Foundations in Woods Manufacturing

• Recognize and practice safety behaviors within a lab setting.
• Demonstrate accuracy and correct use of a tape measure and other measuring tools.
• Create accurate drawings based on measurements and design requirements.
• Develop a Bill of Materials for a cabinet project.
• Design parts layout using principles of orientation, accuracy, and grain direction.
• Identify species of lumber and manufactured wood products and their uses.
• Use a variety of electric and hand-powered tools and equipment to create cabinet components.
• Demonstrate competency through a certification process on the following equipment: table saw, power sander, miter saw, band saw, routers and drill press.
• Demonstrate basic woodworking techniques (e.g., sanding, glue-up, assembly).
• Define basic woodworking terminology.

1. Introduction & Safety

Outcomes

• Recognize program philosophy, expectations, employer perspective.
• Describe and adhere to woodshop protocols and practices.
• Identify unsafe acts.
• Explain how to reduce or eliminate hazardous conditions around machines and equipment.
• Handle and store materials properly.
• Name various types of fire protection equipment.

Assessments

Formative:

• Safety organizer
• Class discussions
• Safety inspection activity

Summative:

• Safety quiz

2. Measurement

Outcomes

• Identify measurements up to 1/32 on tape measure.
• Add, subtract measurements (fractions, decimals).
• Explain relationships among numbers, reductions.
• Demonstrate accuracy and correct use of measurement tools.
• Explain the importance and relevance of measurement skills in the workplace.
• Demonstrate three measurement skills required to master: 
  • Names of marks
  • What the marks mean
  • How to use them

Assessments

Formative:

• Measuring tool data collector
• Measurement flashcards
• Decimal flashcards
• Measurement pre-test 
• Scale drawings

Summative:

• Measurement test

WCA Standards:

• Given material with a minimum of 5 marks to measure, one each on some multiple of 1/32”, 1/16”, 1/8”, 1/4”, and 1/2”, with at least 1” separation between each mark, and tape measure calibrated and ready to measure, determine the length of each mark from the end of the board. (L1)
• Given material and tape set up and ready to measure, determine the size of an inside opening within the range 12” to 48”. (L1)
• Given material and device set up and ready to lay out, determine the size of a (12” x 48”) board, then distribute two 3/4” spaces (such as shelves or dividers) evenly within the length. (L1) 

3. Drawing Basics

Outcomes

Thumbnail

• Describe purpose, components of a thumbnail drawing.
• Draw accurate illustrations based on measurements and design requirements.
• Define measurement terminology (e.g., width, height, thickness/depth).
•  Use measurement symbols and terminology on drawings.
• Explain the relevance of using thumbnail drawings in the workplace.

Working Drawing

• Describe difference between thumbnail and working drawings.
• Draw accurate illustrations based on measurements and design requirements.
• Define measurement terminology (e.g., width, height, thickness/depth).
• Use measurement symbols and terminology on drawings.
• Explain how separate components fit together to make a complete rendering of a cabinet.
• Explain the relevance of using working drawings in the workplace.

Parts Takeoff & Bill of Materials (BOM)

• Describe and demonstrate the process of Parts Take Off in preparation for a Bill of Materials.
• Identify names of parts and materials within a project.
• Determine measurements and numbers of components needed for a project.
• Complete a Bill of Materials for a cabinet project.
• Explain the relevance of using a Bill of Materials in the workplace.

Assessments

Formative:

• Drawing basics organizer
• Drawing exercise #1
• Bill of Materials activity

Summative:

• Final Bill of Materials

Skills USA Standards

• 4.0 Design and layout
• 4.1 Determine materials from a blueprint
• 4.2 Draw detailed plans
• 4.3 Estimate labor and material costs
• 4.4 Sketch shop plans

4. Plywood Basics

Outcomes

• Define various wood characteristics (e.g., grain, types, species) and terminology.
• Identify differences among different wood samples.
• Identify the structure of plywood.
• Identify the structure and properties of hardwood, MDF, OSB, chipboard, and composite sheet goods.
• Identify grading used for hardwood and softwood plywood.
• Describe the materials found in each category of manufactured panel products.
• Explain the uses of various panel products.
• Explain how knowledge of plywood basics is relevant to woods manufacturing. 

Assessments

Formative:

• Plywood basics organizer

Summative:

• Student presentations

5. Parts Layout

Outcomes

• Identify dimensions on a large piece of wood.
• Create lines and shapes using a rule or T-square.
• Describe wood grain and explain the importance of positioning.
• Design parts layout using principles of orientation, accuracy, and grain direction.
• Demonstrate geometric understanding of multiples and which cuts to make first.
• Describe how skills used in parts layout (e.g., efficiency, accuracy) are important in the workplace. 

Assessments

Formative:

• Manufacturing the carcass organizer
• Template development
• Guided practice

Summative:

• Parts layout rubric

WCA Standards:

Combination Square

• Given 3 pieces of material 3/4” thick, 6” wide, and at least 12” long, with the end of one piece cut slightly out of square (about 1/2”) to the long edge, and tool set up and ready to measure, and/or calibrate, check the end of each piece of material for squareness; or given one piece of 12” panel stock, verify if it is square or out of square.
• Given material of uniform width and thickness and tool set up and ready to layout, make marks around a 3/4” x 4” S4S (Surfaced 4 Sides) board (all 4 faces) for a 90° cut.
• Given material and tool set up and ready to measure and/or calibrate, mark 3/4” x 4” by any length stock for a 45°cut across the wide face of stock.
• Given material and a combination square, lay out a 3/8” x 2” mortise, centered on the edge  of a piece of milled stock, 1/2” from the end of the stock.  

6. Sanding & Assembly

Outcomes

Gluing:

• Differentiate between various types of adhesives.
• Apply selected adhesives properly.
• Assess the strength and other properties of various adhesives.
• Identify a variety of clamp types.
• Use and adjust selected clamps.

Sanding:

• Follow proper safety procedures for operating portable power sanding tools.
• Use hand and power abrasive tools to remove tool marks.
• Identify parts, adjustments, and uses for orbital, random orbital, and air sanders.
• Install abrasive material properly in sanders.
• Select correct abrasive for the required use.
• Maintain proper shape of the workpiece by not rounding corners or sanding through veneers.

Assessments

Formative:

• Manufacturing the cabinet organizer

Summative:

• Parts layout and sanding & assembly quiz
• Cabinet assembly rubric
• Sanding rubric

WCA Standards:

• Given material and machine set up to operate, sand part(s) through specified sequence of progressively finer grits. (L1)
• Given material and machine set up and ready to operate, sand a solid wood panel with a portable belt sander. (L1)
• Given material and machine set up and ready to operate, sand a veneer panel with a portable belt sander. (L1)

Skills USA Standards:

• 2.0 Assemble, fasten and install components
• 2.1 Apply clamping devices 
• 5.0 Finish surfaces
• 5.2 Clean surfaces
• 5.3 Remove excess glue
• 5.4 Sand surfaces

7. Manufacturing the Face Frames and Drawer

Outcomes

• Measure and cut face frames for the cabinet front.
• Attach face frames to cabinet.
• Glue and nail the face frames to the cabinet front.
• Explain the concept of “tolerance” in woodworking.
• Measure and calculate drawer specifications.
• Layout and cut drawer components.
• Assemble drawer using various joints.
• Create an “outside mount” drawer front.
• Mount the drawer front to the drawer.
• Sand the drawer components.

Dry Fit / Glue Up:

• Identify types of clamping devices.
• Select clamps to assemble various joints.
• Protect workpieces from clamp damage.
• Explain the procedure for assembling your products with clamps.
• Identify adhesive characteristics that affect the assembly time and strength of your product.
• Describe the proper application of adhesives.

Sanding:

• Identify and select abrasives by type and grit size.
• Use abrasives by hand.
• Operate various portable and stationary power sanding machines.
• Inspect surfaces ready for product assembly or finishing.
• Maintain electrical and air-operated power tools and machines.
• Select abrasive materials for smoothing surfaces.
• Identify the major natural and synthetic abrasive materials.
• Choose abrasive grain type and grit size. 

Assessments

Formative:

• Manufacturing the drawer organizer

Summative:

• Manufacturing the drawer rubric
• Sanding rubric

Skills USA Standards:

• 3.4 Cut face frames
• 3.2 Cut drawer front, sides, back, and bottom

8. Manufacturing Cabinet Tapered Legs

Outcomes

• Identify materials, tools, and procedures used to make tapered legs.
• Follow proper safety procedures for operating equipment.
• Use a jig to make cuts for tapered legs.
• Describe how geometry and measurement skills are used to make a tapered leg. 

Assessments

Formative:

• Manufacturing tapered legs, door , and table top organizer

Summative:

• Sanding rubric
• Tapered legs rubric

WCA Standards:

• Given material, taper jig, and machine set up and ready to cut, cut a taper to specifications. (L1)
• Given a jig, safely taper four pieces to given specifications. (L2)

Skills USA Standards:

• 2.9 Reinforce joints with block/dowel

10. Manufacturing the Door

Outcomes

• Identify hinge types for mounting doors.
• Follow proper safety procedures for operating equipment.
• Use a jig or template to cut parts for a door.
• Describe how geometry and measurement skills are used to make a cabinet door.

Assessments

Formative:

• Manufacturing tapered legs, doors, and table top organizer

Summative:

• Sanding rubric
• Manufacturing the door rubric

11. Manufacturing the Table Top

Outcomes

• Identify materials used to make cabinet and tabletop.
• Follow proper safety procedures for operating equipment.
• Use a jig or template to cut parts.
• Attach a one-piece top with glue blocks, joinery, and mechanical fasteners.

Assessments

Formative:

• Manufacturing tapered legs, door, and table top organizer

Summative:

• Sanding rubric
• Manufacturing the table top rubric

12. Final Evaluation

Outcomes

• Recognize and practice safety behaviors within a lab setting.
• Demonstrate accuracy and correct use of a tape measure and other measuring tools.
• Create accurate drawings based on measurements and design requirements.
• Develop a Bill of Materials for a cabinet project.
• Design parts layout using principles of orientation, accuracy, and grain direction.
• Identify species of lumber and manufactured wood products and their uses.
• Use a variety of electric and hand-powered tools and equipment to create cabinet components.
• Demonstrate competency through a certification process on the following equipment: table   saw, power sander, miter saw, band saw, routers and drill press.
• Demonstrate basic woodworking techniques (e.g., sanding, glue-up, assembly).
• Define basic woodworking terminology.
• Complete the cabinet casework with required components at a satisfactory level.

Assessments

Formative:

• All module organizers
• Student presentations

Summative:

• Final cabinet evaluation rubric
• Final exam

A. Table Saw

Outcomes

• Demonstrate tool protocol.
• Set the table saw for making straight or curved cuts.
• Discuss the proper operation of a table saw.
• Follow proper safety procedures for using the table saw.
• Identify adjustments and tooling associated with the table saw.
• Identify the properties of rip, crosscut, combination, and dado blades.

With the instructor or approved proxy, demonstrate on a table saw:

• Machine hazards and lockout/tagout procedures
• Proper adjustment of blade height
• Proper adjustment of throat plate
• Calibration of fence
• Calibration of miter gauge
• Check for squareness
• Minimum width of rip without push stick
• Dry run of rip (proper hand and standing position)
• Dry run of narrow rip (proper hand position, use of push stick)
• Dry run of miter gauge (proper hand position)
• Use of fence as a length stop (offset block)
• Use and adjustment of the fence
• Clean and accurate cuts at proper angles
• Accurate measurements according to plan and specifications
• Proper cleanup after use and at end of the day 

Assessments

Formative:

• Table saw organizer
• Guided student practice

Summative:

• Table saw quiz
• Table saw competency checklist & certification (demonstration)

WCA Standards:

• Given material with one straight edge and machine set up and ready to cut, rip material to a specified width (> 4”) using the fence. (L1)
• Given material with machine and necessary fixtures/jigs set up and ready to cut, crosscut both ends of the stock using a miter gauge or similar accessory perpendicular to the adjacent edge, to yield a specified length. (L1) 

B. Portable Power Sander

Outcomes

• Demonstrate tool protocol.
• Discuss the proper operation of a portable power sander.
• Follow proper safety procedures for using the power sander.
• Identify adjustments and tooling associated with the power sander.
• Explain how to choose sandpaper grit for a given application.
• Operate  a power sander correctly.

With the instructor or approved proxy, demonstrate on a sander:

• Tool hazards and proper care
• On/off switch
• Speed adjustment
• How to choose sandpaper grit for a given application
• Lubrication requirements
• Dry run of start/stop
• How and when to change abrasive
• How to store tool when not in use
• Use of sander on a piece of wood or panel

Assessments

Formative:

• Portable power sander organizer
• Student guided practice

Summative:

• Power sander operation and safety procedures quiz
• Portable Power sander competency checklist & certification (demonstration)

WCA Standards:

• Given material and machine set up to operate, sand part(s) through specified sequence of progressively finer grits. (L1)
• Given material and machine set up and ready to operate, sand a solid wood panel with a portable belt sander. (L1)
• Given material and machine set up and ready to operate, sand a veneer panel with a portable belt sander. (L1) 

C.  Miter Saw and Measuring Machine

Outcomes

Miter Saw:

• Demonstrate tool protocol.
• Set the miter saw for making straight or square angled cuts.
• Discuss the proper operation of the miter saw.
• Follow proper safety procedures for using a miter saw.
• Use a tape measure to mark cuts.
• Identify parts, adjustments, and tooling associated with the miter saw.

Measuring Machine:

• Follow proper safety procedures for using a measuring machine.
• Set the machine to cut several pieces to the same length.
• Identify parts, adjustments, and   tooling associated with the machine.

With the instructor or approved proxy, demonstrate on a miter saw and measuring machine:

• Machine hazards and lockout/tagout procedures
• On/off switch – saw and measuring machine
• Enter length of required cut (fraction) on the measuring machine keypad 
• Dry run of miter cut
• Dry run crosscutting a board
• Calibration of the length stop
• Laser on/off switch
• How to change the tooling
• Clean and accurate cuts at proper angles
• Accurate measurements according to plan and specifications
• Proper cleanup after use and at end of the day

Assessments

Formative:

• Miter and measuring machine organizer
• Student guided practice

Summative:

• Miter and measuring machine quiz
• Miter and measuring machine competency checklist & certification (demonstration)

WCA Standards:

• Given material and machine set up, cut stock to specified length. (L1)

D. Drill Press

Outcomes

• Demonstrate tool protocol.
• Set the drill press to create a single hole to specifications.
• Discuss the proper operation of a drill press.
• Follow safety procedures for operating a drill press.
• Identify parts, adjustments, and tooling for a drill press.
• Operate a drill press following procedures.

With the instructor or approved proxy, demonstrate on a drill press:

• Describe machine hazards and demonstrate lockout/tagout procedures
• Removal / installation of tooling 
• The proper drill speed selection for a:  
  • 1/4” diameter twist drill 
  • 1-1/2” diameter Forstner cutter
• Table height adjustment
• Depth stop adjustment
• Use of quill lock while positioning fence
• Setup and use of a stop for repeat boring
• Use of clamps for boring small pieces
• Proper cleanup after use and at end of the day

Assessments

Formative:

• Drill press organizer
• Guided student practice

Summative:

• Drill press quiz
• Drill press competency checklist & certification (demonstration)

WCA Standards:

• Given stock marked for single hole to be drilled, machine set up to work with bit installed, fence, location, and depth stops set, drill hole in proper position to specified depth. (L1) 

E. Band Saw

Outcomes

• Demonstrate tool protocol.
• Set stationary power saws for making re-saw or curved cuts.
• Discuss the proper operation of stationary power saws.
• Choose the most appropriate saw for a given operation.
• Maintain stationary power equipment.
• Follow proper safety procedures for using a band saw.
• Identify parts, adjustments, and tooling associated with the band saw.
• Resaw wood using a band saw.

With the instructor or approved proxy, demonstrate on a band saw:

• Machine hazards and lockout/tagout procedures
• Show the following controls: 
  • On/off switch
  • Blade guard adjustment
• Proper adjustment of the blade guard
• Dry run of crosscutting with a miter gauge (proper hand position)
• Clean and accurate cuts at proper angles
• Accurate measurements according to plan and specifications
• Proper cleanup after use and at end of the day

Assessments

Formative:

• Band saw organizer
• Guided student practice

Summative:

• Band saw quiz
• Band saw competency checklist & certification (demonstration)

WCA Standards:

• Given material, a pattern of a finished part, and machine set up and ready to cut, trace the pattern on the part and make the cut. (L1)
• Given material with one straight edge and machine set up and ready to cut, freehand rip material to a specified width (> 4”). (L1)
• Given material with one straight edge and machine set up and ready to cut, rip material to a specified width (> 4”) using the fence. (L1) 

F. Handheld & Table-Mounted Routers

Outcomes

• Demonstrate tool protocol.
• Discuss the proper operation of a handheld or table-mounted router.
• Follow proper safety procedures for using a handheld or table-mounted router.
• Identify parts, adjustments, and tooling for a handheld or table-mounted router.
• Operate a handheld or table-mounted router following procedures.

With the instructor or approved proxy, demonstrate on a handheld and/or table-mounted router:

• Tool hazards and proper care
• Identify variable speed dial (if equipped)
• Dry run of routing on an external profile
• Dry run of routing on an internal profile
• Correct selection/identification of the following cutters:
  • Straight bits
  • Core box bits
  • Round over bits
  • Beading bits
  • Cove bits
  • Rabbeting bits
  • Slot cutters
  • Spiral up, spiral down, and compression cutters
  • Dovetail bits
  • Flush trim and pattern bits
  • Chamfer 

Assessments

Formative:

• Router organizer
• Router flashcards
• Guided student practice

Summative:

• Router quiz
• Router competency checklist & certification (demonstration)

WCA Standards:

• Given material and machine set up and ready to operate, use a 6 mm (1/4”) carbide quarter round bit with live bearing, machine quarter-round profile on 1 edge and 1 end of solid wood board. (Edge Profile)
• Given material and machine set up and ready to operate, use a 13 mm (1/2”) straight shank carbide bit, machine a 13 mm (1/2 x 1/2) rabbet in edge of a 610 mm (24”) board. (Rabbet)
• Given material and machine set up and ready to operate, use a 13 mm (1/2”) straight shank carbide bit, machine a 13 mm (1/2 x 1/2) dado inset 1” from, edge pf a 610 mm (24”) board. (dado/Plough/Groove)
• Given material and machine set up and ready to operate, use a 13 mm (1/2”) straight shank carbide bit and template collar, set template and machine a pre-determined cutout in board. (Template Cutout) 

G. Multi Router

Outcomes

• Demonstrate tool protocol.
• Discuss the proper operation of a multi-router.
• Follow proper safety procedures for using a multi router.
• Identify parts, adjustments, and tooling for a multi router.
• Operate a multi router following procedures.

With the instructor or approved proxy, demonstrate on a multi router:

• Tool hazards and proper care
• Identify variable speed dial (if equipped)
• Dry run of routing on an external profile
• Dry run of routing on an internal profile
• Correct selection/identification of the following cutters:
  • Straight bits
  • Core box bits
  • Round over bits
  • Beading bits
  • Cove bits
  • Rabbeting bits
  • Slot cutters
  • Spiral up, spiral down, and compression cutters
  • Dovetail bits
  • Flush trim and pattern bits
  • Chamfer 

Assessments

Formative:

• Router organizer
• Router flashcards
• Guided student practice

Summative:

• Multi router quiz
• Multi router competency checklist & certification (demonstration)

WCA Standards:

• Given material and machine set up and ready to operate, use a 6 mm (1/4”) carbide quarter round bit with live bearing, machine quarter-round profile on 1 edge and 1 end of solid wood board. (Edge Profile)
• Given material and machine set up and ready to operate, use a 13 mm (1/2”) straight shank carbide bit, machine a 13 mm (1/2 x 1/2) rabbet in edge of a 610 mm (24”) board. (Rabbet)
• Given material and machine set up and ready to operate, use a 13 mm (1/2”) straight shank carbide bit, machine a 13 mm (1/2 x 1/2) dado inset 1” from, edge pf a 610 mm (24”) board. (dado/Plough/Groove)
• Given material and machine set up and ready to operate, use a 13 mm (1/2”) straight shank carbide bit and template collar, set template and machine a pre-determined cutout in board. (Template Cutout) 

H. Upcut (Cutoff) Saw

Outcomes

• Demonstrate tool protocol.
• Set the upcut saw for making straight cuts.
• Discuss the proper operation of the upcut saw.
• Choose the most appropriate saw for a given operation.
• Maintain stationary power equipment.
• Follow proper safety procedures for using an upcut saw.
• Identify parts, adjustments, and tooling associated with the upcut saw.

With the instructor or approved proxy, demonstrate on an upcut (cutoff) saw:

• Machine hazards and lockout/tagout procedures.
• Proper adjustment of blade height
• Proper adjustment of throat plate
• Proper operation of switches and dust collection
• Calibration and adjustment of measuring machine
• Dry run of crosscut (proper hand, push stick, and standing position)
• Use and adjustment of the fence
• Clean and accurate cuts at proper angles
• Accurate measurements according to plan and specifications
• Proper cleanup after use and at end of the day

Assessments

Formative:

• Upcut saw organizer
• Guided student practice

Summative:

• Upcut saw quiz
• Upcut saw competency checklist & certification (demonstration)

WCA Standards:

• Given material with one straight edge and machine set up and ready to cut, rip material to a specified width (> 4”) using the fence. (L1)
• Given material with machine and necessary fixtures/jigs set up and ready to cut, crosscut both ends of the stock using a miter gauge or similar accessory perpendicular to the adjacent edge, to yield a specified length. (L1)

I. Double 45° Miter Saw

Outcomes

• Demonstrate tool protocol.
• Set the saw to make a mitered cut.\
• Discuss the proper operation of a miter saw.
• Follow proper safety procedures for using a miter saw.
• Identify parts, adjustments, and tooling associated with the miter saw.

With the instructor or approved proxy, demonstrate on a double 45° miter saw:

• Evaluate the condition of the tool before use and explain lockout/tagout procedures
• Check power and air supplies
• Turn machine on and off 
• Dry run of miter cut
• Make multiple cuts on a piece of stock
• Produce clean and accurate cuts at proper angles
• Explain how to cut stock that is too short to hold safely
• Produce accurate measurements according to plan and specifications
• Proper cleanup after use and at end of day.

Assessments

Formative:

• Double 45° miter saw organizer
• Guided student practice

Summative:

• Double 45° miter saw quiz
• Double 45° miter saw competency checklist & certification (demonstration)

WCA Standards:

• Given material and machine set up, cut stock to specified length and miter angle. 
• Given material and machine, set up machine, obtain and use mitering jig or fixture, cut stock to specified length and miter angle. 
• Given material with one straight edge and machine set up and ready to cut, rip material to a specified width with a 45 degree bevel along the edge. 
• Given material and saw set up and ready to operate, cut linear stock to a given length with opposing 45 degree ends.  

J. Pocket Hole Machine

Outcomes

• Demonstrate tool protocol.
• Set the machine for making single and double pocket-holes.
• Discuss the proper operation of a pocket-hole machine.
• Follow proper safety procedures for using a pocket-hole machine.
• Identify parts, adjustments, and tooling associated with the pocket-hole machine.

With the instructor or approved proxy, demonstrate on a pocket hole machine:

• Evaluate the condition of the tool before use and explain lockout/tagout procedures
• Operate on/off power 
• Make adjustments for stock thickness
• Adjust the drill bit depth stop
• Adjust the height of the clamping cylinder
• Connect and disconnect the air supply 
• Read the air gauge and remove or add air  

Assessments

Formative:

• Pocket hole machine organizer
• Guided student practice

Summative:

• Pocket hole machine quiz
• Pocket hole machine competency checklist & certification (demonstration)

WCA Standards:

• None