Behind the scenes in production

What goes on when Masonite Beams’ lightweight joists are manufactured and what characterises production? Erica Nordström is working as Acting Production Manager and takes us behind the scenes in the factory in Rundvik, in the Norrland region of Sweden.

547,364 metres of finished lightweight beam. This is how much Masonite Beams produced in September 2019, which was the best month so far in terms of the number of metres produced.

“We operated two shifts in the factory all month, and production ran without any major operational disruption. This requires us to carry out maintenance on the machines meticulously and perform continuous checks,” explains Erica.

Joists up to 18 metres
So what does the process look like, from start to end, when a lightweight beam is manufactured? Erica explained:

“Firstly, all the timber goes through a scanner that sorts out any timber that fails to meet our high quality requirements. Then all of the timber is cut lengthways and glued into different lengths. All of the timber is then planed into flanges and in some cases cut, depending on the type of beam. We do manufacture lightweight joists in standard lengths up to 13.3 metres and are also able to produce lengths up to 18 metres. Finally, the flange and web material are mounted to create lightweight joists in the station we refer to as the beam line.

“In addition to production, we also have our own department in which we functionally adapt the joists, for example with mitre cuts, insulation and hole-cutting,” explains Erica.

Benefits the (household) environment
Masonite Beams’ lightweight joists are unique from several perspectives, and demand for them is increasing as electricity prices increase and the environmental requirements for new construction projects are tightened.

“The lightweight joists have an I-profile that means better material utilisation and minimised thermal bridges, which reduces heat leakage and cuts household costs,” says Erica, continuing:

“One new feature this year is that we’ve replaced web material from OSB with particle board. The updated lightweight beam has the same good properties as before, we know that from precise long-term tests. The difference is that we now have full control over the whole production process, as we’re now using particle boards that have been produced within our own Group. This increases both delivery performance and price stability, and we also reduce our transport operations.”

Stimulating improvement work
As a general rule, there are 22 operators working at the factory in Rundvik, allocated to two different stations and shifts. Erica herself is usually an operator, but right now she is serving as Acting Production Manager for one station, the finger cutter.

“As Production Manager, my work deals a lot with improvements, for example processing new ideas that enhance safety and further improve the work environment. It’s also my job to make sure that production runs efficiently and smoothly. Being closely involved and being able to have an influence is incredibly stimulating,” explains Erica.

Guarantees quality
Performing continuous random sample checks and controls on the joists is one of the cornerstones of the whole business.

“Our ongoing quality tests are incredibly important for us, as we’re extremely keen to guarantee the strength, so that the joists maintain the high level of quality we promise. Thanks to the tests, it’s very rare for us to have complaints about our products,” explains Erica.