With the complete refurbishing of its window production, the medium-sized insulated glass and window manufacturer Stader Glas has taken an important step toward innovation and expanded its capacities.
Outside Hamburg, Germany and not far from the company’s headquarters in Stade, Stader Glas found ideal conditions for the production of its ELKA window and door systems: a generously-designed, barrier-free hall.
By starting with raw space, Stadler was able to design its new, highly automated window production facility to maximize efficiency. This began with optimal placement of profile storage, right next to the processing center for direct feeding.
In this facility, no extra steps are taken – and this is a good thing. No components or production papers are carried around – there is no 'worthless' work. Rotox buffer systems, shuttles, and transport lines ensure that the components in the various areas make their way correctly through production, and that they are combined and glazed intelligently.
This high-tech production is controlled by A+W Cantor industry software. Information that was once provided on paper is now displayed on large production screens, production steps are triggered and reported completed by continuous bar code support, work is done on machine and manual terminals: machine technology, buffer, and transport systems and the A+W Cantor EDP system work hand-in-hand and are optimally attuned to one another.
Cleanly planned – delivered right on time
Nobody has to search for parts, everything is ready at the right time in the right place. Even before production starts, A+W Cantor MaWi (materials management) ensures this. A+W Cantor schedules each order immediately after it is "clear." Production capacities are reserved, start and end dates in production, and especially the delivery date are calculated.
Thanks to materials management, when an order is entered, it is automatically determined whether all required parts are available or whether something has to be (re)ordered. This allows the Stader team to plan reliably. "The MaWi," explains Managing Director Hans-Hermann Lemke, "works really well – which is a clear advantage of A+W Cantor."
Orders that are cleanly planned and checked—to ensure they can be built—run reliably, without faults, and as quickly as possible through the production processes. This is the secret of on-time delivery and, naturally, also of great customer satisfaction.
Intelligent production logistics
Processed frames and sashes are conveyed via transport routes and shuttles to defined storage spaces in buffers or on to assembly. Sashes, frames, and glass are combined centrally and in time-optimized fashion. The feeding in and removal of elements happens in the clever interplay of the buffer and conveyor technology with the A+W Cantor production software.
In glazing, the sheet and construction elements come together automatically. After an order-related pre-entry of the sheets via scanner and bar code, the appropriate sheets can be fed in and, by reading a bar code on the sash, requested by the worker and sorted out. Because there is no need to look for sheets and move them manually, there is less damage from scratching or glass breakage.
Insulated glass production and management in Stade
At its headquarters in Stade, the company has been producing functional insulated glass for con-struction element and facade manufacturers and metal workers in Northern Germany since 1969, and of course also for the company's own window production, which began in 1979.
Therefore, Stader Glas is one of the few companies in Germany that manufactures both insulated glass as well as PVC windows and doors. Stader Glas provides a full spectrum of high-quality Sanco functional glass, including thermally-insulated glass, combined sound-proof/heat protection glass, solar pro-tecting insulated glass and safety glass.
For the glass and window divisions, sales and advising, order processing, and shipping control are handled centrally in Stade. In both business areas, Stader Glas has relied on A+W software for dec-ades. The company places great value on expert customer support by inside sales: the company regards itself as the customer's partner and a problem-solver in complicated cases.
Glass orders from the Cantor window construction software are transmitted electronically via EDI to A+W Business, the commercial system in the glass division.
With the EDI connection, explains IT Manager Karin Heinsohn, all order parameters such as complex glass structures, shapes, and grilles are taken over reliably and generally without manual reworking directly into A+W Business.
From there, they are transferred to glass production for scheduling with A+W Production. For the glass division too, explains Managing Director Hans-Hermann Lemke, investments will soon be made in software and machines so that the company can optimize its processes there too and reduce pro-duction costs.
Top service for top products
Beyond having the highest quality, a broad product line, and a readiness for constant innovation, Stader Glas' service makes the company stand out. Their expert, committed technical advising also includes assisting customers with difficult installation situations on construction sites.
All Stader Glas trucks are equipped with cranes, and suction frames with high load capacity are also available. This enables Stader Glas specialists to provide professional storage, assembly, and implementation assistance on-site and to bridge distances of up to fourteen meters – a service that is especially important to facade builders who can save time and personnel costs.
The company’s knowledgea-ble drivers have become brand ambassadors for Stader—contributing significantly over the years to customer loyalty.