Multi-Phase Automation for Building Product Rollout

Background

A US-based building product manufacturer developed and implemented first-of-its-kind machine design and automation solutions to support a new product launch. Our involvement in this project included concept development and feasibility, preliminary engineering with proof-of-principle, detailed design and fabrication, along with installation and start-up support including operator training. The project involved several phases tailored to the client’s strategic initiative and deployed to multiple manufacturing sites. 

Approach

The new product was scheduled to enter the market through a corporate partnership between the client and a major building products supplier, with a fast-approaching launch date. To meet this goal, the client initiated a multi-phase strategic plan. Phase 1 focused on modifying existing equipment to produce a limited pilot run of the new product, which was self-performed. In Phase 2, the manufacturing process was optimized, and a complete production line was designed from the ground up, incorporating more than 35 unique assets into an integrated system capable of delivering the full product offering on time. Phase 3 expanded these capabilities to an additional facility to meet growing demand, while continuing efforts to reduce costs and accelerate schedules. 

Results

To launch a new product in the window market across multiple sites, the client implemented a phased strategy focused on speed and efficiency. The initiative began with understanding the product design and developing innovative equipment solutions to meet performance and quality goals. Leveraging industry expertise and fabrication partnerships, the required equipment for Phase 2 was delivered on time for the launch. Through collaborative design, assets were engineered for reuse across facilities, generating $1.91MM in cost savings and eliminating 35 weeks from the Phase 3 schedule.