The Next Step Into Automated Off-Site Construction in the US

2024/07/18   |   Hugo   |   United States

Casey Harless, National Sales Manager for Off-Site Construction from STILES Machinery recently had the opportunity to sit down with Blake Schwieters from JL SCHWIETERS CONSTRUCTION to review their off-site construction process. As the Plant Manager of SCHWIETERS in Hugo, Minnesota, Blake oversees all prefab operations. His responsibilities include overseeing the team, ensuring safety compliance, managing project details, and keeping costs within budget. Blake plays a critical role in implementing continuous improvement strategies, including their new truss division. The new WEINMANN line purchased by JL SCHWIETERS is designed to maximize the efficiency and ergonomics of the employees. Allowing for JL SCHWIETERS to produce a superior product quickly and accurately. Framing of walls starts on the WEINMANN framing station FRAMETEQ F-500. This machine enables automated framing with highly accurate indexing, cutting, and nailing and is operated by just one employee. After that the wall panel is automatically moved to a powered buffer table BUILDTEQ A-500 which allows to add blockings to the wall panel and offers some buffer space between the framing station and further process steps. Tacking of the sheathing for exterior wall panels is done on another BUILDTEQ A-500, with additional clamping units to secure squareness of the element. With the multi-function bridge WALLTEQ M-500 the wall panel will be finally processed. That includes automated nailing and routing of rough openings, like window and door openings. Due to high quality requirements of JL SCHWIETERS the wall panel is clamped on another BUILDTEQ A-500 WEINMANN table with a stud straightener to avoid shiners, when nailing the sheathing. This additional support allows the customer to produce high quality products and reduce rework at the end of the line. The final BUILDTEQ A-500 WEINMANN table is used as an off-load table, to stack the wall panels and do the final quality inspection.

Could you tell us about JL SCHWIETERS CONSTRUCTION and the types of projects you work on? 

Blake Schwieters (BS): SCHWIETERS specializes in turnkey framing solutions for residential and commercial buildings by manufacturing, delivering, and installing building components. We are committed to excellence, a commitment that is reflected in high-quality craftsmanship and professionalism on every project.

Can you tell us more about how you learned about STILES and WEINMANN equipment for your business?

BS: Before engaging with STILES, I had limited knowledge about WEINMANN equipment. JL SCHWIETERS has been producing wall panels for 20 years and has been in the industry for 40 years. I became a part of the team in 2013, and being an engineer, I was naturally interested in the machines and equipment we use. I researched to find the best wall panel line. However, during that time, limited options were available in the market. Although some US manufacturers had been around for a while, I didn't find their level of automation to be on par with what we had in our facility. Then, I found WEINMANN through an internet search on wall panel lines and watched several videos about the equipment. That's when it all began.

When you first connected with STILES, what were your initial impressions of STILES as a distributor of WEINMANN equipment? 

BS: My initial perception of STILES was based on the equipment. To me, I don't differentiate between STILES and WEINMANN. In my mind, they are the same, and I associate the quality of the WEINMANN equipment directly with STILES. Unlike some equipment distributors who take an arm's length approach, selling you the product but refusing to support it, STILES stands out as different. Regarding the product, it was clear that STILES is the only one doing that level of service and automation. I wasn't entirely aware of the scope until I entered the sales cycle and understood how big WEINMANN is in Europe and how many lines are operating there. But after talking to people in the industry, it was evident that if you want that level of quality and precision, WEINMANN is the answer.

Could you elaborate on your process of comparing different equipment brands before selecting WEINMANN?

BS: Our new manufacturing facility comprised seven buildings, covering almost 500,000 square feet. Half of the facility was constructed before the recession, while the other half was built post-recession in the spring of 2019. We expanded into truss manufacturing and added another wall panel line. Unfortunately, we didn't have the budget for a WEINMANN line then, so we opted for a local wall panel line instead. It turned out to be a wise decision, as it is a great entry-level line with good value for the price. However, I always knew I wanted to invest in a WEINMANN line for additional automation. I know that many other manufacturers are in a similar position when considering taking the next step in the automation curve.
Based on the STILES service and the reputation of the WEINMANN brand, the decision was easy to make, despite other equipment options available on the market. Other equipment suppliers lack a significant presence in the US, and we wanted a well-developed support structure for our equipment. SCHWIETERS has been in manufacturing for many years, and we understand the importance of having a solid support structure. At the end of the day, we are carpenters and wall panel manufacturers dedicated to producing high-quality products for our customers. We prioritize our craftsmanship and rely on Stiles for support and service to ensure our equipment runs smoothly.

Since purchasing the WEINMANN line, have you needed to seek out service or support? If so, how has your experience been? 

BS: UWe have been in touch with STILES for support since day one, and we communicate with them quite a bit. We understand it's a custom piece of technology, not an iPhone you can buy off the shelf, so we expect it to have some quirks and setup time that we need to figure out. So far, our experience with STILES support has been very good.
The STILES support techs are doing a phenomenal job, especially the one that installed our line. He was extremely helpful during the setup of the machine, and I almost wished that I had talked to him before buying the tools for my line. Another positive experience was placing a parts order, which was like ordering from Amazon in a good way. It was seamless, and everything was delivered quickly.

Were there any other advantages SCHWIETERS experienced while working with STILES throughout the sales process?

BS: Based on our experience, having a supplier who can help with plant layout and provide assurance that machinery will fit in the space can make a significant difference. Having a partner who can offer guidance and support in this area has been critical. STILES provided valuable insights on optimizing production processes and integrating machinery into our existing facilities.
WEINMANN equipment is highly customizable, and it can be overwhelming to select the right options. The way we build today is different from the way we built on our existing line, and it can be challenging to imagine what the new line will be like. We visited a large facility in the US manufacturing with WEINMANN equipment. When I saw their line, I could base our line on what they bought because I knew they think the same way we do. I learned a useful hack that has helped us maximize the use of this equipment, having up-cut saws on the framing station. Overall, I'm happy with all our selections for the line. Having such references in the US is a big advantage when working with STILES, as seeing the WEINMANN equipment up and running is a value-add compared to other equipment manufacturers. 

How has your team benefited from STILES training programs while implementing the new equipment?

BS: I think the training is tough because, while the STILES support techs did a great job since day one, it's hard to train on this equipment. You can work on how the buttons work and how production is supposed to flow, but the real training comes when there's an issue, such as when the machine breaks down. It's hard to do that not in a production flow. Together with STILES, we also found a solution for that. It's essential for us to operate the equipment ourselves for a while to gain proficiency in handling it. Following that, we will undergo additional production support trainings with the STILES support tech to enhance our equipment operation and maximize the effectiveness of the new production line. This paid service is a valuable addition offered by STILES.

The partnership between JL SCHWIETERS CONSTRUCTION and STILES, featuring WEINMANN wall panel equipment, marks a significant advancement in off-site construction capabilities. Blake Schwieters, Plant Manager at SCHWIETERS, highlights the company's commitment to excellence and continuous improvement, particularly through the integration of WEINMANN's automation. This strategic decision enhances production efficiency and solidifies SCHWIETERS' position as a leader in providing comprehensive framing solutions.