How Machinery Makers Ensure Their Equipment Remains Relevant
By Drew Vass
In the door and window manufacturing industry, machinery providers are tasked with two conflicting challenges: delivering equipment that meets current production needs while ensuring that it can also adapt to production of whatever the future holds for fenestration.
“The glass and window industry across the world has seen massive regulatory and developmental changes over the past years in the pursuit of energy efficiency and enhanced thermal performance,” says Scott Knisely, president of Forel North America.
Yet, the machines that a door and window manufacturer invests in today are expected to hold up for years, if not decades.
These days, technologies such as triple-pane insulating glass (IG), vacuum insulating glass (VIG) and thin-glass quads and triples are making their way into designs originally intended for double-pane glass. With those changes comes the need for revised products and, in some cases, new machinery. But, thanks to a new level of adaptability, that’s not true in every case.
Machinery manufacturers are “seldom consulted when really big changes are on the horizon,” says Todd Tolson, director of sales for Pro-Line, leaving them in the dark about what lies ahead for the industry. But that hasn’t stopped them from “future proofing” their designs.
With advancements in tooling and the flexibility of software-driven processes, equipment providers say their latest machines are capable of doing just about any and everything. It’s all in the tooling and the software.
The same advancements also fuel an emphasis on integrating smart capabilities, such as predictive maintenance alerts, self-calibration, and process data visualization, says Gustavo Chohfi, vice president of quality and continuous improvement at Cornerstone Building Brands. In today’s landscape for door and window manufacturing, those details are critical, Chohfi says.
“By identifying when machinery is the root cause of a defect, we can establish specific process parameters that must be controlled and monitored to ensure we produce high-quality products,” he says.
With those added features and responsibilities, machinery companies must ask themselves, “Is what you’re designing needed, and can you build something that makes a difference?” Knisely says. “Research and development are, for the most part, a machinery company’s ‘be all and end all’ in determining future equipment design,” Knisely says.
“When new products come to market, especially in the IGU industry, it is crucial that you have machinery that can adapt or be modified.”
The Path to Adaptability
One of the key strategies for future proofing machinery includes the adoption of modular designs. Officials for companies like Erdman Automation and Forel North America say their companies create machinery that can be easily adapted or expanded as new technologies and product designs emerge. For example, Jessica Metz, Erdman’s marketing representative, says her company’s modular IG lines allow for the integration of new stations or technologies as needed.
“One of the ways Erdman Automation keeps its eye on future proofing is by designing and building its IG lines in a modular style so that the line itself can be adapted for additional technology or even replacement technology,” Metz says. In this way, machinery companies have equipped their designs with “plug and play” capabilities. “Because we have our own design and controls team, it makes it possible for us to pivot and integrate new technology into an existing line,” Metz says. “This may not work for all new technology, but it certainly puts us in the best position to do so.”
Similarly, Knisely says his company’s approach to modular design allows customers to configure their IGU lines according to their specific needs—both before and after implementation.
“Forel’s modular concept is part of our philosophy—building a range of compliant modules that allow our customer free choice on an IGU line configuration,” he says. “This is where forming that foundation for success is incredibly important to our clients. They’re safe in the knowledge that if they do need to add another module for a given product, they’re able to do so.”
Modular features also allow equipment manufacturers to base their designs on common platforms, says Stephen Kucer, president of Haffner Machinery.
“We have multiple platforms that we use depending upon the application and then that platform is tailored, modified and customized for the particular user,” Kucer says. “The platform is versatile enough that it can handle almost anything within a certain market segment.”
Unlocking the Future
Modular designs also allow machinery providers to offer retrofittable upgrades to enhance efficiency and output. Upgrades range from software updates to complete module replacements. For example, Cornerstone Building Brands recently upgraded more than machines with sensors that continuously monitor functionality and issue alerts if variations occur within key process parameters.
“Retrofittable upgrades are also a critical part of our constant development path and are generally provided to improve efficiency and output,” Knisely says. “These upgrades can range from as little as a software change to a complete module replacement.”
How machines are wired affects future additions. Haffner’s modules are equipped with standard wiring harnesses, similar to what’s used in the automotive industry, Kucer says. That allows his company to connect additional features or make changes by simply plugging them in.
“If we have to add another motor or another tool to our machines, it’s not a problem, because the wiring harness is there and it can be added,” he says.
At the same time, with today’s software-driven systems, times out of ten additional tooling and hardware isn’t necessary, he says, adding, “We can accommodate any profile change by just using the CNC software.”
With CNC equipment, in particular, the only limitations are in the physical abilities of the machine.
“Ultimately, it’s a mechanical device that transforms, right? The mechanical device sings and dances under the control of software,” Kucer says.
So long as the proper tooling is in place, a machine can be programmed to produce just about anything, within size limits, by reprogramming software.
“The advantage of CNC machinery is the flexibility,” Kucer suggests. If a profile changes, or a window model changes, and a machine isn’t equipped with the right tooling, “We are able to accommodate that,” he says.
The same is true of welders, says Mitchell Heckbert, vice president of sales and service for Urban Machinery.
“Our newest welder, the AKS cut, fits into this category,” Heckbert says. “The welder is very flexible and can produce multiple levels of quality, fit and finish, allowing our customers’ marketing teams to sell the same products with different levels of finish. As quality specifications evolve, the welder can be reprogrammed to meet all expectations.”
Welders can also be reprogrammed to accommodate changes in extrusions, he says.
In this way, “Customers can best help themselves by purchasing machinery that doesn’t utilize fixed position tooling, by sourcing machines that are programmable to cover a wider range of current and future applications,” Tolson suggests.
Artificial Intelligence
Another factor that’s dissolving boundaries in the adaptability of machinery includes artificial intelligence (AI). By enabling real-time vision analytics and instantaneous corrections, AI can significantly reduce defects and optimize production processes. For instance, at Cornerstone, AI is employed to create a closed-loop system where machinery self-calibrates to reduce or eliminate product defects, Chohfi says.
Manufacturers such as Cornerstone are actively involved in manufacturing councils, where they continuously learn the best practices for using AI and how it’s being adopted by other companies, he says. “The notion of AI making instantaneous corrections due to imperfections or deviations that were not otherwise anticipated absolutely has a role to play,” Kucer says. “The trend is to more and more use vision and to take advantage of real time analytics. And then, through the use of AI and different, very fast processing capabilities and analytic capabilities, make instantaneous corrections … the most important tool that we have, which feeds AI, at least in our case, are cameras.”
As hardware and software reach new heights, ultimately one of the most important tools a machinery company has is its design and operating philosophy, some suggest. The market demands not just innovative solutions, but also a willingness to evolve gradually, ensuring that today’s investments remain relevant. When it comes to the timing of machinery investments, as Kucer aptly puts it, “The person who says, ‘I’m going to wait,’ has already missed the boat. In the automation business, you’ve got to get into the market as soon as you can afford it, to stay competitive.” The other factor includes the right employees to operate and maintain high-tech equipment and software. Together, “These efforts have and will continue to deliver significant results,” Chohfi says.
Drew Vass is the executive editor for [DWM] magazine.
dvass@glass.com
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