I BCMX=300 LMT=I 6.5 LSP=60 LEP=60 LTYP=I LMX=300 RMT=16.5 RSP=60 REP=60 RTYP=I RMX=300 HDIA=5||24|Back|7150|NSW1234

|BSASH|3|l|830|528.5|16.5mm WhtBrdMan WHITE HMR Particle

Board|0||I|||PRNT=l||25|Adjustable Shelfl7151|NSW1234 |BSDOOR_L|3|l|777|429.5|18mm Laminex WHITE SATIN BOARD Satin|O|||||PRNT=l

HAND=I HIN=22 HSP=IOO HEP=IOO HTYP=I HMX=700||26|Left Door|7152|NSW1234

|BSDOOR_R|3|l|777|429.5|18mm Laminex WHITE SATIN BOARD Satin|O|||||PRNT=l

HAND=2 HIN=22 HSP=IOO HEP=IOO HTYP=I HMX=700||27|Right

Door|7153|NSW1234

Cabinet Type - Upper - Fridge Cabinet. Cabinet Number: 5

Cabinet Dimensions - Height: 500 - Width: 850 - Depth: 300 - Quantity: 1

lUSENDJJSIllSOOpδS.SIlό.Smm WhtBrdMan WHITE HMR Particle

Board|0|I||I|I|PRNT=l HAND=I STYP=2 ASSP=65 ASEP=50 NUMH=6 NASH=I ASMT=16.5 HDIS=50 CCTP=O YHNG=37 BHNG=IOl THNG=IOl HTYP=I

HNGM=700 BOTS=60 BOTE=OO BMT=I 6.5 BTYP=I BMX=300 HDIA=5

PHLP=0| |28|Left End|7154|NSW1234

|USEND_R|5|l|500|283.5|16.5mm WhtBrdMan WHITE HMR Particle

Board|0||I|I|I|PRNT=l HAND=2 STYP=2 ASSP=65 ASEP=50 NUMH=6 NASH=I ASMT=16.5 HDIS=50 CCTP=O YHNG=37 BHNG=IOl THNG=IOl HTYP=I

HNGM=700 BOTS=60 BOTE=OO BMT=I 6.5 BTYP=I BMX=300 HDIA=5

PHLP=0||29|Right End|7155|NSW1234 lUSTOPISIllSπ^δS.SIlό.Smm WhtBrdMan WHITE HMR Particle

Board|0||I|||PRNT=l||30|Top|7156|NSW1234 |USBOTT|5|l|817|283.5|16.5mm WhtBrdMan WHITE HMR Particle Board|0||I|||PRNT=l

PHLP=O PHLD=O PHLC=0||31|Bottom|7157|NSW1234

|USBACK|5|l|500|849|16.5mm WhtBrdMan WHITE HMR Particle Board|0||||I|PRNT=l BACS=60 BACE=OO BMT=16.5 BCTP=I BCMX=300 LMT=16.5 LSP=60 LEP=60 LTYP=I LMX=300 RMT=I 6.5 RSP=60 REP=60 RTYP=I RMX=300 HDIA=5 PHLP=O PHLC=0||32|Back|7158|NSW1234

|BSASH|5|l|815|268.5|16.5mm WhtBrdMan WHITE HMR Particle

Board|0||I|||PRNT=l||33|Adjustable Shelfl7159|NSW1234 |BSDOOR_L|5|l|498|422|18mm Laminex WHITE SATIN BOARD Satin|O|||||PRNT=l

HAND=I HIN=22 HSP=IOO HEP=IOO HTYP=I HMX=700||34|Left

Door|7160|NSW1234 |BSDOOR_R|5|l|498|422|18mm Laminex WHITE SATIN BOARD Satin|O|||||PRNT=l

HAND=2 HIN=22 HSP=IOO HEP=IOO HTYP=I HMX=700||35|Right

Door|7161|NSW1234

APPENDIX B

[COMMENTO] CNC Layout

[CENTROOl]

PARAMETRI=000000217

UTENSILI=000000329 LABELF=000020320

LABELC=000020307

FORATURA=000020274

CONTORNATURA=000000344

TABELLEFORI=000020289 CONFASSIST=000020333

ATTREZZAGGIO=000020350

[PARAMETRIO 1]

NlO G71 HC=I FIL=O BLO=O ACC=O RUO=O PRS=I PRL=I KA=O PLPZ=I 6.5 PCSG=25 LX=3610 LY=1210 LZ=I 6.5

%

[UTENSILIO 1]

% [CONTORNATURAO 1]

; Layout No: 2

;Results FiIeC :\ARDIS\Data\NSW2595.R41

;Generated:23/05/2007 6:59:52 AM

;ToolOpt: True . ********************* pRiNX USTOP

.********************* usYOP USTOP

N20 XO437.5 YO5 RT=90 N25 EDGl=O EDG2=-1 EDG3=0 EDG4=0

N30 L=USTOP PX=750 PY=432.5 RUN=I PRNT=I ST7="0|l|0|0| l|1.0|WHT| NSW2595| 6539|Top | |" . ********************* PRINT USBACK .********************* USBACK USBACK N50 XO451.5 YO5 RT=O N55 EDGl=O EDG2=0 EDG3=-1 EDG4=0

N60 L=USBACK PX=519 PY=782 RUN=I PRNT=I BACS=60 BACE=60 BMT=16.5 BCTP=I BCMX=300 LMT=16.5 LSP=60 LEP=60 LTYP=I LMX=300 RMT=16.5 RSP=60 REP=60 RTYP=I RMX=300 HDIA=5 PHLP=O PHLC=O ST7="0|0|l |0| l|1.0|WHT| NSW2595| 6541|Back | |"

. ********************* pR _j NX BSASH .********************* BSASH BSASH

N80 XOl 512 YO5 RT=90

N85 EDGl=O EDG2=-1 EDG3=0 EDG4=0

N90 L=BSASH PX=765 PY=527.5 RUN=I PRNT=I ST7="0|l|0|0| 6|1.0|WHT|

NSW2595| 6568|Adjustabl| |" • ********************* pRJNT BSBOTT

.********************* BSBOTT BSBOTT

NI lO XO2068.5 YO5 RT=90

Nl 15 EDGl=O EDG2=-1 EDG3=0 EDG4=0

N120 L=BSBOTT PX=767 PY=542.5 RUN=I PRNT=I AFTP=O ST7="0|l |0|0| 6|1.0|WHT| NSW2595| 6566|Bottom | |" . ********************* pR _j NY BSBACK .********************* BSBACK BSBACK N140 XO2701.5 YO5 RT=90 N145 EDGl=O EDG2=0 EDG3=0 EDG4=0

N150 L=BSBACK PX=720 PY=619 RUN=1 PRNT=1 BACS=60 BACE=60 BMT=16.5

BCTP=1 BCMX=300 LMT=16.5 LSP=60 LEP=60 LTYP=1 LMX=300 RMT=16.5

RSP=60 REP=60 RTYP=1 RMX=300 HDIA=5 ST7="0|0|0|0| 5||| NSW2595|

6561|Back | |" ; ********************* PRINT BC SHLF

;********************* BC SHLF BC SHLF

Nl 70 XO2715.5 YO5 RT=O

N175 EDGl=O EDG2=0 EDG3=0 EDG4=0

Nl 80 L=BC_SHLF PX=829 PY=782 RUN=I PRNT=I LCS=427.5 RCS=427.5 EDG5=-1 SHR=IOO ST7="0|0|0|0| 12||| NSW2595] 6601|Adjustabl| |"

; ********************* PRINT BSASH

;********************* BSASH BSASH

N200 XO532.5 YO801 RT=90

N205 EDG1=O EDG2=-1 EDG3=0 EDG4=0 N210 L=BSASH PX=390 PY=527.5 RUN=I PRNT=I ST7="0|l|0|0| 9|1.0|WHT|

NSW2595| 6581|Adjustabl| |"