Automation for windows and doors: More efficient production thanks to smart technology
The key here is to choose the right type and level of automation. Making the wrong choice can backfire in several ways: a line that is too rigid will grind to a halt when dealing with bespoke orders or non-standard dimensions, whilst a solution that is too under-specified will limit your production volume just when you want to grow. Furthermore, this can easily lead to new bottlenecks: a station that cannot keep pace with the rest of the line slows down the entire process – regardless of how fast the other machines are running. Automation is therefore not about automating as much as possible, but about precisely coordinating the modules with one another and with the requirements of your production, both today and tomorrow.
What does automation mean for windows and doors?
Automation means that parts of the production process are carried out, either partially or entirely, by machines and software. This is not about a single step in the process, but about machines and processes that communicate with one another.
An automated production line, for example, looks like this:
Profile feeding → CNC sawing and machining → Temporary storage of profiles prior to welding → Welding of the sawn elements into frame components → Conveyor systems → Temporary storage of frame components → Fitting of fittings and final assembly → Final inspection
The software ensures that the correct production data is available at the right time for the right machine or module, and distributes the processing steps optimally across the various stations. Buffers compensate for differences in cycle time between these stations, so that no machine has to wait for another.
The result is a production process in which manual intermediate steps are virtually no longer required. The aim remains the same throughout: maximum optimisation and increased yield, without compromising on flexibility.
Why invest in automation?
Automation is not an end in itself. It is a decision about the future of your business: building a production system that is more efficient, more reliable and more scalable, and one that is equipped to meet the demands of the market in the years to come. Those who invest today are, in effect, determining what their production will look like in ten years’ time and whether it will still be able to keep pace with developments in profile systems, customer requirements and the available workforce.
For manufacturers of windows and doors, automation can offer a number of benefits.
Higher production capacity
Automated machines carry out repetitive tasks quickly and consistently. This means that order volumes can increase without each additional order requiring a correspondingly greater amount of manual labour. Importantly, this additional capacity is often achieved within the same space and with the same team.
Less repetitive work
A large part of window and door manufacturing consists of endlessly repetitive work steps: feeding, moving, positioning, sawing, drilling and milling profiles. Specialist knowledge is certainly required, and that is precisely the problem: today, most of this knowledge is applied to tasks that a machine can perform just as well, if not better.
If these tasks are automated, your staff can apply their expertise to what really matters: preparing, setting up and optimising the process, monitoring it and seeing it through to completion. Automation does not, therefore, replace them, but rather harnesses their knowledge where it is most valuable.
Consistent product quality
Automated machines carry out their machining operations according to pre-defined digital parameters, thereby eliminating the influence of human error. A CNC machine carries out the thousandth machining operation with exactly the same precision as the first, even when producing large quantities and even when a different shift is working on the production line.
Ultimately, it all comes down to this consistent quality. You know in advance what will come off the production line, regardless of the time of day, the volume or the staffing levels. This makes production predictable, simplifies quality control and ensures that commitments to customers can be honoured: you can actually deliver what you promise, even when things are busy.
Fewer production faults
As the production data is forwarded directly from the master programme to the machines, the number of manual entries is practically zero. There is no longer any need to retype, repeat or misread anything, which significantly reduces the risk of errors in dimensions, positions and machining operations.
The benefits extend beyond the workshop. Fewer faulty parts mean less material wastage and fewer lost working hours, but above all, less rework: no repairs on site, no repeat visits by fitters, no discussions with customers and no disruption to planning. Every error avoided at the start of the process ends up costing a fraction of the cost.
Shorter lead times and rapid response times
Anyone looking to reduce lead times in their production of windows and doors, respond more quickly to complex enquiries and handle larger projects, should not focus primarily on the speed of a single machine, but on the overall solution. By linking or combining the various production steps and optimising them within one or more machines, efficiency and response times can be dramatically improved.
The result: shorter and, above all, more reliable delivery times for windows and doors, which represents a tangible economic advantage for building contractors, architects, construction firms and private customers.
Automation of PVC windows and doors
PVC window and door profiles undergo far more production stages than just sawing, drilling and milling. An automated production line for PVC windows combines these stages into a single, continuous process.
The production process begins with the delivery and positioning of the profiles, followed by their cutting and machining, and then the sawing, machining, insertion and bolting of the steel reinforcements. This is followed by the counter-profiling and the preparation of the fittings. The welding and grinding of the corners is carried out using CNC control, which directly determines the precision of the visible result. Finally, the window passes through the various fitting stations, where the fittings are positioned and fitted automatically or semi-automatically.
Two invisible yet crucial elements run through this entire process: the identification of each individual part by means of a barcode or label, and the transfer of data between the machines themselves. These ensure a predictable production flow.
That is precisely where the competitive advantage lies. PVC is a sector where price pressure is high and where competitors are based both on our doorstep and across the border. A production line that delivers consistent quality with a small team and guarantees short lead times has a significant competitive advantage.
For manufacturers producing a wide variety of window types, flexibility remains of crucial importance. The system must be able to process different profile dimensions, products and orders equally smoothly.
Automation of aluminium windows and doors
Machines are required for machining aluminium that are tailored to the type of profile, the application, the dimensions and the desired machining operations. Examples of this include CNC machining centres, which combine sawing and machining, CNC press brakes, machining and sawing operations on different planes (3D), as well as end-face machining such as counter-profiling and thread cutting. In addition, flow drilling, assembly systems for fittings and the actual assembly process itself are also suitable for automation. An automated production line for aluminium windows can link these modules together.
Aluminium is also the segment in which requirements are evolving most rapidly: narrower visible widths, heavier glass units and ever-larger dimensions call for machining processes that are virtually impossible to carry out consistently by hand. Anyone wishing to secure these more complex projects needs a machine park that is capable of meeting these requirements, both technically and in terms of turnaround times.
The scope of application extends beyond the mere manufacture of windows and doors. Wherever aluminium profiles or bars need to be sawn and machined, automated solutions are available: conservatories, balustrades, patio canopies, various aluminium systems, exhibition stands and numerous other applications.
CNC as a component of automation
CNC technology is a key component of modern automation in the windows and doors sector.
CNC stands for ‘Computer Numerical Control’. The machine is controlled digitally and carries out programmed machining operations.
When it comes to window and door profiles, the work involves, amongst other things, drilling, sawing, complex profile machining, fitting hardware, welding, polishing, pressing, logistics, temporary storage, …
The main advantage is that the machine can carry out the machining steps automatically and with precision.
However, a CNC machine on its own does not constitute a fully automated production line. Further efficiency gains can be achieved when CNC machines are integrated with other machines, software and material-handling systems.
From individual machines to an integrated production line
Many window and door manufacturers start out with individual machines. As production volumes increase, there is a need to expand these and link them together. .
Instead of: Machine 1 → Employee → Machine 2 → Employee → Machine 3
This creates an automated material flow: Machine 1 → automated handling → Machine 2 → automated handling → Machine 3
The difference lies not only in the time saved. A production process that no longer relies on manual steps becomes, above all, predictable: you know when a job will be finished, regardless of who is working on which machine on any given day.
Automatic transfer systems
Transport systems are an underestimated component of the automation of windows and doors. Profiles must be transported to the correct machine at the right time. If this is done mainly by hand, a significant proportion of production time is lost to transport and searching for parts, the risk of damage whilst handling the parts increases, and the work remains physically demanding for your staff.
The greatest risk, however, lies in the waiting times that arise between the various modules. After all, each processing step has its own cycle time: a sawing operation does not take exactly the same time as machining operations or a welding cycle, and fitting assembly, in turn, does not take exactly the same time as welding. Without buffer times in between, each station has to wait until the next one becomes free, which means your fastest machine becomes just as slow as your slowest. These losses are rarely visible on the clock, as they consist of dozens of short interruptions per day, but on a weekly basis they quickly add up to several hours of lost production time. If a fault, a shift change or an order with different machining steps is then added to the mix, the effect spreads to the entire line.
The modules must be arranged in such a way that the processing steps are distributed evenly across the stations and the cycle times are coordinated. Buffers compensate for any remaining discrepancies, ensuring that each machine has its own work to do and never stands idle whilst waiting for the previous or next step.
The correct composition and distribution are therefore of crucial importance: a plant with high-performance machinery, but where the workflow is not balanced, will never deliver the performance for which it was designed.
The aim is simple: to keep throughput under control without causing a bottleneck anywhere.
The role of software in automation
A modern production line consists of more than just machinery. Software acts as the link between design, work planning and production, and in practice determines just how much performance you can get out of your machinery.
Software is often reduced to the window-based programme in which one carries out calculations and draws. The real benefit, however, lies in the layer behind it: the link between this window-based programme and the control systems of the machines and the various modules. This level translates a job into specific machining steps and determines which profile is required, which dimensions apply, which machining steps follow, on which machine they are to be carried out, in what order, and where the workpiece must subsequently be transported to.
That is where the real intelligence begins. Good machine software optimises the use of offcuts, groups machining steps together where this saves time, or distributes them evenly across different stations if this improves throughput. Furthermore, it records what actually happens: production times, downtime, consumption and output per order, per machine and per shift.
Equally important is the question of who wrote this software. If it is developed by the machine manufacturer itself, the expertise in mechanics, control systems and software all lies with a single supplier. You notice this immediately as soon as something specific is required: an interface to your ERP system, a new profile system or a different machining process.
Automation and Industry 4.0 in the windows and doors sector
The automation of windows and doors is closely linked to the principles of Industry 4.0, in which machines, software, data and processes are interconnected. The aim is not to install more machines in the production hall, but to establish a chain in which the systems communicate effectively with one another.
In practical terms, this means: a job that is prepared digitally and forwarded to each machine without the need for re-entry; material that is automatically fed and temporarily stored as soon as a station requires it; and control systems that coordinate amongst themselves to determine which machine carries out which operation.
The biggest change lies in what you get in return. A connected production system shows, at any given moment, where an order is, which machine is on standby, where the production flow is stalling, and what your actual capacity utilisation is. Whereas production figures used to be known only retrospectively and only approximately, making adjustments has now become part of the daily routine. Capacity planning also becomes significantly more reliable as a result.
Automation isn’t just about speed
When it comes to automation, people often think straight away of speed. But speed is only one aspect.
A well-automated production process must also:
Be precise, so that products are processed in accordance with the correct specifications.
Be flexible, so that different products and profile types can be processed.
Be reliable, so that machines and processes operate stably.
Be scalable so that production can grow in line with the business.
Be user-friendly so that staff can use the technology efficiently.
In other words: automation is meant to solve problems, not create new ones. And that starts with making the right decisions. Anyone who gives this careful thought will find an approach that drives the whole process forward.
How can we determine what level of automation is required?
Proper automation does not start with the machine, but with a thorough analysis of your existing production processes. The following questions will help you find the right approach.
Where are the manual intermediate steps? Map out the entire production process. Which steps are carried out more than once? Where do staff move or position profiles manually? These steps are usually the first to be considered for automation.
Where do errors occur? Find out where production errors and delays arise. If the same errors keep recurring, the cause is rarely down to the staff, but rather to a process that requires too much manual input.
Where do you lose the most time? Not every production step carries the same weight. Automating a critical step or an existing bottleneck yields far greater benefits than automating a minor part further down the line.
What do you expect in five years’ time? A solution that is adequate today is not automatically suitable for tomorrow’s production. You should therefore take your expected growth, product mix and future customer profile into account when making your selection.
Will I retain my flexibility? Check whether the solution implicitly restricts your product mix. Will it still allow you to process non-standard dimensions, special profiles and small batches, or will the system force you into standard production?
Am I creating new bottlenecks? A faster machine at one stage often simply shifts the bottleneck to the next step. You should therefore always consider the cycle times of the entire production chain, not just those of the new machine.
How much autonomy do I want? Determine how long your system must be able to continue operating autonomously without intervention. Is it sufficient for a machine to keep running during breaks, or do you want to continue production during a shift change or at night? This objective directly determines how much buffer capacity, automatic feeding, sorting and inspection you will need, as autonomy stands or falls on the availability of materials and a system that can detect deviations independently.
Is my automation plan future-proof? Your requirements today are not the same as they will be in five or ten years’ time. You should therefore opt for a modular design that can be expanded later to include additional stations, further processing steps or extra buffers, without you having to start from scratch.
Step-by-step automation
A fully automated factory does not have to be set up all at once. Many companies deliberately opt for a step-by-step approach:
Step 1: Individual CNC machines
Step 2: Connecting the various machines
Step 3: Automatic sorting systems and buffers
Step 4: Further digitisation and data integration
How to tailor automation to your business’s growth and investment opportunities. Above all, it is important that you choose the right level of automation. Too little automation leads to lost revenue, but if you go too far before your production is ready for it, you end up with a system that is not being used to its full potential or – worse still – one that restricts your flexibility.
What benefits does automation bring for staff?
Automation is changing the role of workshop staff and, above all, their skill levels. Whilst the work used to consist largely of manual tasks, it is now shifting towards operation, monitoring and control: quality control, process monitoring, maintenance, adjustments, problem-solving and production planning. This requires different skills, but also leads to more engaging tasks and makes the roles more attractive to younger skilled workers who want to work with technology.
Added to this is the fact that the required skills are changing. Alongside specialist knowledge of windows and doors, an understanding of the machines themselves is becoming increasingly important: mechanics, control systems, pneumatics and preventive maintenance. After all, an automated production line requires more monitoring and systematic maintenance than a collection of individual machines, and spotting minor deviations in good time prevents prolonged downtimes. You should therefore ensure that your team possesses the necessary technical expertise, or arrange for your operators to receive appropriate training.
In short, it is all about efficiency and the transfer of knowledge: what used to reside in the minds and hands of a few experienced staff members is now embedded in the system. This ensures that this knowledge remains available, regardless of who is operating the machine on any given day. In a labour market where skilled workers are in short supply, this is one of the strongest arguments in favour of automation.
Automation technology for windows and doors by Soenen Hendrik
Soenen Hendrik develops and manufactures automated production systems for manufacturers of windows and doors made from PVC, aluminium and hybrid profiles, and operates in the high-tech segment of the market. Its product range extends from CNC machining centres and sawing technology to automated material handling, buffer storage and fully integrated production lines.
The focus here is not on individual machines, but on the entire production process. This is precisely where efficiency is achieved: in the configuration of the modules, in the distribution of processing steps across the stations, and in a process free of bottlenecks. Every solution is tailored to your specific production process, your output volume, your product mix and your desired level of autonomy, without compromising on flexibility.
As the mechanics, control systems and software are developed in-house, we can respond quickly to specific requirements: integration with your host application or ERP system, a new profile system or a different machining process. What’s more, you work directly with the machine manufacturer – from the initial consultation through to commissioning and training your operators, right through to after-sales service years later.
From a single automated processing step to a fully integrated production line with the option of phased expansion: the right solution depends on how you want to manufacture your products today and in ten years’ time.
Frequently asked questions about the automation of windows and doors
What is meant by the automation of windows and doors?
The automation of windows and doors refers to the automation and integration of production stages using machinery, software and material handling systems. As a result, processes such as sawing, drilling, milling, welding, fitting hardware and transport are carried out either partially or fully automatically and are controlled on the basis of the same digital data.
Why should windows and doors be automated?
For increased production capacity, consistent quality, less repetitive work, fewer errors, shorter lead times and a more efficient flow of materials. In a market where skilled staff are in short supply and customers expect short delivery times, your production process plays a key role in determining whether you remain competitive.
Which processes can be automated?
These include, amongst other things, profile feeding, sawing, drilling and milling, the processing of steel reinforcements, counter-profiling, welding and polishing, the fitting of hardware, sorting, material handling and the exchange of data between the machines themselves. There are many different levels: from a single machine performing a specific operation, through interconnected stations with automatic feeding, to a fully integrated production line that operates largely unmanned. Which stage is right for you depends on your production volume, your product mix and your growth plans.
Can both PVC and aluminium be processed using automated methods?
Yes, there are automated machine solutions available for both materials, as well as for hybrid profiles. The exact configuration is tailored to the material, the profile systems, the required processing steps, the dimensions, the number of operators and the production volume.
However, the design of an aluminium system differs significantly from that of a PVC system in terms of the number of modules required: a PVC system requires more modules than an aluminium system.
What is the difference between a CNC machine and an automated production line?
A CNC machine operates at a single station: it positions the profile and carries out the machining steps in accordance with the instructions it receives from the programme. An automated production line links several of these machines together – using material handling, buffers and software interfaces – so that all production steps flow seamlessly into one another. The difference, therefore, lies not in the machining itself, but in the workflow between the individual steps: with stand-alone machines, transport and waiting time between steps are carried out manually, whereas on a production line these are eliminated from the process.
Is automation only of interest to large window manufacturers?
Certainly not. Even manufacturers with lower production volumes can automate production steps, design their workflows intelligently and achieve high productivity with a minimum of operating staff. The right solution depends on your production volume, your product mix and the efficiency gains you’re aiming for – not on the size of your business. By intelligently combining modules, you can determine for yourself the configuration and level of automation that best suit your volumes and objectives.
Can an existing production line be automated?
In many cases, yes. Existing machines and processes can be expanded to include new automation solutions or integrated with them, provided they are capable of receiving and returning production data and their input and output points are suitable for transport or temporary storage. An analysis of your current production workflow will identify which components are best suited for automation and where you can achieve a return on investment most quickly by adopting a step-by-step approach.
What is meant by Industry 4.0 in the windows and doors sector?
Industry 4.0 refers to a production environment in which machines, software, data and processes are interconnected. For window and door manufacturers, this means a process that is not only automated but also measurable: You can see at any time where an order is in the process, which machine is idle, where the workflow is stalling and what level of efficiency is actually being achieved. As a result, adjusting processes becomes a daily routine rather than an annual exercise.
Are you ready to automate your production and processes?
Automating windows and doors makes your production processes more efficient, more precise and more scalable. You will derive the greatest benefit not from automating a single machine, but when machines, software and material handling work together as a unified whole.
This development also goes beyond what can be seen in your production facility today. Whilst production lines already operate largely autonomously, the industry is moving towards the ‘dark factory’: a production process that continues even after the lights have gone out and the last employee has gone home. Those who invest today will play a decisive role in determining how well their company can keep pace with these developments.
Soenen Hendrik develops and manufactures high-tech production solutions for windows and doors made from PVC, aluminium and hybrid materials, making it one of the market leaders. Guided by a clear vision for the future, we are consciously one step ahead of the industry’s requirements, ensuring that the system you install today is also equipped to cope with tomorrow’s developments. You work directly with the machine manufacturer throughout the process – from the initial consultation through to commissioning and training, right through to after-sales service years later.
Together, we are setting up a production operation that is paying off today and will still be a leader in ten years’ time. Discuss your plans for the future with Hendrik Soenen.
