How much waste is okay?

Joe Dellert CPF

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Joined
Jan 25, 2002
Posts
48
Loc
San Francisco
I am getting so tired of the declining quality of mouldings I buy in length. I recently recieved a shippment of 100' of a particulair profile of which there was a net yeild of 45' usable feet. Yes I am going to ream the supplier for not checking before they send out their product but I am beginning to feel like my employees are working for their quality control dept. I would go after one company or drop them but this seems to be indemic to our industry. Is there anything we can do to help this situation? I have received wrapped scratched and dented moulding from La marche, Larson, Roma, ..... I stock alot of length moulding but I makes me shy to continue if I only find the problem months later when we hit that deep in to a profile. What are your experiences and ideas? I don't think my customers would like to hear that this is the best that the company could send us, maybe you should hang it on a corner to take advantage of the unique wrap of your frame. Arrrgghhh!!!!!
 
I know length can be more profitable - if you can turn it - but you reach a point where chop can be a much better deal.

Assuming they do a better job of inspecting that.
 
We can't inspect everything as it is delivered, but we try to and reject substandard materials. I do get most of my mouldings from Larson. Several reasons for this but a big one is they have never quibbled over prompt replacement.
 
I don't mean to stradle the fence, but I think there is two sides to this situation.One is in favor of the Shops.In my days as a shipping clerk for GM ,there was a condition that most vending companys accepted resposibility for ,it was HIDDEN damge. It was when you opened a package that showed no signs of distress and found damaged material. If it had torn packageing then it could be the fault of the carrier. However in this case that would most likely be the Supplier. So they should accept reposibility.What amazes me is when there is no obvious packing damage and there is already a sticker allowing a "FOOT" inside the wraper and then there is clearly much more wrong with the stick. Quality control is very obviously insufficent at these suppliers and there is ways to let them know your displeasure as well you should.
The second favors most of the suppliers .The GOOD suppliers will eagerly correct the situation "after the fact" if it is brought to their attention. If the main office or warehouse won't cooperate call your REP. I'll bet He/She doesn't want to loose your business and will make things right.
If all else fails ,there is a lot of suppliers and not all of them disregard wellfounded complaints.
BUDDY
 
We add an additoinal .25 to our markup to cover flaws & waste. IE if your markup is 5 times on length make it 5.25. I don't feel that I have to make a profit on waste, but i don't want to lose money on it ether.
 
My employee just pulled two orders today that she could not complete due to junk moulding sent out from Roma and Studio Moulding. She claims this seems to be happening all the time now.

West coast is another vendor she says she been having problems with. Her opinion is that due to the slowdown in our industry, distributors have not been purchasing as much and are now rooting through the bottom of the barrel to fill orders. I tend to agree with her.

I also feel that distributors just don't give a darn what they ship. Sometimes they will get away with it because framers can cut around flaws to fill their orders. The complaints or returns don't warrant not shipping junk. If they ship out ten bad sticks, get complaints and returns on four, they are ahead of the game.

Nothing will change until they actually see their bank accounts dwindle.

John
 
In my experience there are too many reasons for damaged moulding, but 2 of my favorites:

:UPS throws a stack of tires on top of the package (I saw it happen) :mad:

:"that's been in the warehouse a long time, it might be warped" :rolleyes:

Decent vendors should work with you on these problems. I had a consistent problem with a particular mldg from D**** and was ready to drop the entire line. I was lucky to get 50 usable feet out of 100 feet. The rep stopped by and we negotiated a better price because of above-average waste. :cool:

LJ, Roma and Nurre Caxton have been nothing but terrific regarding taking back bad chops or credit on shipping-damaged stuff.

I have to agree with Ron on length vs chops. I think many shops automatically buy length for the cost savings. We buy about 50-50 chops vs length, and price accordingly to factor waste. But what do you do with the $5000 worth of cut-offs and shorts you accumulate over the course of a year?? Unless it's a bread and butter mldg (and there aren't THAT many of them)I'd rather price according to chop price and put the $5000 in my pocket :D

[ 11-13-2003, 05:20 PM: Message edited by: AWG ]
 
Simple solution...

Charge as if you were buying chops and buy length.
 
I haven't purchased length in two years and I don't miss it at all. Far too much time was spent inventorying it, unpacking it, inspecting it, and returning it than it was worth. Not to mention the extra space, and the equipment, it consumed (1000 sq. ft) for which I was paying. I sold length for a fairly long time. The problems you are experiencing are nothing new. I can remember sending back about 25-30% of a couple of orders from two different vendors several years ago. Alot of these mouldings are imported. The vendors are not going to unwrap it, inspect for you, and re-wrap it for shipping. Why do you think length costs less than chop?

You won't get perfect chops sometimes, either. But I look at it this way-I am paying extra to have someone else stock and cut the moulding. The flaws, warps, dings and mis-matches are their problem.
 
Excellent Pam. Also, keep in mind that the quality of wood, overall worldwide is getting worse. Old growth timber is not available anymore so your seeing more finger joined materials, mdf and polystyrene. Most manufacturers will tell you that the quality of the wood they get now compared to even 10 years ago is astonishingly BAD.
 
I was told by an industy insider (makes me sound pretty important huh?) that this problem is direct result of our economy, and rising wood prices. As the economy slowed our suppliers kept trying to find new ways to keep costs low, so many of them have renegotiated with the manufacturers, and cut corners on finishes and wood substrates. This has kept their prices low, but at the expense of the quality of the final product.
We use mostly LJ because even though they are (in my opinion) using the same tactics, their quality, as well as their service, is superior to most on the market.
 
PS. As to the original question, "How much is too much?", it depends on what type of moulding you are using. If it is a cheapy, then expect problems, but if it is a nicer moulding, accept no flaws. At two or three dollars (or more) a foot, you should be able to use all you were charged for.
 
Well thank you elframo for getting the point. If I am being billed by the foot I expect to be able use the feet. Waste in this industry used to be called gravy. If we efficently use a ten foot stick that was dedicated to job leaving a usable short that actaully gets used it was gravy. Now it seems all the gravy is going into the trash giblets and all. It must be getting near thanksgiving. What this situation has lead me to do is what I call choplength buying. I gather my chop orders round to the nearest feet and order only that much. This allows my staff the chance to inspect the order in a timely fashion, which is probably why I am so perturbed since each week I get the flaw review from Joiner. Yes I could order chops and I do judicously but that locked into bad cuts in flawed moulding usaully.
 
Most frame moulding suppliers that I have dealt with has somebody somewhere inspect their lines of mouldings. Either at the mfgr's plant or at the warehouse (if the moulding isn't wrapped) somebody has to look at it to put those little white stickers on the moulding. And, if I find a flaw or more that wasn't caught, I either call for a replacement chop at no charge or I save the flawed portion for the next visit of my rep.

It is extremely rare for a flaw of 1' actually cover an entire foot! It is usually a flaw in the finish or a knick or an outrun of the moulding machine, but most times the actual flaw is so tiny that you only lose maybe a few inches or so. I have dealt with LJ for years and have had many unmarked flaws and they were good for replacements on all of them. That goes for the Williamson Company too. So far, I have found only 2 unmarked flaws in any moulding I have ordered and now I am dealing with 11 distributors instead of 5. I may be proved wrong as my orders become larger but I have had good luck all along with getting flaw moulding credited or replaced.

Framerguy
 
Well framerguy we definitely see things differently. When I see those love white stickers I see that they are approving of the flaws. what really urks me is that they put a sticker for one foot allowed two feet from the end of a stick. Which way does the foot go toward the end or toward the middle, either way it looks to me that the minimun allowance should be two feet since the odds of my being able to use that one foot at the end is unlikely. It is especially annoying when you were counting on a continous 4 feet to make a leg of the frame you're building. Besides I have found that the allowed stickers are not always deducted from the total shipped. Granted they do take them back but my whole rant is about my staff becoming the quality control dept for the moulding companies. Oh what I could do with the extra production time? Maybe even make money.
 
Joe I have to agree . I too find that while the flaw is usually ,As tom points out, Just a small ding of less than an inch normally the replaceing FOOT isn't ever in the right place. If what you need is a leg that is say 3 feet or more long and the flaw occcurs a foot or two from the end what goood is a foot.
However My previous statemnet was about the fact that even when the stick has one of these GENORUS foot compensations there frequently is even more dings, dents and flaws that aren't event caught . further more there are no tares or rips in the wrappings so this most likely occured at the manufacturer.
I do as suggested save these overights and give them to my reps . However what good does that do when the frame is due to the clent before the rep 's vist is scheduled? and even if they come at the same time I still have to wait for a re-delivery.
make no mistake ,i appreciate the attempt to correct the problem and I realize that everyone is human and we all make mistakes. However the place to correct and control this problem is at the manufacturer and their quality control. But it seems there really isn't any control being exercised.
it seems like the old adage "we don't have time to do it right the first time,but we sure can find time to do it several times."
BUDDY
 
I agree that quality control should start with the manufacturer, and that it should be "control", not merely a report of the statistics. And if there is a distributor involved they should also have a hand in maintaining that quality.

That said, there is a point of diminishing returns. If you want me to supply you with 100% useable material 100% of the time, you are going to have a calf over the price. It's a matter of balance, and consistency in that balance once accepted.

Believe me, we have seen the same type of problems with the suppliers of our lumber. In our case it is somewhat dependant on the world market. To simplify things, suppose that a board is allowed one knot to meet the grade. During "good times" five out of a hundred boards has that one knot. But when demand begins to exceed supply, not only does the number of boards with knots jump to fifty out of a hundred, but you may find a board or five that have two knots. C'est la vie.

The solution for us has been to find suppliers who are willing to take on a partnership-like relationship with us, realizing that what's best for one is what's best for the other, in the long term. Similarly, we have attempted to extend ourselves in the same partnership to our customers. We have found it to be very helpful in maintaining a happy and profitable (if not overly large) business. That is not to say that in the above example we have demanded that our supplier keep our ratio of boards with knots to five out of a hundred, because we understand that doing so would not be in their best interest just as they understand it's not in our best interest to get the "run-of-the-mill" material that has the fifty out of a hundred. So we work with each other and try to strike a balance. While we've never gotten this far, the ideal solution is to work together as if you are sister companies reporting to the same headquarters.

Sorry to ramble on, hopefully you get the gist of what I'm trying to say, cause I can't say it any better.

Edit: I just want to clarify that in our case I am referring to the quality of material, not the machining or finishing, which the manufacturer or anyone downstrean who handles the material has control of.

[ 11-20-2003, 03:38 PM: Message edited by: David N Waldmann ]
 
David your last comment "Edit: I just want to clarify that in our case I am referring to the quality of material, not the machining or finishing, which the manufacturer or anyone downstrean who handles the material has control of."

Is precisely the type of flaw I was refering to. I fully understand the ONE who makes the trees and there by controls the knots and grains isn't subject to any quality control.LOL
However the scratches chips ,uneven colorations and the like are exactly what i would think "Quality control" is used to catch. Therefore when I see one sticker allowing an extra foot for a small ding ,but then I find others that aren't compensated for I get even more annoyed then when the extra footage doesn't take into accont that the flaw is where he rest of the moulding doesn't leave a useable amount of footage.
And as far as paying extra for the control--WHY? Aren't we entitled to all the advertised footage being useable? Are am I misunderstanding the priceing method? But then How would anyone know what to expect to pay ,since there is no telling how much undetected flaws may come in a given stick which we thought included ALL 8-10 feet. Which is another sore topic. Why can't we be told exactly what to expect in a given stick(Not counting any compensations for flaws)?
BUDDY
BUDDY
 
IT'S WOOD. It's soft. It dings before, during and after wrapping, during shipping, during handling in the shop. Waste is a part of dealing with molding.

As much as I'd like perfect molding, each and every time, I don't think it is reasonable 100% of the time. The vendors (mfrs and distributors)have a resposibility to provide the best molding they can - and I think that in the majority of cases (at least with responsible and respectable) vendors do just that.

I've never had a rep refuse to take back bad molding, sometimes even after I've chopped it. I've had vendors ship me new stuff overnite at their cost for a bad chop. Maybe it's part of having a good relationship with your rep - the previous owner didn't always. We've made it a point to work with our vendors to create positive and equally rewarding realtionships with our reps.

Just my 2 cents . . .

PS - We don't carry Vermont Hardwoods (maybe we should) and not an apologist for them - just being realistic.
 
Buddy: It is understanding when the flaw occurs within the last two feet of a stick and that it is not usable for a particular rail. However, as was pointed out earlier in the topic, the manufacturer typically give a 1 foot allowance for a 1" or less flaw. Because most sticks are wrapped at the factory and not unwrapped by the distributor before shipping to the framer, the distributor doesn't know where the flaw is. You should only be charged for the amount shipped. If you order a 10' stick and there are two flaws that have a 1' allowance, you should only be charged for 8'. Chances are 9' 8" of the stick is usable. If your suppliers are not doing this then you really need to talk to them.

This discussion has come up a number of times. Chop buyers pay more, but the distributor is eating the waste. Can't have your cake and eat it too.
 
Originally posted by BUDDY:
And as far as paying extra for the control--WHY? Aren't we entitled to all the advertised footage being useable? Are am I misunderstanding the priceing method? But then How would anyone know what to expect to pay...
I'm not suggesting to pay extra for quality control. I was referring to providing 100% useable sticks 100% of the time as opposed to paying for what is useable. Paying for what is useable sounds like a reasonable method, although it is not one we use. (we charge for every foot we ship, whether you can use it or not. The reason we get away with that is there is very little that is unuseable, and our customers have accepted the product at the price).

What is not reasonable, IMHO, is to expect 100% good material 100% of the time, regarding either material or finishing. If the manufacturer/supplier were to provide it at "normal" price they would be out of business in no time, and if they charged what it would cost no one could buy it.

While there are, no doubt, those companies that "gouge" their customers by providing a product at a price point that is not justified by the quality, they will not stay in business long. There is no great mystery to the production of moulding. Everyone has the same parameters to work in. It's a matter of deciding what you want to offer, and charging a fair price for that particular product. If you charge too much you won't sell it and if too little you run out of cash. Set expectations and keep them. If the customer is not satisfied they go elsewhere.

Originally posted by BUDDY:
But then How would anyone know what to expect to pay ,since there is no telling how much undetected flaws may come in a given stick which we thought included ALL 8-10 feet. Which is another sore topic. Why can't we be told exactly what to expect in a given stick(Not counting any compensations for flaws)?
BUDDY
I can only speak for ourselves, and as I understand, we're a little different. Maybe even wierd. There are two factors.

First and simplest is that trees are all different, and we want to use as much of them as we can (again, I speak for ourselves - some people could care less). Because of that, when a tree is felled the logs are made as long as possible. That means that there are logs anywhere from 6 - 16' long (in the US). Since the majority of our customers are relatively small- medium length buyers (less than 1000'), UPS is the most cost effective shipping method. UPS has a maximum package size of 108", so we buy predominantly 8' lumber (which, by industry standard includes 6' & 7' as well). So before we even get started we have random lengths. Emphasis on random - there is absolutely no pattern.

Then there is the manufacturing variable. Sure, we can go the route where what we get is what we ship (and have the random 6', 7' & 8' lengths mentioned above), but we don't choose to go that route. We don't see the point of shipping stuff that can't be used - it costs you more money for freight, you need more storage space, and you get frustrated with all the stuff you have to throw out. So first we throw away those pieces that we deem are too crooked or discolored to be of any use (actually, we sell the less-bad ones as seconds), then we cut back defects that are within 18" of the ends, and any discolorations that are at the ends.

However, our business premise is one that relies on customers that don't really care how much it costs, they just want good stuff. This is because we have selected a market (OK, so it selected us - we're still learning about control) that builds predominantly very large frames for people with lots of money. This goes back to the first part of what I said about deciding what you want to do and selling that product at a fair price - fair to both parties or it's not fair.
 
Sorry for the misunderstanding that I am obviously causeing. I have ABSOLUTELY no problem with David nor his company. Infact the reason I quoted his EDIT was I thought it made the very point i was makeing . Furthermore it didn't set the blame with the vendor.
Most of my disagreements stem from someone just not wanting to be bothered with the small stuff(Cheking the moulding completely before it is wrapped at the source,and telling consumers the length if a stick "VARIES" when they are less then Bundle puyers).
Iagree MOST Suppliers I deal with and All of my reps are very cooperative when it come to replaceing a damaged moulding. What I am trying to suggest is a way that both they and I can avoid this problem,and it starts with the MANUFACTURER and their QUALITY CONTROL and accurate measurements even when dealing with just ONE stick.
I hope I have cleared up any seeming insults at David and Vermont Hardwoods or any other parties who don't deserve them.However I have long bristled at those that would say that unless I buy in bulk I should only buy chop .Why ,if this is true ,do my suppliers advertise and sell single stick lenghts, and don't the rest of the framers feel even the smallest purchase should receive the same treatment as a bulk purchase?
BUDDY

[ 11-21-2003, 11:13 AM: Message edited by: BUDDY ]
 
Buddy,

I took no offense at what you said, I was just trying to make sure my point was clear, because your response made me wonder if I had been. As you said, it comes down to a relationship between a particular supplier and a particular customer. If you can't agree you can't do business.

You know, after all this, I wonder if Joe's question ever got answered - "How much waste is OK?" my answer - "How long is a piece of string?". It depends....
 
Daivd
Thank you for answering my question. I will answer the next myself. If i have to spend my whole day calming own staff over efective prouct and calling companies for replacements then how much shoul I charge for that companies moulding? Maybe 20 times chop price that way I will never sell it and then I won't have the problem. How long is my patience about as long as that string you mentioned. These flaws in materials have very real costs associated with them and it can hurt this industry greatly if we allow it to pass on to our clients in anyway. "i'm sorry miss Jones your $10000 810 frame has an inherent to the manufacturing flaw that can not be helped here is the number of my sales rep if you don't believe me."
 
Joe,

I'm sorry if I came across as being callous or sarcastic. It was not my intent, as I thought that the thread up to this point was pointing to that very fact, without actually saying it.

I think it does depend.

If you're paying $50/foot for length moulding you should expect 99% yield. If you're paying $0.20/LF for moulding(?!!), don't be surprised if you have 50% waste.

However, you have final control and say in what is acceptable, because you are the customer and the customer is always right. You may not happy, because you have a hard time finding something that is acceptable to you, but you are right. You may have to change your expectations if no one can provide a satisfactory answer, because happiness is dependant on meeting (or exceeding) of expectations.
 
David
I apperciate your point of view and actaully agree with it to an extent. Our shop use to specialize in .60 mouldings and at least a third went into the trash bin. I figured that the moulding actaully cost .90 with all the waste, so I have been ordering more moulding in the 2. to 3. range with expectation the yeild would be better. I have been able to sell the fancier moulding but there is still a good 25percent loss, that hurts the old profit margin. over the summer I had a run in with a different hardwood company in colorado that told me the 33 percent loss on a 1 3/4 walnut moulding was the best I could expect, That seem like a lot of wasted lumber to me. So that is little background to my rant,but your are perfectly correct about happiness I hold high expectations and they are often not met but that is what keeps my customers expectations satisfied and my business cugging right along in this weird economy. Have a happy Thanksgiving.
Joe
 
Joe and David ,I have been following this thread for a while. I must admit that I must expect TOO much. Because If I were told to expect 25 to 33% waste on any moulding regaurdless of the price range I'd be looking for another supplier.
In all fairness I belive that David has said that his products are much better controled but do cost a bit more per foot.
However I can't help but remember an old addage that my Carpenter Father used to tell me when ever I was working (Or attemping to ) with him.It was ,"If the job is worth doing then it's worth doing RIGHT or don't do it at all".From this I would advise any manufactureer to control the quality of his product to a reasonable amount of flaws(25-33% ain't near any control).This is regaurdless of the price (.60-2.00-3.00 /ft.) the price is set by the Vendor and if he can't make a good product for that price WHY in the He ll is sticking the buyers with this sustandard stuff instaed of " makeing something worth doing"? Unless he is just doing shabby work and trying to sell it for less because it's the only way it will sell.
I may be cheap or dumb but if I am offered .60/ft. moulding I expect the waste factor to be the same % as the high price stuff,the differance should be in the quality of the type of wood and the finish that is applied ,not the number of Knots or the amount of scratches in the finish,and definetly not he number of these problems that the Manufacturer catches or admitts to.
Charles BUDDY Drago CPF®
PS after all We can always buy discontinued and flawed mouldings at discount sales and closeouts from most moulding suppliers when they want to get rid of substandard or real slow moving stuff.

[ 11-27-2003, 08:57 PM: Message edited by: BUDDY ]
 
If a framing supplier expects a frameshop to eat a 25%-30% loss on frames, then they should not mind if a frameshop only pays them 25%-30% of their out standing account. I agree with some of the other post that this is not exceptable. We have enough wastage from being over shipped on footage that becomes unuseable.
 
Ireland
+ or - 5% on length shipping only…..full credit on all unusable moulding over and above this, supplier picks up return shipping…….what are you guys nuts….25% to 30% wastage……..if you are buying into that that sort of deal……some one is doing a great sales job on you……..I have being in business for over 30 years in a number of different business areas and I have never come across anything like that sort of deal…….even raw food suppliers don’t expect you to eat that sort of wastage.


Dermot :rolleyes:
 
AWG; I think your point is off the point.LOL There should mot be 25-30% waste on any lenght purchases. 1 stick or a bundle that is excessive. It almost sounds like some vendors are trying to make us do exclusively chop business.
The only justification for that is that they know they can't use that stuff when they fill chop orders so they lump it into the LOW PRICED length orders and tell us that the price dictates that amount of waste.
Maybe you're right ;lets only buy that stuff in chops and then I wonder what the supplier will say about that amount of waste?LOL after all their saying only the High End stuff doesn't have that amountof waste,so that is OK to buy in length .Yeah right.LOL
BUDDY
 
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