powerProfiler - Primus inter Pares 

The “powerProfiler B722” offers outstanding flexibility for the fully automatic complete processing of all kinds of windows including non-standard shapes, profile systems for eco homes / sound proof versions and materials such as wood/aluminium, wood/composite materials and sandwich constructions. And the same applies to front door leaves and upright / transom constructions for conservatories.

The ability of the B722 to process the complete range of both windows and front doors made the purchase decision a foregone conclusion for those responsible at HM Fenster + Türen. For Production Manager Andreas Landgraf, the prospect of working in cooperation with HOMAG to optimize internal operational sequences, processing software and tooling represented a major selling point. “We knew from the large number of processing centres which have been delivered here over the past 12 years that Homag is able to call on a wide-ranging and impressive fund of experience in the field of individual part processing for window construction. This was our opportunity to make additions to some of the components to create the final configuration of our machine, and so contribute with the input of our many years of accumulated knowledge and also put into operation our ideas about some of the detail aspects”.

Given the highly complex nature of some of the reqirement criteria faced by the development team configuring the processing centre’s functional features, HOMAG’s assumption of the project management role under the direction of Sales Manager Peter Chr. Nass and Project Manager Volker Schmieder, encompassing also the tooling (Leitz), software integration (Adulo, order entry/processing, cutting lists, material order lists, customer order confirmations etc.) proved a highly beneficial move. The HOMAG software package with the powerControl system generates all the processing programs, ensures optimum table loading including collision monitoring, organizes parallelization of all production steps and coordinates all production sequences. The CNC programming system woodWOP allows the additional manual generation of different programs for all different types of doors and non-standard window components.

Another priority requirement for the powerProfiler was the ability to produce completely new window types and configurations such as the new HM window corner with a number of special features as tested by the ift Rosenheim. Following gratifying initial sales interest in the new window corner, the time has come to deliver. The catalogue of sales arguments in favour of the new window series under the heading “the seal tight window sash” made a convincing impact:

• Trimmed glazing bar for greater stability and an improved seal
• Double sash seal against wind and rain
• Window frame profile with smooth rebate
• Mechanical corner screw connection permits all-round surface protection on all six sides of the wood profile, as well as ensuring improved corner strength
• Glass panes permanently glued in the sash = increased break-in protection, torsional stability and static strength of the sash, improved insulation values.

Even considering purely economic factors, a feasibility analysis of the new processing centre throws up all the right answers. Installation of the powerProfiler made a total of over 40 machines belonging to the company’s existing outfit redundant, allowing them to be sold. An automatic outside moulding and profiling machine, several moulding machines, drilling units, two angular plants, double end tenoners and a variety of special-purpose machines are now surplus to requirements, as the new plant is capable of performing all these processes in one. A major role is played here by the two independently operating processing tables with 3-step clamping, the generously dimensioned tool storage system (up to a maximum of 432 tools), including 72-slot tool changer and automatic workpiece handling. Thanks to the unit equipment outfit – a 13-spindle drilling head, 15 kW working spindle, sawing unit, 4-spindle drilling / trimming unit, 2-spindle lock case trimming unit, FLEX5 sawing / trimming / drilling unit and label printer for part identification – the following operations are all performed, some of them entailing several combined work steps:

• Longitudinal and transverse profiling
• Construction hole drilling / trimming operations
• Hardware hole drilling / trimming operations
• Trimming operations for supplementary functions such as ventilation or alarm mounting
• Sash bar boreholes
• Also separate snipping saw in a version for precise customized cutting to length.

For the cost accounting specialists at HM, this high degree of automation means

• A good 25 per cent less manpower (employees have their hands full in other departments)
• Energy savings, for example through lower extraction output
• Lower space requirement due to compact integral design of the “B700”
• No buffer zones required
• Fewer handling processes due to concentrated sequences
• Economical both for one-off and batch production.

The sums also add up for Managing Partner Volker Meyer from a different point of view: “We can now actually offer our higher-quality windows at the same price as before, as the economical production costs mean that additional important material components can be supplied even in the standard version. This also means that customers are now getting more window and higher quality for the same money. We consider ourselves ideally equipped to meet the challenges of the next ten years – and if need be, we can retrofit additional units or newer unit versions at any time in the future”.

A real “pact between generations” in which HM Fenster + Türen has invested around one million EURO in the company’s overall infrastructure. And should there ever be a change of direction for the company, then other business divisions of the company group can also benefit from the advantages of the new “powerProfiler”, which can be used for the production of a completely different range of components such as terrace roofs or car ports.