Modern production management of windows, doors and roller shutters

The Production Viewing Module is a tool that streamlines manufacturing processes. It uses barcodes placed on production labels attached to profiles. These labels are automatically generated by Stolcad^® Professional. Based on data provided by Stolcad^® Professional they can be printed on saws or cutting centres equipped with printers. Alternatively, if these machines do not have printers, labels can be printed in the office.

In that case, they are printed in the same order resulting from the profile cutting optimization. The employee does not have to search for specific labels, as each subsequent cut always matches the next label. An alternative to barcodes on labels is the programming of electronic data into chips placed on profiles. Such a solution is used when traditional labels are problematic, e.g. in wooden technologies.

Computers with barcode or alternatively chip scanners are installed at individual workstations. At subsequent production stages, the data contained in the barcode or chip allow for quick identification of individual elements. This makes it possible to recognize which order and item they come from. Individual construction parts, such as the frame or sash, are also distinguished.

By scanning the code at their workstation, the employee receives from the database a complete set of production information regarding those elements necessary for further work at their station. The computer screen displays the elements to be installed, selected for that workstation, along with a drawing tailored to their needs.

Imagine a typical workday on the production floor. An employee approaches their workstation, where a task awaits them as part of the window, door, or roller shutter production stage. Previously, they would have had to search through documentation to find out which elements were necessary to complete the order. Today, a single barcode scan from the production label is enough for a precise list of elements to appear on the monitor. The employee immediately knows what to assemble and what the finished product looks like. No time is wasted, and no mistakes are made. Everything runs smoothly and without delays. This scenario is a reality made possible by the Production Viewing Module.

Reducing chaos and automating key processes not only improve efficiency but also increase work comfort. Employees can focus on their tasks instead of wasting time searching for information. The module allows defining various types of workstations, such as reinforcement, gasket installation, fitting, glazing, or quality control. The module does not impose what these workstations are – the technologist can define them freely. Utilizing the advantages of this solution, production employees receive only the data that are necessary at a given moment. As a result, time is saved that would otherwise be spent on manually organizing documentation and searching for information relevant to a specific workstation.

By scanning a barcode, the employee sees on their monitor which elements of a window, door or roller shutter should be assembled at their workstation, taking into account the specific nature of the tasks performed. The displayed lists of necessary elements for the construction are always tailored to the needs of the specific production workstation. The elements shown on the terminals vary depending on the workstation where the barcode was scanned. The same label scanned at two different workstations will display different information and drawings.

For example, the glazing station will display the glass panes to be installed, while the hardware fitting station will show the necessary fittings for the specific sash. Additionally, the drawing at the glazing station will include glass dimensions, while at the hardware station, it will include sash dimensions. What is displayed is determined by the technologist during system configuration. Such data personalization allows employees to respond quickly and efficiently to production requirements without being overwhelmed by unnecessary information.

With the aid of colour markings for non-standard elements and graphic visualizations of finished products, even the smallest details requiring special attention are immediately noticeable. For instance, at the sash hardware fitting station, the data can be configured so that variable elements such as espagnolette locks are listed in blue, and scissors in green. This way, the employee quickly becomes accustomed to associating the blue-coloured information with the espagnolette to be installed.

Construction drawings can be individually configured for specific workstations. If the structure contains more than one sash, the program will recognize and display information only for the scanned sash, which is particularly important at the hardware fitting station. Such visual assistance ensures precise execution of each production stage, regardless of its complexity. This guarantees that no critical element is overlooked. Employees can quickly respond to specific requirements, improving product quality and shortening order completion time.

Stolcad^® Professional also ensures that non-standard and critical elements are never overlooked. Highlighting such elements on the production screen using colours helps employees to identify them. For example, non-standard elements can be marked with bright colours, and a standard corner joint or sash hinge can be listed in black. At the same time, if a short corner joint or a hinge over 130 kg is to be installed in the sash, its symbol can appear in red so that it is clearly visible.

The employee will immediately notice that a non-standard element must be installed and will not miss it. Colours can also be used to categorize elements. Moreover, production managers have the option to send individual text messages assigned to specific order items directly to production screens. These messages are helpful in cases of non-standard solutions or when items require special attention. This ensures that even the smallest details are not overlooked during production.

One of the main causes of production disruptions is shortages or defects in materials, such as damaged profiles, cracked glass panes, or missing hardware elements. These problems can lead to downtime, decreased product quality, increased operational costs, and order delays. The key element in minimizing the effects of disruptions is the quick and efficient reporting of issues. Previously, when a production worker noticed an unexpected situation, they were required to immediately inform a supervisor to take appropriate action.

However, this involved leaving own workstation. Upon returning, the worker had to resume work and continue processing the next items from the production plan. Failure to report an error could lead to a decline in the quality of final products, while the absence of the worker from his or her workstation could cause delays and disruptions in production continuity. Additionally, an unreported error might be lost in the workflow and might be not resolved effectively.

The Production Viewing Module addresses these issues by enabling workers to report any problems quickly. Production managers can define various types of errors individually assigned to different workstations. Such errors may include, for example, a "cracked glass pane" or a "scratched profile". A specific error can be reported by selecting the error message from a dropdown list or by scanning a special error message barcode located at the workstation. Then, the worker scans the standard production label. Error messages are automatically sent to Stolcad^® Professional and the error status is immediately visible in the system. The colour of the reported order line changes automatically, making it stand out from orders with no detected issues.

When a production manager sees a highlighted order, he or she can check its details. In the case of a reported error, it is immediately clear which item it concerns. Additionally, they can see what the error is, the time it was reported, the data of the reporting person, and the workstation from which the report originated. Based on this, the manager can take appropriate action at a convenient time. After resolving the problem, they can remove the error information directly from the workstation by scanning a special barcode designated for this purpose. This solution significantly improves production process stability and minimizes downtime-related losses. The worker does not have to leave their station to notify a supervisor of an error. They can set aside the problematic product and continue working on the next item.

The Production Monitoring Module is a modern IT tool for production managers, enabling the monitoring and mapping of the physical production process in real time. The entire production flow is recorded and reflected in the computer program, allowing progress tracking at every stage – from the start of the order to its completion – without having to leave the office. Data from the production floor are automatically collected in the central database of Stolcad^® Professional, as well as it is visualized in the order screen and production tracking panel. Every barcode scan is saved as an individual entry assigned to a specific window piece in the order. With the help of this IT solution, full control over the production process is achieved, increasing management efficiency.

The finished goods warehouse is the place where completed structures are temporarily stored before being handed over to the customer or prepared for transportation. Continuous tracking of the finished goods warehouse status is crucial when deciding to release the goods once the entire order is complete.

The Finished Goods Warehouse Module allows for the collection of production data and their clear presentation to support decision-making in the process of preparing orders for customer delivery. Information on the finished goods warehouse status is collected in the program and can be checked without leaving the office.

The arrival of the finished product at the warehouse and its release are two key stages in the production process. To accurately reflect warehouse stock in the system, the warehouse worker scans the product's barcode at the computer station responsible for receiving the product. The passage of products through warehouse stations automatically updates statuses in the production monitoring window, providing a complete picture of their flow.

Additionally, if the worker enters the cart number while scanning – for example, by scanning its barcode – the system assigns the product to that cart. It is also possible to assign compartment numbers on the carts, which helps later locate products in the warehouse. Compartments can be registered automatically according to the scanning sequence or manually using dedicated barcodes.

Information about all products received into the warehouse is available in Stolcad^® Professional in a dedicated table: "Status of finished goods warehouse". This table includes data for each piece of product, such as the order number, customer, warehouse location, date and receipt document, and possibly the date and release document number.

If the information about the location of a product on the cart and shelf does not match reality, all needed corrections can be made in the status window. The data from the status of the finished goods warehouse can be printed or exported in table format, for example, for inventory purposes.

In the window production, there is always a window assembly station where pre-assembled sashes are inserted into the prepared frame. Since the lines of fitting hardware to frames and sashes are two different lines, synchronizing these two independent processes – frame and sash production – is crucial. These elements are produced at different speeds and in different sequences, making their efficient assembly more difficult. The worker who assembles the window already has the frame available. Now, they must find the sashes for that frame. Without IT support, they would need to leave their station and search through the completed sashes to find the ones to be installed in that frame. This wastes time and may also result in the situation where the sashes are not yet ready.

One solution to this problem is the sash buffer, which is an area with numbered compartments where employees place completed, hardware-fitted sashes. To optimize this process, the employee assembling the window should quickly receive information on whether the sashes for the prepared frame are ready for assembly and in which compartments they are located. The sash buffer system allows for instant identification of sets – it is enough to scan the barcode on the frame to check the status of the sashes. If the sashes are not available, the employee can scan the next frame. Enhanced by this, the process of joining frames and sashes does not require strict coordination between production lines, and each line can work at its own pace, adjusted to available resources and the production schedule.

After completing the hardware fitting of a sash, the employee scans its barcode label. On the screen the number of a free compartment in the sash buffer is displayed so that it is clear where the sash should be placed. The completed sashes wait in the buffer until the window assembly worker retrieves them, and scans the barcode label on the frame. The screen displays which compartments in the sash buffer contain the sashes for that frame. They immediately know where to go and which sashes to take. After removing a sash, the compartment in the buffer becomes available. The employee fitting hardware on a sash, after completing the work and scanning the label, can receive information indicating that the sash should be placed in the just-freed compartment.

Such cycle repeats many times. It may also happen that, instead of receiving the compartment number where the sash is located, the assembly station displays a message that the required sash is not yet available. The employee then temporarily sets aside that frame and takes the next one for assembly. He or she no longer has to waste time looking for a sash that does not exist yet. Multiple independent sash buffers can operate in production. Stolcad^® Professional ensures precise production synchronization and smooth cooperation between production lines. With the help of the software each production line can operate at maximum efficiency, without downtime caused by missing components.