STANDARD OPERATING PROCEDURES

01. Introduction:
P2P Furniture aims to become a highly reputed Furniture manufacturer in the Domestic &
Global market by producing best quality products. We have been inspired by our customers
and their choice to make completely authentic furniture. We believe in Customer Satisfaction
first!
We have a group of furniture experts, experienced designers, renowned architects and
technicians to create the best product. Our all products are differently designed and go
through strict production and quality control. We use selected raw materials such as 100%
seasoned and treated wood, the best quality processed wood, Boards, Hardware, Accessories
and world famous coating items.
We always aim at offering the unique design and more competitive price and after sales
service of your trust and faith. Everyone can enjoy thoroughly the life form our products.

02. Mission:
To foster a customer driven philosophy by developing distinctive competencies and being the
market leader in the industry of home and office furniture. We want to spread our products
in international market.

03. Vision:
Our vision is to be a leading global furniture manufacturer offering advanced and superior
quality products.

04. Objectives:
a) Setting standards of manufacturing the finest quality furniture for all class and generation.
b) Setting standards of performance of materials processing, manufacturing and value
addition of furniture products.

05. Production Procedure:

05. 01. Team

A well-organized team led by a Production Manager is required to increase production
dynamics and quality production. He will oversee the activities of the entire production team
and will coordinate the activities of all departments. He will collect daily reports from all
 STANDARD OPERATING PROCEDURES

these departments, will submit a comprehensive report to the General Manager at the end of
the day after review these reports.
05.02. Process
The process flow chart is as follows-

Order & Finished Product /

Inventory Analysis

Production PLAN
(Weekly or Monthly)

Maintenance
Purchase Seasoning
Q/C

Raw Materials Cutting in

Quality Check Machine
Q/C

Procurement
Return
Storing Carpentry
Crafting & Shaping Q/C

Relocation Lacquer
Q/C

Store
Upholstery Carpentry
(fitting)
Q/C

Packing
Administration
Accounts &

Finished Store

Customer Satisfaction Showrooms or Customers

 STANDARD OPERATING PROCEDURES

05.03. Production Plan

Weekly / Monthly / Annual Product Production will be prepared against product requirements
of customers / franchisees / showrooms, on the basis of 'inventory of finished products at
warehouse, factory store and display center(s)', inventory of factory production floor (work
in process)', 'inventory of raw materials at store'. Production Manager will be responsible to
generate Product Production Plans by ensuring the proper data from subordinates of his
team. Necessary data also be collected from the Sales & Marketing Department, Procurement
& Logistics Department, Store Department and Accounts & Administration Department. Note
that, Accounts & Finance Department, Store Department and Procurement & Logistics
Department will be obliged to provide all possible assistance to the Production Department for
implementation of production plan.

[Deduct the total quantity of current stock of finished products (a sum of stocks in display
center, factory store and warehouse) and subtract the total quantity of work in process (a
sum of under processed Products in machine shop, carpentry, coating and upholstery
department) at factory production floor from the targeted production quantity to calculate
the required quantity of Production (as per Production Plan).]

The Production plan must be approved by the proper authority (assigned by the Management
Board of the P2P) and along with the soft copy, a hard copy will also be reserved in the Accounts
and Administration Department for minimum 12 months to face any internal or external
audit(s).

05.04. Product Management File

An efficient person will be assigned to generate ‘Product Management File (Mandate for
Production)’ by the Production Manager. All data related with the production of mandated
products must be written in the Product Management File. Cost of production of these
products will be calculated as per data provided with these Product Management File. Data
will be written by the section chief / supervisor on the scheduled form after completing the
work by his section. At the end of sectional work, the data will be recorded on the Product
Management file and the work and files will have to be relocated to another section.

The Product Management File (Mandate for Production) must be approved by the proper
authority (assigned by the Management Board of the P2P) and along with the soft copy, a hard
copy will also be reserved in the Accounts and Administration Department for minimum 12
months to face any internal or external audit(s).
 STANDARD OPERATING PROCEDURES

05.05. Estimation

Estimates of quality raw materials / accessories / equipment / services should be prepared as

there are sufficient supply in the domestic market to produce the products as per approved
production plan. The quality of raw materials / accessories / equipment / services will be
ensured by the production department. If necessary, they will provide the required raw
materials / accessories / equipment / services samples to the Procurement Department. The
estimate of raw materials / accessories / equipment / services will be provided to the store
department to make a requisition.

05.06. Design & Development

Design development, Product modification on demand / situation or product improvement is

very vital work in furniture production process. 5 steps should be followed to develop designs
and to improve the process, these are-

a) Situation: New, modified, improved product

Factory follows the guide line to design the product(s) selected by the higher authority of the
P2P, but adequate plans and strategies should be taken to modify or improve regular products
to meet market demand, customer preferences, project alignment and business needs.

b) Investigation: brief, analysis, concept, and information gathering

Changes in product design, raw materials, manufacturing methods or services provided are
analyzed to reduce the impact on costs. The cutting list of the product, production cost and
production time are determined with the help of all the departments, and it is ensured that
the product is produced at the scheduled cost.

c) Possible solutions: schematic, components, models, working drawings

Model design, working drawing, cutting plans, boring plans, hardware lists, packing lists for
Knock-down Products and schedule of production costs and production time should be
generated with the help of all departments.

d) Realization: constructional methods, the final solution

The first stage of testing and implementation of a new, modified or improved product is
mostly termed as prototyping. Prototype products are made for the purpose of testing design
solutions under real conditions, determining production problems, time involved with people,
cost of materials, determining tasks.
e) Evaluation: solution (outcomes)
The evaluation process is the last stage before the client takes possession of the piece.
We should inspect the final piece to make sure that it was built according to the design
specification. It must be ensured that it functions the way it was designed as well as checking
that the finishes match. It is a good idea for the designer if the design cannot build the
 STANDARD OPERATING PROCEDURES

prototypes, should make sure to see the piece when fabrication is done and before the finish
is applied. It is easier and quicker to fix any problems and keep the project on schedule at this
point rather than waiting until the end.

Situation

Evaluation Investigation

Possible
Realization
Solution

05.07. Machine Shop

a) Cutting / Shaping / machining

A work schedule for the next working day will be sent along with the cutting list to the
machine shop by 3:00 pm every day through the supervisor from the production department.
Supervisor will submit a demand slip for raw materials against assigned work to his section.
After ensuring the sufficiency of the raw materials, the supervisor will monitor the machine
operators to complete the work within the stipulated time. Wood, board and ply board are
sent to the machine shop for cutting, shaping, molding and designing with the specific pattern
/ forma on the basis of approved cutting list / manual.

A proper check will be done to ensure quality after finishing the cutting, shaping, molding and
designing work of product components. Dimensions of as per cutting list, shape as per pattern
/ forma, design as approved will be taken in consideration to check the quality. Only quality
passed components will be moved to the Carpentry / framing section to make raw structure
or frame.
Supervisor will input the data [machine to machine cutting / shaping / molding / designing
time, component dimension and component materials] in the product management file.
 STANDARD OPERATING PROCEDURES

b) Process flow chart of Machining:

Machine process for wooden component(s)-

INPUT OF RAW Wood, MDF / MFC / UV / Acrylic / Visual check to ensure useable
MATERIALS PVC / Ply Board size & wastage issues

Visual check to pass cutting

ROUGH CUTTING Industrial Saw Mill
errors

Ruler, Compass, Tri-square, Visual check to confirm

MARKING OUT
Pencil accuracy with Pattern & Forma

Panel Saw, Sliding Saw, Circular Technical check to confirm

CUTTING TO SIZE
Saw, Coping Saw actual size as cutting list

CUTTING TO Band Saw, Stand Zig Saw, Hand Technical check to confirm
SHAPE Zig Saw, Meter Saw actual shape as Forma

PLANNING & Jointer, Thickness Planner, Technical check to avoid

SANDING Moulder Sander, Belt Sander cutting errors

DESIGN,
CNC Router, Copy Router, Hand Visual check to control
CRAFTING &
Router, Moulder, Wood Lathe alterations of pattern
TURNING

Automatic Straight Edging, Technical check to confirm

EDGING
Profile Edging heat, cut, glue uses

BORING & Multi Boring, Drills, Cisel Technical check to ensure drill
DRILLING Mortize hole accuracy with drawing

Inspection of joining and

ASSEMBLING Carpentry
assembly method

c) Support machineries:
i) Power Generator to ensure uninterrupted electricity supply,
ii) Air Screw Compressor / Air Compressor for pneumatic machineries and
iii) Grinder to sharp Blades & Cutters.
 STANDARD OPERATING PROCEDURES

05.08. Carpentry

Carpentry supervisor will receive all quality checked and approved components from machine
shop with product management file. He will handover these components to a carpenter
group or an individual to make a product structure after engraving its part(s).
The assigned carpenter group or individual should submit a demand slip to the store
department through his supervisor for primary hardware needed to construct product
structure.
Raw product structure will be moved with product management file to the coating section
after proper quality check and approval. Measurement of product structure, assemble as per
drawing, nailing and joining issues will be taken in consideration to check the quality / standard
of raw structure.

Carpentry process-

Sturcture
Pattern & Forma Manual Engraving Development, Fitting
& Fixing

05.09. Coating

Carpentry Finished Structure obtained from Carpentry Section will be handover at the
specified site as per the instructions of the Supervisor.

At this phase, the team leader of the lacquer group will collect the chemicals by submitting
the demand list of the required chemicals for the product coating to the store through the
supervisor. In this case, the store section must supply the prescribed quantity of chemicals for
the specific product.
Coating process for Board / Process wood

SANDING PUTTY SANDING BARRIER SANDING

CLEAR BROWN
SANDING SANDING FIBER
SEALER SEALER

LITE
COLOR SANDING TOPCAOT
SANDING

Barrier, Clear Sealer, Brown Sealer, Fiber, Color and Top Coat will be mixed as per proper ratio.
 STANDARD OPERATING PROCEDURES

Coating process for Wood / Veneered Ply

GRINDING SANDING PUTTY SANDING FILLER

LITE CLEAR CLEAR

SANDING SANDING
SANDING SEALER SEALER

COLOR SANDING TOPCAOT

Filler, Clear Sealer, Brown Sealer (if needed), Color and Top Coat will be mixed as per proper
ratio.

If the product lacquering process is completed properly, the section supervisor / staff in
charge will check the quality. When the quality check is passed, it will go to the upholstery
section or fitting-fixing section as required, otherwise this product will be sent to the relevant
group for re-lacquering.

05.10. Upholstery

Upholstery group leader will collect the raw materials such as foam, cotton, belt, jute sheet,
pad foam, adhesive, stapler pin, bit yarn, sewing thread, board paper, fabrics etc. from the
store by submitting demand slip through supervisor.

Frame should be made under the supervision of upholstery group. Webbing is the most vital
part of upholstery process, it ensures the strength of an upholstered product, uniqueness in
padding makes it comfortable and attractive proper covering gives it a noble look.

Process of upholstery

Frame Webbing Padding Cover

The product will be transferred to the packing section for packing or to the carpentry section
for fitting, only if the expected quality is maintained at the quality check stage.
 STANDARD OPERATING PROCEDURES

05.11. Fitting & Fixing

Almost all the products are sent to the carpentry section a second time for final finishing /
fitting. Clear Glass / mirror glass, finishing hardware such as concealed hinges, tower bolts,
glass clips, shelves supports, magnet cases, push magnets, channels, knob, handle, hanger
socket, hanger tube, lock, lock support, wheel, star screw, top screw, nail on glade, 3 in 1, 2 in
1, wood pin, aluminum cap, nut & bolts, support rubbers, l-clams etc. are being used for fitting
- fixing of a product. After fitting and fixing, a product’s quality should be checked by the
assigned production staff, this product will be moved to the packing section when it will be
declared as quality passed product.

05.12. Packing, storing & Delivery

All quality passed products should be wrapped / packed with essential packing materials such
as carton, corrugated sheet, polyethylene foam (PE foam), polythene, gum tape, PP packing
belt and PP belt strapping machine by the skilled worker.

A report of completely finished products (which is wrapped, packed after QC pass) must be
generated by assigned staff and this report will be recorded by store department, means
these products will be counted in finished products inventory.

The store department will deliver only QC passed and properly wrapped and pack products
against any requirement / demand.

05.13. Sales & Service

So far P2P furniture only sells its manufactured products to the central supply chain
department of P2P family. The selling price from the factory of the product is determined by
adding the sell balance as determined by the management along with the material cost,
wages and related expenses.

P2P always pay special attention to the issue of after sales service considering the satisfaction
of the user. A specialized team of carpenters, lacquer and upholstery technicians work to
ensure this service. An experienced officer has assigned to maintain records of customer
complaints and to supervise the activities of this specialized team.
 STANDARD OPERATING PROCEDURES

06. Maintenance Procedure:

06.01. Installation & Observation

Machine will be installed at machine shop as per installation guide provided by the supplier or
manufacturer in the specified place according to the layout. We strictly follow the details
about the tools / equipment, fitting / assembly instructions, belt / wheel / cutter / blade / nail
installation instructions and electrical wiring diagram described in such guidelines to install
machineries usually.
Maintenance personnel will regularly check the vital parts (belt, bearing, switch, motor, blade
or cutter etc.) 0f all machineries and he will take the necessary action to replace or repair any
parts that appear to be defective or inoperable.

The working condition and working capacity of all machineries needs to be reviewed and
recorded regularly, which data will be the reference to calculate the actual production
capacity of Machine Shop.

A 'Machine History Record' will be maintained for installed machineries, including machine
number, machine name, brand, country of origin, model number, date of installation and type
of its work.

06.02. Preventive Maintenance

Production Management will prepare a 'Preventive Maintenance Schedule' for a calendar

year, maintenance check-list and frequency should be defined in this schedule. The frequency
of machine maintenance will be determined as per guidelines given by the machine supplier
or previous experience.

Servicing and maintenance history must be written in the ‘Machine History Record’, and ‘Daily
Maintenance Log’. Cleanliness of machine and machine shop must be confirmed by the
workforce of the relevant shop.

Blade, cutter, spares and accessories related with machine shop will be stored in a tidy and
locked place, only an assigned person will be responsible to distribute these for specific task.

Any machine that is deemed unsuitable for quality production in the ongoing production
process should be advised in writing for maintenance by the operator through the supervisor.
During the maintenance, the work of the machine under maintenance should be done in an
alternative way.
 STANDARD OPERATING PROCEDURES

06.03. Safety Issues

Woodworking machineries – with their moving parts and sharp blades – can be extremely
dangerous if not used correctly. Amputations, blindness and lacerations are common injuries
related to working with these machineries. Although we appoint only properly trained
workers to operate our woodworking machineries, we follow certain safety policies to avoid
any accidents. Employees must follow the following safety guides to avoid injury:

• Wearing appropriate personal protective equipment, including safety glasses or

goggles, a face shield, hearing protection, protective footwear, and gloves. (Note:
Don’t wear gloves near rotating blades and other moving parts, as they could catch.)
• Inspecting equipment before use. Ensure it is properly grounded, guards are in
position, and the keys and adjusting wrenches are removed before turning on the
power.
• Making sure all machines have start and stop buttons close to the operator, and that
start buttons are protected against unintentional contact.
• Keeping all cutting tools and blades clean and sharp.
• Using proper lighting, and ensuring the area around machinery is free from clutter and
spills.
• Having efficient local exhaust ventilation systems to help remove sawdust and wood
chips.

Employees should take additional precautions when using woodworking machines:

• Never wear loose clothing or jewelry, as these items can become entangled in moving
parts.
• Never attempt to clean or dust off a machine when it’s running – use a brush once the
machine has stopped.
• Never leave woodworking machines running unattended.

Further, workers should know that horseplay can lead to injuries and is not allowed –
especially around machinery.

07. Store & Procurement Procedure:

07.01. Requisition & Budget

The store department will prepare an authentic requisition in a printed format for raw
materials / accessories / equipment / services by analyzing the present stock of raw materials
/ accessories / equipment in store. Requisition will be made by deducting stock in hand from
the estimated raw materials / accessories / equipment. The store department will send the
requisition format to the procurement department to prepare a budget (approximate) to take
initiatives to purchase these raw materials / accessories / equipment / services.
 STANDARD OPERATING PROCEDURES

[Note that the Procurement Department should have a fairly good idea about the price of
each item of raw materials / accessories / equipment / services.]

Procurement & Logistics department will submit the appropriately filled requisition form with
budget (approximate) for approval to the assigned authority. Approved copy of the
requisition form will be sent to the Central Supply Chain Department to issue required
materials to the Store.

The requisition of raw materials / accessories / equipment / services must be approved by the
proper authority (assigned by the Management Board of the P2P) and along with the hard
copy, a soft copy will also be reserved in the Accounts and Administration Department for
minimum 12 months to face any internal or external audit(s).

07.02. Receiving, Storing, issuing on demand & Book Keeping

After properly checking quality of raw materials, store department will arrange raw materials
in rakes as they can handle smoothly. As per P2P furniture’s arrangement raw materials will
be located to the specific store. Store department will take necessary action to send back of
canceled (due to quality / quantity issue) items and damaged (due to transportation / date
expire issue) items to the suppliers / vendors as appropriate with proper documentation.
Information of received raw materials will be written in to the Stock Ledger / Register (Manual
& computerized system).
According to the production process of P2P furniture, raw materials has been distributing with
05 stages as per departmental demand against under implementation production plan, which
will be properly approved by the proper authority and all information about issued raw
materials will be written in to the Stock Ledger / Register (Manual & computerized system).
05 distribution stages are-
a) Wood, Board, Ply against the demand of machine shop
b) Primary Hardware against the demand of carpenters to make a raw structure
c) Lacquer Chemicals against the demand of Lacquer technicians
d) Finishing Hardware against the demand of Carpenters
e) Foam / Fabrics / Upholstery accessories against the demand of upholstery technicians

07.03. Preparing raw materials

Since it is purchased raw, wood needs to be prepared before use. Preparing wood means its
treatment and seasoning. The process flow chart of ‘Wood treatment & seasoning’ is as
follows-
 STANDARD OPERATING PROCEDURES

Wood Log Saw Mill

Treatment Chemicals: Boric Acid and Borax Treatment House / Tank

Fire Chamber / Heat Generator Seasoning Ovens

Special Saw machine to Cutting by selected shape Final Product to use

Purchased wood log against requisition will be sliced in saw mill in an operational size, then
these sliced wood will be transferred in treatment house. The house / tank will be made of
RCC and its size will be 7.2 cubic meter [length 6m x width 1.2m x height 1m]. For each
treatment process, 822 liters of mixture has to be prepared, which will require 700 liters of
water, 50 kg of boric acid and 75 kg of borax. 6 cubic meters of wood should be immersed in
this mixture for at least 72 hours for proper treatment.

After the completion of the treatment process, the wood has to be taken out of the tank,
after 12 to 24 hours the water should be drained and lay these wood in the seasoning chamber.
The wood should be seasoned in a seasoning chamber at a temperature of 550 to 600 Celsius
for 120 to 240 hours to ensure its moisture content 9% to 14%. Moisture content will be
measured and confirmed by the Moisture Meter.

Records of treated and seasoned wood should be maintained regularly and reserved for
minimum 12 months by the Store department to face any internal or external audit(s).

07.04. Damage & Wastage Management

Coating chemical and hardware goods can be damaged for date expiry reason or for theft, on
the other hand a small portion of board, ply wood or wood can be wastage for the reason of
cutting, shaping and crafting.
i) Damage component will be treated as outward as per commence and approval of the
proper authority.
ii) Wastage Board, Ply wood, wood and others component will be sold as per commence and
approval of the proper authority.
It is mandatory that all kind of damage/ wastage will be declared by the proper authority and
will be written to the Stock Ledger / Register (Manual & computerized system).
 STANDARD OPERATING PROCEDURES

All demand slips must be dually signed by the production supervisor and production officer /
Assistant Manager / Manger. Hard copies of all records of materials received, returned,
damaged and demand slips should be reserved for minimum 12 months by the Store
department to face any internal or external audit(s).

10. Quality Check Procedure:

Assigned officials will follow this procedure properly to control the quality at different levels
of production of the infrastructure and furniture produced. Exception / misapplication of this
procedure at any level will disrupt the normal production process and its proper
implementation should be ensured by the concerned authorities. Production management of
P2P Furniture usually involves to check and control of quality in six levels.

a) After purchasing the raw material before stocking it

b) After seasoning the wood before delivering it to the machine shop
c) After cutting & shaping of components before provided to the carpentry
d) After making structure before moved to the coating section
e) After coating before fitting & fixing
f) After fitting & fixing before packing & deliver

In the case of quality verification at all levels, the issues that need to be considered on a
priority basis-

i) Visual condition of product accessories / components

ii) Strength of product components / accessories
iii) Dimension of product components / accessories
iv) Consistency of product components / accessories with pattern / forma
v) Engraving accuracy with developed design
vi) Dimension accuracy of entire structure with developed design
vii) Steps of coating process, mixing of chemicals, applying of mixing chemicals
viii) Color Coating & final coating compatibility with sample
ix) Cutting, pasting, sewing & fitting of foam / fabrics
x) Through check for packing

10.01. QC Check-list for Raw Materials

Generally, it should be checked visually that the raw materials quality is up to mark to see and
its quantity is compatible with purchase order. Length, width and thick for wood and board,
size, color and strength for hardware, viscosity, transparency and coverage for chemicals will
be treated as check-list for check quality of raw materials.
If proper quality raw material is not available then action will be taken-
a) Should be moved to another section to prepare
b) Should be returned to the vendor
 STANDARD OPERATING PROCEDURES

10.02. Moisture content check-list

Moisture content of fresh wood should be taken by moisture meter before moved it to the
seasoning chamber and this record must be reserved for calculation in this process. The wood
should be seasoned in a seasoning chamber in a temperature of 550 to 600 Celsius for 120 to
240 hours to ensure a moisture level of 9% to 14%.
Formula to measure of Moisture-
(Wf-Wd) Where, Wf = fresh weight of wood, and
Moisture Content (MC)= X100
Wd Wd = oven dried weight of wood

Moisture content of quality wood

7% 9% 12% 14% 16% 20% 24% 30%

normal borderline high

Fungal growth Fungal growth and potential
No fungal growth
possible @16% wood decomposition

10.03. Machine process check-list

A standard product structure is made up of multiple components, so each component of the

product must be the right size and quality. Only the best components which has been cut and
shaped as per specific pattern and measurement.

Reasons why components will not be considered as quality passed-

a) Unless cut to a specific pattern
b) Unless cut to a specific measurement
c) If the right materials are not cut

10.04. Carpentry process check-list

The product, which design is approved by the management, structure prepared in perfect
measure with proper precision and proper application of technical skills in the design without
any modification of the parts obtained from the machine shop shall be considered as quality
structure only.

Reasons why product structure will not be considered as quality passed-

a) If less than or more than the acceptable size
b) In case of inconsistency of the approved design of engraving with the engraving done
c) If unauthorized patching is seen by intentionally cutting
d) Insufficient chisel work and excessive uses of glue
e) Joint fault & assembly error
 STANDARD OPERATING PROCEDURES

10.05. Coating Process Check-list

A color sample approved by the management must be followed in each steps of coating
process. All kind of colors, filler and fiber are the mixtures of two or more chemicals, mixing
ratio of chemicals will be approved by the management. Every sanding steps should be
checked to control the quality.

Reasons why products coating will not be considered as quality passed-

a) Ups and downs, uneven or scratches due to insufficient grinding and sanding
b) Flying dust on surfaces
c) Uneven joints and nail heads due to insufficient / uncontrolled use of putty
d) Color difference between components used in a product
e) Cloudy final coat

10.06. Upholstery, Fitting Process Check-list

Reasons why upholstered products will not be considered as quality passed-

a) Sewing fault
b) Incompatibility of manufactured products design with approved design

Reasons why fitting completed products will not be considered as quality passed-
a) Any kind of fitting error
b) If the coating is injured at the stage of fitting