ConDoor offers a wide range of doors with customized dimensions for every door size. Each door consists of multiple components where a profile plays one of the key roles. A door profile refers to the joint where the sticking and panel come together. Profile machinery alongside with processes around its usage are the main subjects of modernization in this project.
Traditionally, such profile machines are operated manually: a factory worker would receive an order, configure, start, monitor, control and report on the execution process. In this way, errors would happen since people always make mistakes. The first challenge was to remove the human factor from the manufacturing process of a door profile.
Taking into account that there are multiple profile machines at Condor, it was an operational burden to execute such manufacturing process controlled by the corresponding to machines amount of workers. The challenge here was making costs less at the same time producing more profiles.
Integration and digitalization
A profile machine was operated manually, jobs were configured according to previously printed out sheets. The challenge here was to remove printed forms out of the profile manufacturing process and make profile machine listen to production orders orchestrated by the central system digitally.
Another challenge which Condor wanted to solve is optimal scheduling. It was rather difficult for a worker to determine the best order to achieve maximum speed and efficiency and required departments to negotiate who does what and when. The responsibility was with the worker and often led to a far from ideal processing where the whole door assembly process might queue up waiting for necessary profiles.
Having transparent operations is one of the core values for ConDoor, that is why the challenge of having real-time monitoring was placed on the table and had to be answered in the course of this project.
No impact on local hardware
ConDoor wasn’t ready to invest further into their local hardware and the challenge to build software which would not impact available hardware capacity had laid on our shoulders.
Ability to operate offline
The previous challenge was further constrained with the requirement to be able to produce profiles with internet connection being offline for up to one week.