Each and every machine, employee, and environment has unique limitations. It’s knowing how to exploit the strengths of each that will contribute to the success of the company and the success of each product line. We recognize the strengths of unconventional wall framing for the North American market. It is unlikely any conventional system can out produce a Spida style Wall Panel Extruder or similar system. Production will certainly vary based on the amount of automation implemented; but stud for stud, conventional framers are considerably slower. Many say the Extruder is great for interior walls because the Spida Extruder lacks squaring and sheathing stations. Although this is true, third party sheathing stations are available. The problem is, they can’t keep up with the production. With that being the case, the problem is not that of the Spida Extruder, but rather that of the sheathing and squaring stations. In the following cases, the Extruders will support multiple sheathing stations.
Last week, we visited with three corporations. All three have, could, and will benefit from additional volume through their wall panel operations. That is exactly why they contacted Square 1 Design & Manufacture Inc. As with many operations, each believe they suffer from inadequate space. Physical constraints are only a small part of the entire process.
As equipment manufacturers, we are often required to provide production capabilities for each piece of machinery. During the equipment design phase, we typically have production goals for each design, based on ideal circumstances. Usually, that number is confirmed by production numbers from component manufacturers. In most cases, defining the ideal circumstances is not available to us, but rather fitting into the current production environment for each customer. Let me give you an example: the Spida Extruder operator can easily nail a stud every 10 seconds. Let’s assume each stud is 16” on centers. Using a 7.5 hour shift: 7.5*60*60=2700 seconds per shift. Therefore, 2700 seconds divided by 10 seconds per stud multiplied by 16” spacing divided by 12”/ft=2700/10*16/12=3600 lineal feet of walls. Now, we can all agree this is so unrealistic and unattainable, it is not even a marketable number. However, that is the true capability of the machine, IF YOU WERE CAPABLE OF SUPPLING MATERIAL TO IT!
One of the three organizations has rearranged his facility numerous times over the last two and half years to increase production because flow was less than optimal. In that case, we were provided a material flow diagram and were limited to that area to accomplish the goal. We did just that; however, reality set in and the manufacturer was not capable of utilizing the efficiencies of the equipment. They realized their equipment was capable of much more. The other two corporations have requested plant layouts utilizing both new and existing equipment. Both have given us the leeway to scrap their entire layout and start from scratch. We can then exploit existing equipment or source new, whichever increases production to the desired capacity.
One particular company was producing around 400 lineal feet per shift, so far below the threshold of the Spida Extruder that it was incomprehensible to sell them high performance equipment. Even though we are solely equipment manufacturers/distributors, we realize budgets exist. Let’s face it, most brands of equipment produce product, some better than others. In all honesty, we want to sell equipment, but Cullen and I both left and said: “there is no way we can sell them a Spida Extruder without fixing the entire plant.” In an effort to double or triple their production, we need to sheath at multiple stations rather than the bottlenecked single sheathing station currently in use. As equipment manufacturers our goals cannot be to simply sell equipment, but rather to make a plant efficient and more profitable. Square 1 Design & Manufacture Inc. is pleased to spend time with each and every potential customer discussing their needs, goals, and production layouts. If you see Square 1 Design as a resource, regardless if you purchase from us, we have accomplished our goal.