"A decisive step for the future" — window production at the next level

2024/10/21   |   Sulz am Neckar   |   Germany

Since its foundation in 1951, Grathwol has developed from being a small furniture joinery to become a specialized manufacturer of wooden windows and doors, as well as a specialist dealer for awnings and insect screens. Now under the leadership of the third generation, the company recently made pioneering investments: The family-run company intends to significantly increase its production capacities by building a new production hall and purchasing the CENTATEQ S-800 CNC processing center from Homag.

In its early years, under the direction of the founder Gottlob Grathwol, the company concentrated on the production of furniture, doors and caskets. In 1969, Erhard Grathwol, the founder's son, took over the management of the company. Under his leadership, the company specialized in the production of wood and wood-aluminum windows. In 2004, Axel Grathwol, master glazier and grandson of the founder, took over the management. "We have established the production of high-quality wood and wood-aluminum windows," says Grathwol. In addition to the above-mentioned products that are manufactured in-house, the company also sells aluminum front doors, plastic windows, all shading solutions, insect screens and awnings.

"Our main customers are primarily private individuals as well as other assembly companies and window manufacturers who order windows and doors from us," explains Grathwol. Spruce, pine, silver fir and oak are currently used for production. The sales concept focuses primarily on customer recommendations and an active presence on social media such as Instagram and Facebook, as well as through Google reviews. "Marketing is critical to our success, and my wife, Mayline Grathwol, plays a central role here," says Grathwol. The sales area covers a radius of 50 kilometers, with a preferred distance of 20 kilometers. "The smaller the radius, the better, because we want to build up a close connection with our customers."

Strategic investment in state-of-the-art technology

The decision to invest in the CENTATEQ S-800 CNC processing center from Homag was strategic. "We wanted to continue to produce high-quality wooden and wood-aluminum windows. Individual machines for the processing were no longer profitable," explains Grathwol. "The new technology enables us to make the desire for automation a reality and make production more efficient. We also wanted to meet the current high demands of the market in terms of material, form, function and system diversity. With the new machine, which combines several functions, we can also process round arches and front doors efficiently."

The new machine is the first that the company has purchased from Homag. Due to the proximity of the two companies, the team has already been able to gain good experience with the quality of the products. The company first came into contact with Homag during Ligna 2019, after which there were several visits to the factory in neighboring Schopfloch. Grathwol had also used the exchange with other window manufacturers to experience the machines live in practical use.

The first thoughts and planning took place five years ago. Due to the lack of space at the old location, in 2022, the ground was broken for a new production hall, which was commissioned at the beginning of this year. "The investments in modern technology are not only necessary, but also a sign of our commitment to quality," emphasizes Grathwol.

The employees were involved in the entire planning process from the start to ensure that the new system is optimally tailored to the needs of the team. As part of this process, a true-to-scale model of the new hall and the individual machines was also created. This enabled optimal planning of the workshop with the support of an external consultant. "The workshop was planned in a two-day planning session with our employees. This coordination was very valuable for us throughout the entire construction period and still is today," explains Grathwol. The planning costs, at a total of EUR 1500, were also sponsored. The final decision was then made together with the technicians and later machine operators.

The investment costs for the new machine were approximately EUR 500,000. The largest investment in the history of the family company, which included the machine, software, tools and the new hall, was partly sponsored by the German Rural Development Programme (RDP).

Significant increase in production capacities 

With the construction of the new production hall with the office space and prestigious showroom, the company can achieve double-digit efficiency increases in processes and production structures. Non-productive standard processes such as loading and unloading can be delegated by setting up loading and unloading areas for interim storage.

The capacities freed up as a result of this are used to increase sales in all areas. The shortage of skilled workers, which is already clearly evident, is also counteracted in two respects. On the one hand, fewer skilled workers will be required in production thanks to intelligent machine and software control. On the other hand, at the new location, the company will appeal to new employees as an attractive employer in a modern working environment and therefore significantly improve employee recruitment.

Prior to the purchase of the new machine, the company produced around 500 window units per year; the new targets foresee a production of up to 2000 units per year. This year, the company is already operating at almost full capacity, resulting in the need for new hires. "We would like to recruit one or two new employees in production and assembly in order to be able to meet the new capacities. In doing so, we are also increasingly focusing on training to promote young talent," explains Grathwol.

Challenges

Commissioning brought with it some challenges, especially since the company was entering new ground in the field of CNC machines. "The lack of a fiberglass connection at the new location still presents us with some challenges. However, a highlight has been the excellent support provided by Homag throughout the entire project. There were only minor bottlenecks that were resolved quickly and we were able to meet all the schedules," said Grathwol. "Having a single point of contact made communication much easier."

Machine specifications

The new Homag CNC machine offers comprehensive options for processing wood and wood materials. It is characterized by high precision and advanced automation. With its user-friendly touchscreen interface and modular adjustment options, the machine meets a wide range of requirements. In addition, its robustness and energy efficiency help to reduce operating costs and environmental impact. The machine's special features requested by the company include the processing of workpieces up to six meters in length and the enlargement of the infeed and outfeed table. As a result, up to 35 parts can be laid out, which significantly increases productivity.

The machine is currently equipped with 60 tools, with a total of 72 tool slots available. "We work with tools from Zuani and use the Klaes software, which is already integrated into our other machines," explains Grathwol.

The excellent cooperation between Homag, the tool manufacturer Zuani and the software company Klaes is particularly noteworthy here. "The individual participants were experienced and coordinated very well, which was the foundation for successful implementation, as the topics are very complex and deeply intertwined," says Grathwol, summarizing the situation.

Benefits of the new processing center

Prior to the acquisition, production involved several individual machines, which was often inconvenient. "Now we can do everything in one process step, which significantly increases efficiency. 25 frames and 25 wings per day are possible; with full utilization, 100 window units per week would even be conceivable," explains Grathwol. At present, front doors are not yet being produced on the new machine, as this would require investment in special trimmers.

The new processing center enables production in batch size 1 and works with almost no personnel. The mechanically pre-punched holes for drilling fixtures completely eliminate previous errors due to incorrect positioning of the fixture templates. In addition, individual, faulty parts can be easily reproduced correctly, which significantly increases flexibility in production.

Employee training

Employee training took place in several phases. "Before the machine was put into operation, we ran it in at Homag in Schopfloch for two weeks. Three employees were then trained on a training machine before we had another two weeks of training in our new hall," explains Grathwol. "I recommend that other newcomers to the field of CNC technology take this step and gain experience; it is the best way to work more efficiently and to a high level of quality."

Future investments 

In addition to the new CNC machine, the company has also invested in a new painting system that includes a suction device. "Over the next five years, we plan to automate our painting system and possibly purchase a painting robot," says Grathwol with confidence. “I am convinced that with all these measures, we have taken the right step into the future.”