Since Oregon Timber Frame’s acquisition by Barratt Redrow, significantly higher production volumes have been required. In 2023 the group replaced its manual production facility in Derby, with a new plant equipped with a largely automated production line from WEINMANN.
This marked the first time the company utilised the option of automated manufacturing of closed elements. For Operations Director Jason Powell, this was a logical step: “I think the demand for housing and the skilled labour shortage in the UK means that prefabrication is the solution of choice for building the required number of houses. The demand for housing is enormous. We can only meet it through automation and the construction of additional production facilities.”
Exceptional production line
Production in Derby takes place on three production lines: line 1, fed by a HOMAG SAWTEQ series panel saw and two joinery machines, eight BUILDTEQ worktables, customised by WEINMANN to the customer’s specific requirements. Ceiling elements are manufactured manually on these worktables, then placed on a WEINMANN-specific storage area at each worktable, picked up by forklift, and transported to the loading station.
Lines 2 and 3 are used to produce wall elements. A finger-jointing line is installed upstream, in which the top and bottom flanges are glued continuously and roughly cut to length. WEINMANN proposes this solution when only a small number of different cross-sections are used in element production. Jorg Gros, Head of Global Solution Engineering says: “Since finger jointing allows for the recycling of offcuts, we achieve an outstanding reduction in waste to 3-4%.”
From the finger jointing system, the bottom and top chords are conveyed to the two production lines, where, after a glue drying time of approximately 20 minutes, they are fed, along with the prefabricated studs purchased from other suppliers, via an automated feeding system to the respective FRAMETEQ frame assembly station.
There, they are precisely cut to size during the frame assembly process. Window and door modules are pre-produced at two parallel stations and continuously integrated into the frame assembly. For better orientation, the installation position of the window and door modules is displayed to the operator on a screen at this workstation.
Lines 2 and 3 differ primarily in the number of workstations. Both primarily enable the production of wall elements that are closed on one side. The latter still constitutes most orders for construction projects in the UK.
In both production lines, a quality control table is located behind the frame assembly station. This is followed by two tables for placing the panels, which can also be used as buffers, and a table with a WALLTEQ M-500 multifunction bridge for fastening and processing the sheathing. The WALLTEQ M-500 is equipped with parallel nailing units for rapid nailing. Two further tables, on which the elements are fitted with an external moisture barrier and prepared for loading, mark the end of the production line.
Line 3 additionally enables the production of closed wall elements. For this purpose, it is supplemented behind the WALLTEQ multifunction bridge by a turning table, which transfers elements to another line as needed. Here, they are insulated, closed, and processed with a second multifunction bridge. According to Steve Seath, Head of Production Integration, closed wall elements now account for approximately 25% of the production volume.
Tailor-made concept and seamless commissioning
According to Jason, a key objective of the automation was to significantly increase the group’s production capacity, saying: “We planned to accelerate the element throughput per line to 1.2 m/min in order to be able to build approximately 4,000 houses per year in Derby.”
Steve adds: “This is only possible with a smooth linear manufacturing process. We discussed the corresponding requirements with several machine manufacturers in advance, and WEINMANN made the best impression on us due to its experience. During the planning discussions, we received tailormade proposals for the equipment of the new plant – not too much, not too little, they recommended exactly what we needed.”
Since the company developed clear concepts for the hall layout and implementation in dialogue with the machine manufacturer, the new plant, whose buildings were completed in November 2022, seamlessly commenced operations in May 2023. Looking back, Steve sees the commissioning process as: “a very smooth process overall, with few problems with the machines.” One of the reasons for this smooth start was the preparatory training provided by WEINMANN, which took place partly in St. Johann-Lonsingen and partly on-site in Derby. This was supplemented by several weeks of production support to familiarise the Oregon employees with the new technology. “Even after that, the HOMAG Group was always
available by phone,” says Steve. Support was largely handled by HOMAG UK, the group’s sales and service organisation in the UK, which is closely networked with WEINMANN.
Strong competition in the job market
One of the biggest challenges in Derby proved to be recruitment: “It took us about a year and a half to reach our current staff of 150 employees,” recalls Jason. This was primarily because Oregon Timber Frame faces powerful competition in the job market at its Derby location, including companies like Rolls-Royce, Toyota, and major aerospace firms.
Most of these competitors operate with a high degree of automation. Production automation by WEINMANN, which offers employees significant ergonomic benefits, therefore gave Oregon a strong advantage in the job market: “Many of our employees live in the region and were familiar with automation in the automotive industry,” explains Jason. “Initially, they assumed they would have to manufacture timber houses using hand tools at workbenches. Our high degree of automation and the efficient processes, which create attractive jobs, pleasantly surprised them.”
Even the employees who were transferred from the previous manual production on-site have readily accepted WEINMANN’s new production lines after some initial hesitation. As a result, there are now enough experienced colleagues to train new employees and support them during the initial phase of their new roles. The production throughput targeted in the planning phase has not only been achieved but has already exceeded. “Thanks to automation,” says Jason. “We have achieved absolute planning certainty in terms of capacity, precision, and quality. This allows the plant to plan better and deliver more consistently week after week. Our partnership with WEINMANN has therefore been very successful, and we are very satisfied with the plant.”
Read the full article in the latest Structural Timber magazine here
