Tel: +971 4 3881999 Fax No.: +971 4 3881900
JOGARAM FURNITURE INDUSTRY PROFILE
TABLE OF CONTENTS: 1. INTRODUCTION 2. PROJECT ORGANISATION CHART 3. TYPES OF PLANTS WITH US 4. LICENSES & CERTIFICATES 5. SYSTEM OF PROCEDURES 6. QUALITY CONTROL PROCEDURES 7. LOCATION MAP & CONTACT
1. INTRODUCTION JOGA RAM FURNITURE INDUSTRY LLC was formed in the year 1999 with the sole purpose of establishing a world class joinery company in the region catering to the various needs of the discerning and quality conscious clientele. Since 1999, the company has grown many folds under the able leadership of Mr. Joga Ram and ever since, it has served the people of Middle East to their fullest satisfaction. Its numerous and varied successfully completed projects are ample proof of the company's performance in the areas of joinery works. Located in the Al Quoz area of Dubai, JOGA RAM FURNITURE INDUSTRY LLC has one of the best joinery, carpentry and furniture manufacturing facilities spread over an area of 10,000 square feet. The factory is equipped with a comprehensive range of latest state-of-the-art machinery, which makes the company one of the most efficient, advanced and sophisticated companies of this type in the region. Manning this facility is 90 highly skilled work force which includes 75 skilled technicians and 15 executive staff consisting of managers and design personnel, who have been carefully selected for their expertise and skills. This amalgamation of the best infrastructure with the finest skills and talent ensures that at all time, the company achieves the highest quality standards within the demanding schedules. Our success has been based on values which are ingrained into our corporate culture and are followed in every aspect of our business operation through four major tenets: zero compromise on quality, consistent value for money for customers, continuous investment in human resources and a strong commitment to maximizing value. We strongly believe that our main strength lies in our most precious asset our people and they are equally a part of our success. As we move ahead to the future, we eagerly embrace new technologies, innovative thinking, and operational & technical change, but our commitment, at all levels, to excellence, quality and relationships with our employees and customers remain the foundation of Joga Ram Furniture Industry LLC s success story.
2. ORGANISATION CHART
3. Types of Plant &Machineries No. Plant /Equipment /Tools Make/Model/Brand Qty. 1 Wood cutting Band saw. HCQ115. 01 2 Hydraulic Hot press. XL/6 01 3 Veneer Splicing Machine. FWS.920. 01 4 Hydraulic Guillotine. 31.5. 01 5 PVC Edge Banding. ME 25. 01 6 Circular saw LDS.3.10497 01 7 Circular saw WDX.132 01 8 Surface thickness planer PA.009712 01 9 Electric Drill(big) Makita 06 10 Cord less Drive Drill Makita.8281D 15 11 Nail gun machine Makita.AF505 03 12 Nail gun machine F30 10 13 Air compressor (big) WQC-25 02 14 Air compressor (Medium) WQC-20 01 15 Air compressor (small) WQC-15 01 16 Slide compound saw machine LS.1216 02 17 Table saw Machine 02 18 Finishing sander(big) Makita.9045B 04 19 Finishing sander(medium) Makita.B03700 03 20 Finishing sander(small) Makita. 03 21 Jig saw Makita.4326 02 22 Air Blower Makita.UB1100 02 23 Grinder Dewalt.DW813 03 24 Spray Paint Booth Auto touch 01 25 Electric Drill(medium) Makita.6413 06 26 Router (big) Makita.3612BR 02 27 Router (small) Makita.3700B 02 28 Hilti Drill D25012HDS 04 29 Tool box with tools Stanley 15 30 Hand cutter Makita.4100NH 02
OUR FACTORY
OUR FACTORY
4. LICENSE& CERTIFICATES
ISO CERTIFICATE
5. SYSTEM OF PROCEDURE After getting the confirmation from the client, a job card will be opened, incorporating the items mentioned in the BOQ and scope of work mentioned in the confirmed order (LPO) The copy of the job card issued to production department, is forwarded to setting out department, quality control department, purchasing department, costing department and account department. Accounts department on receiving the copy of job card will study the financial implications and terms and conditions in the confirmed order. Accounts department after collecting details from estimation department, will make provision for the purchasing of different material and for other financial needs. Purchase department will find out from the estimation department, the details of materials to be used in the project, the quantities required, recommended brand/supplier etc. And will conduct an up to date search for good quality material complying with standards and specifications, as per the quantities required, on time, before starting the actual production. Purchase department will co-ordinate with accounts department to make sure that all the required material of required standard and specifications of required quantity area available locally, Purchase department will make quick arrangements to import it on time in coordination with production and accounts department. Setting out department will make a preliminary study of the project regarding the present condition of the site, the scope of work, the completion time, details of items mentioned in the Bothe specifications to be followed, drawings supplied by the client, consultant, in coordination with production department. The setting out department in coordination with the production department, set the time for each item of work, regarding the preparation of shop drawings to be submitted to the client,additional shop drawings required by production department, samples to be submitted to the client/consultant etc. And prepares programme of work, programme of shop drawing submittal, and programme of samples submittal etc. for wise easy and smooth progress of the project.
The setting out department visit the site and makes a detailed study of site coordination s before the preparation of shop drawings. Preliminary shop drawings are prepared complying with the specifications and drawings given by the client, which will give a clear picture of type of work to be executed. This will be submitted to the client for approval for proceeding with the detailed shop drawings and for the preparation of samples as required by the client. The factory manager, coordinates everything and after getting the approval of the shop drawings from the client issues production order for the samples as instructed by the client. Production department on obtaining the order for the preparation of samples, makes immediate arrangement for the sample including carpentry, joinery, polish etc. and quality controller, after checking the sample issues a quality check and good delivery note so that the sample is ready for submission. Now, the sample will be submitted to the client or consultant (attach with submittal format if available, duly signed) for their scrutiny and factory manager coordinate with the client/consultant for getting the sample approval or does detailed discussion for revisions if any suggested by the client, and the details will be transferred to the production department for further revision of shop drawing or revision of samples required. Factory manager,meanwhile, coordinate the works of accounts department, purchase department, setting out department and production department and conveys the details obtained from client or consultant regarding the important points of specifications regarding the material availability, time of completion, starting of work, further clarification etc. Though various meetings in factory for efficient and smooth start and progress of work, so that the lack of information to any of the department or delay of any department will not be effect the general progress of a whole.
Production department submits the revised samples if required through the setting out department in coordination with factory manager and once the sample is approved, factory manager issues an order for starting of the works and meanwhile, purchase department takes all immediate steps in coordination with the accounts department and production department, to make sure that the required materials will arrive in the factory before actual production starts. Setting out department will now visit the site once again, to take all the relevant site dimensions to prepare detailed shop drawings which is required for easy and simple production process. Setting out department prepares cutting sheet for each and every item, showing the number, length, breadth, Thickness of wood, plywood, mdf etc. Required including the approximate shapes etc. And the cutting sheets are issued to the machine shop in coordination with the project coordinator and quality controller. In the machine shop, the timber or sheets which has already arrived factory through the perfect coordination of the purchase department, will be very carefully selected for defects, knots, moister contents etc.as mentioned in quality control procedures and timber or sheets are cut to the required dimensions. Project coordinator and quality controller, coordinate with setting out department and machine shop to ensure the prepared cutting list includes all the pieces of timber/sheet required as per the shop drawing and specification and also makes sure that timber/sheet have been cut strictly based the cutting list, no piece of timber or sheet is missing which may create problem in the progress in the assembly shop at a later stage and also makes sure the quality required by the client has been maintained in the selection of material etc. Once the work in the machine shop is ready, Project coordinator checks whether cutted pieces are as per the cutting sheet or not and after ensuring that the cutted pieces will be taken to assembly shop for the assembly of the particular item for which the cutting sheet has been prepared.
In the assembly shop, close supervision is done to ensure that the unit being assembled strictly follow the dimensions of and specifications mentioned in the shop drawing. Veneers if required are selected very carefully to match the continuous patterns/other design patterns mentioned in the shop drawings. During all stages of work, it is ensured that all necessary glues, nails, paints, other main materials required are available in store for use. Laminate which are stored carefully are utilised for pressing in the machine. After assembling the unit, thorough checking is done for the dimensions, overall workmanship, matching of veneers, pressing of laminate etc. and once the quality controller is satisfied with the assembly and workmanship, the unit will be transferred to the polishing shop. While works are going on, on daily basis, the details of labour and materials consumed for each item of work is transferred to costing department, to work out the actual cost of the project at any stage. Once the unit enters the polishing shop, sanding will be done to required standards. Sometimes, in the machine shop and assembly shop, some preliminary sanding work will be done. In polishing shop after the necessary sanding with the supervision of charge-hand and quality controller along with project coordinator, necessary putty and primer work will be performed. After selecting the required stain, category of paint etc. as per the specifications, the unit is spray painted in the spray booth and allowed to dry. Before entering the spray booth, thorough checking is done to ensure that unit is perfectly O.K, in all respects. Once the unit is dry to the required level, after spraying the required coats, it will be either packed and stored for delivery afterwards, or otherwise immediately packed and in coordination with the quality controller/project co-ordinator and transport department, arrangements are made for the delivery of the same to site.
Once the unit is complete, before delivery of the goods to site, quality controller inspects thoroughly in all respects, and issue a quality check certificate, to certify that it is perfectly all right confirming to required dimensions and standard. Before delivering the goods, goods delivery note (GDN) will be prepared mentioning the details of items, quantity etc., and is sent along with drivers or other concerned, and will be certified at site by our in-charge or client s representative as the case may be. The copy of the delivery note will also be transferred to costing department as well, for calculating the actual cost of the project, and for raising the invoices, based on the GDN, works performed etc., on a monthly basis or, as per the condition of contract. Once the unit arrives in the site, the site supervisor, inspects whether the quantity mentioned in the GDN, and the actual goods arrived are same or not. Then he checks whether any defect occurred while transporting the goods or in some other way etc. After checking and making sure that the goods ca be received, it will be offloaded and stored in cool/dry place, and packed with great care. If he founds some defects which has to be rectified in the factory, he will inform the same to project coordinator and quality controller and they will make arrangements to rectify the same. Much care will be taken by the site supervisor to see that the goods are not damaged while storing, or while fixing or even after fixing. He takes very care to see that works which are performed are not damaged by other traders/subcontractors/main contractor s work, and if such thing occurs, it will be reported to the project co-ordinator for further process. Project coordinator, co-ordinates meanwhile the works of setting out department, quality control department, transport department, site supervision and client, to see whether the work is going on smoothly as per the programme, whether shop drawings are ready at all stages for smooth working of factory, whether the progress of work in the factory are as per the programme, whether the finished goods are delivered as per the site requirements, whether the site work is as per the programme etc. He also coordinates for any variation work as instructed by client/consultant. The factory manager who manages everything makes sure that the client is satisfied with the quality and progress of the work, and rectifies the problems in each department for smooth progress of work, arranges regular meetings to review the progress of works, discusses the problems in the project and makes arrangements to solve all the problems, so that progress of work is not affected.
Site supervisor, does the supervision of the fixing work, to the satisfaction of client/consultant, informs the problems if any to project co coordinator, makes sure that the works are to required finish, to required dimensions, and in plumb and levels and as per the detailed drawings issued to him. Site supervisor also checks the overall finishing of the works, gaps between different parts of the unit, working of ironmongery etc. Site supervisor also coordinate with other contractors working in the site, to ensure the progress of our work, attend the site meeting in coordination with project coordinators inform the problems from the part of other contractors etc.to the client through project coordinator, and makes sure that the progress of the work is as per plan and quality and workmanship are to the required standards. He also inform the required quantities in site to the project co coordinator as per the progress of our work, as per the progress of other contractors and as per the requirement of the client. Site supervisor also gives daily report regarding progress of work, regarding the additional labour requirements, quantities fixed at site, discrepancies in dimensions, quantities required at site, change of labourers required, finish problems, approvals required, problems from other contractor, instructions from client, instructions from consultant etc. To the project coordinator, and project coordinator coordinates with other departments and others concerned to solve all the problems in coordination with factory manager.
Meanwhile, based on details of goods delivery notes, variation works performed, progress of work in site etc. costing department will raise the invoices as per the terms and conditions of contract. Factory manager coordinates the factory work, site work and client through project co coordinator on daily basis and through production meetings on weekly basis. He also reports to directors, in coordination with finance and administrative manager, regarding the progress of works, finance required for further progress of work, invoices raised, collection of payment etc. Thus the project will be completed smoothly with coordination of all departments and once the project is completed, request will be given for the completion certificate to the client/to consultant/through the client /through the consultant. Once the completion certificate is obtained and project thus handed over, final bill will be raised and other terms and conditions are satisfied.
6. QUALITY CONTROL PROCEDURES SUMMARY: Quality inspection for wood for seasoning, even grains and colour, knots decay, size of timber and workability. Quality control inspection for plywood, MDF, melamine faced MDF, Veneer, Laminate, Paint and other related items. Quality control of work in machine shop, assembly shop, polishing shop etc. Once the above procedures are completed it will be the duty of the quality controller to issue the final quality check certificate for the despatch of the material. Once goods are arrived at site, they are properly inspected by the site supervisor and fixed in site as per the drawings and instructions and after completion, site check sheet will be submitted. The detailed description of the quality control procedures and samples of the quality check list and site check sheet are enclosed herewith. INSPECTION OF RAW MATERIALS The quality control department coordinates with the purchase department right from the stage of selecting the source of supply to get the good quality material of approved brand to avoid future defects which may occur due to defective raw material.
WOOD The timber selected will be in accordance with the latest edition for nomenclature of commercial timbers including sources of supply. The timber selected will be of approved variety and quality suitable for the purpose, of which it is to be used and equal to the samples approved by the consultant/client. All the selected timbers will be properly seasoned and kept under the shade and thorough checking will be done by the quality controller to make sure that the timber entering the factory is free from the following defects. Sapwood, splits, ring shakes, soft pith. Checks exceeding 30cm long. Knots of any description in surfaces for staining or polishing. Knots of any description in glazing bars. Knots exceeding one half of the width of surface. Knots exceeding 2cm mean diameter. Decayed or dead knots unless cut and plugged. Pith pockets. Decay and insect attack including pinworm holes. In joined panels each piece used be of the same species. Quality controller makes sure that all surfaces for staining/polishing are from the same species and some character of grain running in same direction unless otherwise specified by the consultant/client.
All plugs inserted after cutting out defects will be the full depth of hole. Timber connectors where used will be two single sided toothed plate for demountable joints or are double sided toothed plates for permanent joints as per BS:1579 latest edition. Timber shown to be plugged to wall will be properly and securely fixed by means of raw plug/hardwood plug. All timber coming in touch with concrete/block work will be treated with approved quality wood preservative. Quality control will be carried out to make sure that the timbers are having moisture content between 10 to 12%. White wood will be used in places where soft wood is mentioned and to the approval of the consultant/client and will be as per the dimensions specified on drawings. All softwood timber selected will be in accordance with BS 881/589 and will be treated with an approved non staining and nontoxic organic solvent type preservative. All hard wood shall comply with the requirements of BS 1186 part 1 and BS 4007 and All hard woods are selected ensuring that they are having a straight and regular grain throughout. Unless otherwise stated all hard wood will or first qualify red merranti wood, selected to give a harmonious appearance to the approval of consultant /client.
PLYWOOD Quality control is being carried out to ensure that the plywood used of exterior grade and are confirm to applicable requirements of BS 1186, 1952 Part 1 and BS 1455, 1963 and BS 3493, 1962. Plywood will consist of an odd number of plies arranged so that the grain of each layer at right angle to the grain of adjacent layers. In the case of plywood having 3 piles the core will not be more than 60% of the total thickness. In plywood having 3 piles the face and all plies with the grain running in the same direction as the faces will be have a combined thickness between 40% and 60% of total thickness of plywood. Quality control dept. Also makes sure that the plywood are free from end joints(including scarf joints in veneers),overlap in core veneers, dead knots, patches and plugs, open defects, depression due to defects in core, insect attack (except isolated pin worm holes through face veneers only).fungus attack and from decolourisation from normally associated species. Faces veneers will be hard and durable and will be capable of being finished to a smooth surface. Quality controller selects material in such a way that face veneer closely matches the general joinery timber selected. They will be from knots, worm and beetle hole, splits, glue stains, filling and inlay of any kind of other defects. Quality controller makes sure that adhesive comply with the requirements of BS 1203 grade WBP and will ensure proper adhesion between plies. Where required, lipping will be of hard wood i.e. red merranti wood unless otherwise mentioned, tongued and glued to the edge of the plywood to finish minimum of 12 mm thick.
MDF (Plain/Melamine) Quality controller selects melamine surfaces in such a way that they are of standard grade sheets in approved colours,0.9mm to 1.5mm thick as specified, confirming to BS 3794 fixed with heat proof adhesive complying with BS 1204. BLOCKBOARD Blackboards are selected from approved manufacturer and guaranteed not to warp or change in size or suffer any kind of deformation. It will be of timber specified and glued with anti-insect synthetic resin water proof glue all through. Blackboard confirming to BS3444, 1961 and BS 3583, 1963 are selected very carefully. CHIPBOARD Chipboard used will comply with BS 2604.Chipboard used, if specified, will be medium density wood particle board produced in factories by approved process. When cutting is necessary it will be neatly and accurately performed with fine toothed saws. Full and cut sheets will have all edges lipped with hardwood fillets for the full thickness of sheet or as specified in the drawings.
LAMINATES Decorative laminates plastic sheet will comply with BS3794.Laminates selected will be of the quality and shade as mentioned in the drawings. Thickness Bending grade Post forming grade : 0.9mm unless otherwise mentioned. : 0.6mm for onsite bending.radius of about 75 mm : 1.1mm Confirming to fire requirements as applicable. Laminates will be scratch proof, washable with soap and water, on fading colour in direct sunlight and will be nondeforming under extreme weather conditions. Laminates are glued in the factory itself with approved adhesive in the hydraulic press. Care is taken to eliminate all air from beneath the laminate and if air is entrapped, the portions and work so disfigured will be removed and replaced. After complete setting of the adhesive, the plastic laminate will be neatly bevelled along all arisen with a plane.
VENEER Where panels or doors are to receive a clear finish, the face veneers and lipping s will be of hardwood indicated on the drawings. They will be selected giving very careful attention to ensure that they are free of defects as described for wood. Where panels on doors are to have a special veneer on one side only, a balancing veneer will be applied to the other side to prevent warping. Veneers are selected in such a way that they are hard and capable of being finished to a smooth surface. They will be cut, matched and applied by hot press. Veneers used will be roll cut veneers, minimum 0.6mm thick and will be factory applied under pressure using approved quality adhesive. Whole sheets will be used wherever possible to minimize jointing and edges are lipped with matching veneers or hardwood lipping s as specified. Stitching will be done, in the veneer stitching machine to achieve the required dimensions
GLUE Glue for exterior joinery will be water resistant case line or other moister resistance type. Glue for interior joinery shall be grade best suited for the purpose. Adhesive shall comply with BS 1203. FINISHING The following materials &process will be adopted as per the required specification. Clear lacquer Nitro Cellulose Lacquer Acid Curing Lacquer Polyurethane Lacquer Polyester Pigmented Paints Nitro Cellulose Paints Oil Paints
MACHINE SHOP After the initial inspection of raw materials is carried out, the quality check will be carried out in the machine shop for cutting, planning and routing of the raw materials to the right specification. Quality controller co-ordinates with the setting out department to makes sure that there are no discrepancies between the drawings, shop drawings and cutting list, The cutting lists are scrutinised before issuing to machine shop to ensure that all the timber/ply/mdf pieces etc. required for the particular item area listed, to avoid future delay which can occur during assembling and joining due to the absence of a particular piece of timber/sheet.
ASSEMBLY SHOP The carpentry and joinery works are accurately set out, framed and executed in accordance with the detailed drawings and instructions given by consultant/client. Joinery will be cut and framed at an early stage but will be glued/wedged until the building is ready to receive it. All timber that is to be exposed in the finished surfaces of joinery are wrought on the appropriate faces unless otherwise specified. Doors are prepared as soon as practicable after the work is ordered, put together loose and stored in condition of heat and humidity, similar to that of completed building. When natural finish or finish for staining, clear polishing or varnishing is specified, the timber in adjacent pieces will be matched and to make it uniform or symmetrical in colour and grain. Reasonable tolerances are provided at all connections between joinery work and building carcass. All necessary mortising, tenoning, grooving, matching, tonguing, housing, rebating and all other work necessary for correct joinery will be performed. All external joinery will be put together with water proofing glue. Joints are constructed exactly as shown on shop drawings/other detailed drawings issued by consultant/client. Where joints are not specifically indicated, they will be recognised forms of joints for each position. The joints will be made so as to comply with BS1186.
Nails are not used for fixing any items of joinery. Springs are used for glazing beads only if required. Screws will be in accordance with BS No.1210 latest edition. The joinery and fabrication are done in such a way that the shrinkage of any part will be compensated at the joint and will not impair the strength of the finished work nor construction tolerances. Special care is taken to check or prevent capillary penetration of water in the joints and open connections of external joinery works. All joinery work such as architraves, beads etc. required to fit against the contour of irregular surfaces will be accurately scribed to ensure a close connection. In the assembly shop, quality control is carried out in each stage of the assembly and all measurements are checked in accordance with the shop drawings. POLISHING SHOP In the polishing shop, quality control is carried out for the right material application specification and finishing. Joineries are given final coat of finish before despatch to site. All screws will be counter sunk and puttied and all springs will be punched and puttied before first coat. All joinery which is to be polished, varnished or painted will be finished smooth and clear, by rubbing down with fine sand paper.
PACKING, STORAGE, TRANSPORTATION &DELIVERY Once the items is ready for delivery, Quality controller will issue the final quality check certificate for the despatch of materials. None of the joinery items will be delivered to the site until it is required for fixing in the building. Joinery is kept well packed during transit and will be handled and packed carefully to avoid its being damaged and will be covered to kept clear of ground. Material when delivered to the site will be stored to ensure proper ventilation and protection for elements. No Kiln dried materials will be placed in the buildings until the building is sufficiently dry. Joinery and finished wood work will be delivered dry. Interior finish will not be stored or installed in the building until after concrete masonry and wet traders have been completed or cured or dried. Special care is taken to prevent damage to and destruction of joinery during transit, handling, storage and fixing. Joinery and components are kept clean and dry and marking are prevented which will be visible in completed work. Protection will be given to work, as necessary and will be removed on completion. Joineries are stacked on levelled dry floors under cover when stacking components will be separated with spacers to prevent damage by and to projecting ironmongery, beads etc. All wood for joinery works whether is to be painted or left clear finished will be supplied properly planed and rubbed down. Joinery will be properly protected during fixing and work by other traders, especially frames and door linings, which may require temporary casings. While storing, care is taken to see that veneered surfaces are not exposed to direct sunlight.
SITE INSPECTION Once the unit is arrives in the site thorough inspection will be done for the quantity arrived. It will be checked to see whether there is any damage occurred to the goods while transporting.offloading is done with much care to make sure that no damage occurs while offloading or while storing the units in the site. Units are stocked in the site in a suitable cool/dry place without damage, and it will be ensured that while stocking, no damage occurs to any of the item or unit. IF defects found in these stages has to be rectified in the factory, it will be sent to factory. It will be ensured that work or the stored material is not damaged by the work of other contractors. All the joinery such as architraves, beads etc., required to fit against the contour of irregular surfaces will be accurately scribed to ensure a close connection, It is ensured that the work of other contractor is properly arranged to obtain the best both in the joinery and other trades. It will be inspected in the site whether the goods arrived are as per the shop drawings and specifications and as per the site dimensions, and in case of any discrepancies it will be rectified in site or in factory. In the site much care is taken to see that the units are fixed properly, to see that works are to the required finish, the works are in plumb and levels and as per the shop drawings. Care will be taken to see that no damages occurs to work at any stages. Working of the ironmongeries are properly inspected. All the instruction form client/consultant also will be implemented in required stages. HANDING OVER Once the final inspection is carried out and all snags have been attended, the project will be handed over to concerned authority for final completion certificate.
GUARANTEE If any shrinkage or warping occurs or other defects appears in the joinery work before the end of the defects liability period, all the defective work will be taken down and removed to the entire satisfaction of consultant/ client at our own cost if the tender clause specifies. We will be submitting a written guarantee if specified in the tender, in acceptable form that, supplied and fixed material will show no signs of warping or distortion for a period of one year from the date of project completion. Should such warping or distortion occurs, will be provided with corrective action or replacement of the same at client s convenience and at no extra cost of employer if agreed at the time of signing the contract.
7. LOCATION MAP&CONTACT Our Location Our office UNITED ARAB EMIRATES 22 Street, AL Quoz Industrial Area 2, Dubai P.O.Box:282537 Tel.: +971 4 388199 www.jogaram.com