For over 30 years, Cemal Altunkaynak has been handcrafting high-quality knives in our workshop and is now responsible for large parts of the production process. The experienced knifemaker offers unique insights into the inner workings of Böker, explains his multifaceted work, and talks about his career and his life.
What motivated you to learn the profession of knifemaker, and what was your motivation for starting an apprenticeship at Böker over 30 years ago?
After graduating from school, I was 16 years old and wanted to start an apprenticeship. I'd been very interested in knives since my youth and always carried one in my pocket. Solingen was and still is known worldwide as the city of blades, so there was no reason for me to look outside of Solingen. After a short search, I came across Böker, applied immediately, and soon after signed my apprenticeship contract.
In which department did you start your training and what was your career path at Böker?
I started my apprenticeship at the Reiderei . Similar to today, the apprenticeship included six months in the training workshop, followed by a return to Böker, where I could put much of what I had learned into practice. Even back then, I was quite inquisitive and always wanted to learn new things in addition to my regular duties, for example, how to perfectly adjust the machines in our department. During vacation time, I regularly stood in for my foreman, which also broadened my horizons. My hard work definitely paid off, because after a few years I was promoted to foreman and later to department head. But you never stop learning, and so new things are constantly being added to the curriculum. Over the years, I've taken on more and more responsibility, so that today I'm responsible not only for the razor department, but also for hand polishing, vibratory finishing, etching, and final inspection.
At the start of my apprenticeship, I never would have imagined that I would work here for over 30 years. My plan was actually to move back to Turkey with my parents after a few years. Because even though I've lived in Germany since I was six, Turkey has always been my home. A few months quickly turned into ten years, and suddenly I was celebrating my 25th anniversary here at Böker. The factory has become a part of my home, and I hope to stay here until I retire. Perhaps I'll even feel the pull to return to Turkey after that.
Today you are responsible for numerous production departments and employees. With such a diverse range of tasks, what does a typical workday look like?
I start at six in the morning. On a typical workday, I first get an overview of all open orders and check their respective status. In "my departments," we don't just manufacture knives, but also the necessary components such as circuit boards, springs, jaws, and much more. In addition, we build samples and prototypes of new products.
Often, the work arises organically; where are things stuck, or where are there problems with a machine or a material? That's where I come in. Manufacturing steps, such as forging or hardening, are also usually outsourced. Here, too, it's my job to monitor the progress of the work and ensure deadlines are met.
We work on a wide variety of products simultaneously, such as pocket knives, fixed-blade knives, and razors, all of which can be at different stages of production. Therefore, there's no such thing as a typical workday for me; every day brings something new. While I do plan what needs to be done each day, something usually comes up, and I have to improvise. I officially finish work at 3:30 p.m., but I often finish small tasks like paperwork afterward. I simply don't always have the time during the day-to-day operations.
When do you consider a workday successful?
If all deadlines have been met and the planned tasks have been completed without any problems, I go home completely happy.
Can you estimate how many active orders are processed daily in your departments?
Of course, it always depends heavily on the production quantities, which vary considerably depending on the type of order. We typically manufacture knives in batch sizes of 30 to 100 pieces, while orders for smaller components like jaws or springs can quickly reach up to 2,000 pieces. I would estimate that we work on an average of five to ten orders per day.
Which of your skills are particularly difficult to learn and require a great deal of care and experience?
The most important aspect is the consistent and uniform processing of components in high volumes. Ensuring that the first part looks exactly like the last requires a great deal of concentration and dexterity over an extended period. Unlike automated industrial production, where setup costs and economies of scale are the sole focus, small batch sizes are easier for us hand polishers. The manual grinding and polishing of blades is also very demanding. It requires considerable experience and, above all, a great deal of sensitivity.
And what do you enjoy most?
I have to be honest, I really enjoy everything I do. I look forward to getting up every morning and going to work. Although I often experience stress and encounter one or two problems during the day, that doesn't stop me from starting the next day with plenty of energy and motivation.
What do outsiders imagine when they hear the term "Pliesten"?
Polishing is the fine grinding of blades or individual parts by hand. After the individual blades are stamped or laser-cut and their surfaces have been ground, they arrive at our hand-polishing workshop. Here, taking into account the tolerances and the function of the respective component, they are then polished by hand, i.e., finely ground. The surface finish and blue polishing are also part of this process. Blue polishing is a traditional Solingen technique for which a Scotch-Brite wheel is used. The entire surface of the blade is treated with this wheel, and such blades are immediately recognizable by their bluish to iridescent sheen. It is still considered the highest level of Solingen grinding craftsmanship.
How high are the physical and mental demands of the job?
I would say that the physical aspect is the most demanding. Luckily, I have colleagues who are always very supportive and give me a lot of strength. I always try to be careful not to let myself get too stressed mentally and prefer to take some time to breathe so that the next day can go smoothly.
As the person responsible for quality and final inspection, you have high standards for your work and the products. How critical are you of yourself and your colleagues in this regard?
Quality is truly paramount for me, and every knife should ultimately be crafted to such a standard that I would buy it myself. For this to happen, it's incredibly important that my colleagues and I all share a common understanding of quality. While treating my employees and colleagues fairly, I also mustn't lose sight of the productivity of my departments.
Today, as department head and trainer, you are personally responsible for numerous trainees. What do you particularly enjoy about working with younger colleagues?
Working with young people is always a great pleasure for me, and our young "Knife Nuts" in particular often bring their own unique ideas and perspectives. I was once in their shoes myself and can easily empathize with them. I'm very happy that I can pass on this traditional craft to them, because I, too, will not be here someday. One of my protégés was recently honored by the Federal President as Germany's best apprentice in his field, and I was, of course, very proud of him. In my private life, I also frequently interact with young people and enjoy sharing my knowledge, whether it's playing football or in a dance group.
How do you like to spend your free time?
Of course, my family is the most important thing to me; I have two daughters, aged eleven and twelve. I also love to dance, but almost nothing else is more important to me. I've been playing the saz (bağlama) since I was a child, and from an early age, I spent every weekend in our rehearsal room making music and singing in Turkish with my friends. There's always something new to learn in the world of music, and it's become a kind of escape for me. Eventually, I started performing at events and parties, which I enjoy immensely. Music is my second life.
Do you also have a personal connection to knives?
Yes, I definitely do. I enjoy going to trade fairs, not just for work, but also in my free time, and I like to get inspired. To be honest, I can rarely completely switch off from my job and I also pay close attention to the workmanship of the competition and look for things that could potentially be improved. And of course, I always have a knife handy; otherwise, I'd really be missing something.
Do you have a favorite knife?
Of course! The Böker Scout was the first knife I fitted here during my apprenticeship, and it still means a lot to me today. These days, the Scout is available in countless variations and even sizes. I also really like the classic Barlow; it's truly handy and can easily be carried in a trouser pocket all day.
The COVID-19 pandemic has also left its mark on Böker. How are you experiencing the significant restrictions in operations and administration?
Health comes first, which is why we are currently working in a strict shift system. We always adhere to social distancing rules and, of course, wear protective masks while working. The whole world is affected, and we don't know what else the future holds.
The production of forged straight razors requires decades of experience. What does one of the last masters of this nearly extinct craft use to shave?
I shave with different razors depending on how much time I have. When I'm short on time, I use a simple electric razor. I use a classic straight razor when I have a bit more time. Of course, you're very careful with them at first, but you learn quickly and become more confident. My favorite razor is my Böker King Cutter 5/8 inch.
Do you have specific goals for the next few years?
I don't really have any specific goals. My main priority is to stay healthy and be able to pass on my knowledge to younger colleagues here until I retire.