CNC improves Wooden Window
Company owner explains the decision process, outcome of major investment
By Jennifer Hicks / Staff Writer
In February Bill Essert purchased a Biesse Rover C6 CNC machine for his custom window and door shop, Wooden Window in Oakland, Calif., and has already seen advantages such as increased productivity and consistent quality of his product. He had contemplated the decision for nearly nine years.
"The cabinet industry has been using CNCs for the past decade, but [CNCs] are very unique to the window and door industry," said Essert. "There are many large window and door companies in the U.S. using this technology, the Marvins and Pellas of the world, but very few, if any, regional companies like ours are using this technology for windows and doors."
Founded in 1980 Wooden Window uses modern techniques and high-tech machinery to fabricate doors and windows for historical buildings, both commercial and residential. Nicknamed "Betsy," the machine, equipped with 33 woodworking tools, now does most of the small-part fabrication, including the cutting, routing and boring, milling each piece to the precise dimension.
Essert said the machine would likely double the company's current revenue, which reached $2.3 million in 2006, over the next couple of years.
About eight years ago Essert updated his shop by adding semi-automated equipment such as hydraulic clamping machines and also by digitizing all measurements. But after seeing a CNC making some entry doors at a woodworking fair, the dream had been planted, Essert says. He later went on a machinery tour in Germany where he visited eight window and door shops that were using CNC technology.
"I was impressed by the productivity, efficiency, speed, accuracy and repetition — having handwork done by hand, and machinery where it was best for machine processes," Essert reflected.
Still, Essert hesitated to invest in a CNC, mainly because the software offerings for the window and door industry were very limited. Anything that was available was oriented towards European-style windows, such as the tilt-turn windows that open inwards, which do not match the architectural style of the San Francisco area.
When he finally decided to make the purchase, Essert hired a software developer. This new employee is still tweaking the machine's tooling, vacuum pods and programs to meet the company's specific market.
The company will pay a capital investment of about $500,000 over the next five years, which includes the Biesse machine and several others to upgrade the shop, like a Martin planer and joiner, Taylor clamp system, Extrema dust collector and another Alup rotary air compressor.
Moving the 20,000-lb. machine was no simple task. Essert remembers several crane operators struggling to get the machine through the small doorway of the 15,000-sq.-ft. shop. Adapting the entire shop around it was even more difficult.
"We had to remodel our entire shop to make this transition. Every piece of machinery, dust collection, compressed air and the electrical wiring in our shop has moved based on this transition around this machine," said Essert. "These machines, along with the software, make up an entirely new system for our shop production. This turnaround took 2-1/2 months, where similar companies have taken well over a year to make these dramatic changes."
Aside from the pitfalls that will inevitably be worked out over time, Essert has seen a number of significant benefits since it was up and running in March.
The union company has 22 employees, including in-house production workers and outside marketing and installation workers. The workflow for the former group of workers has changed for the better.
"Previously, a craftsman would follow each project step-by-step through the shop, doing all of the rough milling, finish milling, assembly and sanding , all the way until priming, glazing and other final steps," said Essert. "Now the guys can just focus on the highly skilled work."
Essert says two additional employees were hired because the CNC has enabled the company to take on some larger-scale work.
"It's complemented our shop. It's allowed us to increase our throughput, to broaden our market share by allowing us to do repetitive jobs. The machine is breezing through 600 historic window sashes," said Essert.
On the marketing end, Essert says the machine has allowed the shop to add features and details to their product very quickly and responsively to meet the needs of customers.
He cited a recent high-end residential job in Presidio Heights, an affluent San Francisco neighborhood, where the owner of the home was in need of immediate increased security. The house happened to have a "safe-room" complete with 2"-thick bullet-proof glass in case of an emergency attack. The doors, which needed stronger hinges and bulletproof glass, couldn't be left out overnight. Thanks to the CNC, the doors were back in the house the same day.
Design-wise, the CNC has also allowed the company to broaden its product offerings. They recently made a scalloped window for a historical house with a number of scalloped panes. Essert says the machine was critical in making that happen.
"In the restoration business, everything is custom," he said. "We have to be very quick to change over designs concepts, profiles, assembly methods and a lot of it can be done up front on the computer."
Contact: Wooden Window, 849 29th St., Oakland, CA 94608. Tel: 510-893-1157. www.woodenwindow.com
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A breakdown of the benefits
Bill Essert, owner of Wooden Window, discussed how the purchase of a new CNC in February has been a worthwhile investment for the shop and for clients.
• Workflow has changed so employees are able to do more skilled craftwork — a benefit that defeats a common misconception that that machine will replace workers.
• Repetitive milling applications are done quickly and accurately, boosting production. The company has already expanded in the commercial sector.
• Projects can be turned around more quickly than the shop's competitors, especially on rush jobs.
• Design-wise, the CNC has allowed the company to broaden its offerings.