It was a big solution

In 2014 the management at Outline Vinduer made the decision to change part of their production from traditional series production to just-in-time production, in which CNC machining centres are handling the machining proces before painting and final assembly.

Manager Jens Sørensen remembers 2014 and says, that buying the machines was the easy part, the decisions regarding the productions changes were a lot harder. He is happy now for them taking that step, but he also remembers the hugh workload that lead to the choice. It is no easy task to restructure the production. This reorganization could have torn apart the company, in case the project didn’t succeed. It took me almost a year to get convinced. But we needed the flexibility and our calculations showed a long term pay off. After many considerations, we jumped into it.

Once the machines were ordered, preparations started in cooperation with Junget A/S, the total supplier of the project. Initially Outline Vinduer ordered two Weining Conturex machines, avoiding the risc that the whole production of doors doesn’t go down with the only machine. Planned delivery for the two machines was at Christmas time. The months from ordering to delivery were spent on data exchange, programming, testing and training personel, all of this according to a detailed plan.

Choice of partner

The opportunity to have machines, tools and service at the same supplier was decisive for the choice of Junget A/S as partner. According to technical manager Per Kjeldahl, there has been many advantages in collecting the order at one supplier. Most important was to avoid any discussions about whom to blame, machine or tool supplier, if something doesn’t work. Apart from that we have cooperated with Junget for many years, and we are confident in their advice and experience.

”We also needed a partner who could do a lot more than just sell machines. Proper projekt management and competent data programming were crucial. Furthermore it was important to buy products of a renowned brand, in which we could trust in the future as well.” Jens Sørensen adds. Junget A/S has been selling Weinig products for 51 years, and more than 400 Conturex plants have been delivered worldwide.

Big data everyday in Farsø

Big data has been the buzzword in many conferences and debates in recent years. At Outline big data is an everyday occurence. Correct programming and integration of data with the company’s other systems are important parameters for getting most out of the Conturex machines. That is no easy task and it has required persistent effort from all parties in order to succeed. It was not necessary for Outlet Vinduer to invest in new software, but the programmers from Junget almost moved in to get the job done.

The new machines were delivered at christmas 2014, followed by a busy time with training personel and running in the new systems. All the technicians at Outline, who are planning the production, were involved in the cooperation with Junget and Weinig. A reorganization of this size is complex, and the projekt has been challenging at times. If manager Jens Sørensen should leave any recomendations at this point the answer is clear:

”Be well prepared before installation. Sufficient preparation is key for a succesful restructure, as well as dedicated and competent employees.”

Visit at the producion site in 2016

If you take a stroll at the factory in Farså and visit the big machineplant, there is a striking contrast to Workshops with series production. The hugh Conturex machines are positioned side by side, whit carriages og wood pieces lined up, ready to be machined. Everything is calm and orderly and signals ’full control’. Only one employee operates the machines, which are processing one piece after another. A PC monitor shows the actual proces inside the machine. The machines are running in three shifts 24 hours a day.

The sight of a NC controlled Conturex in action is fascinating. Tools on three spindles are ready for action to make exactly the profile, routing or holes needed. The Computer data communicates to the machine how the different pieces are to be processed, and no piece leaves the machine before it is finished and labeled properly. Now the pieces are ready for painting and assembly. 66 different tools in each machine is what it takes to do all the machinings in the production.

Plannings surpassed by growth and increased demand.

If you look down the production hall, you will see not two, but three installed machines. After the restructure things went fast at Outline Vinduer. Original calculations and planning said that two Conturex machines were enough to do the job and provide the company with the required flexibility. Two years later it became clear that the demand for customized solutions has surpassed all expectations, and the investment in another machine was neccessary.

”The new machine is a story of succes. In 2014 we estimated that the two machines not only could manage the current production, but also had capacity for development and special orders. It showed that we were too busy to have as much room for special orders, as we were hoping for. This is of course a positive development, but also the reason why we are investing in another machine now” says production manager Michael Hjelesen.

Technical manager Per Kjeldahl adds with a appreciative nod to key account manger Steen Hansen from Junget, that all the other calculations from 2014 came true. The restructure resulted in minimized waste, reduced labor costs and icreased flexibility by fewer setup changes among other. Facts which were decisive for chosing Junget A/S as a partner for the third machining center as well.

Fast installation

The new Conturex was installed i the summer vacation period 2016 and is already up and running. The integration of data, which was done in 2014 was reusable, so this time the installation was copy/paste most of the time. The major investment in the reorganization is paying off and is a solid base for the future production in Farsø. The current set-up leaves room for further specialization with increased production of customized solutions and short delivery times.