JELD-WEN has integrated a third production line into its Penrith manufacturing facility, increasing capacity and strengthening its ability to deliver doors at scale.
The Penrith facility had previously been operating at maximum capacity, providing an opportunity for the manufacturer to scale up. Now fully operational, the line enables the factory to increase production by 50% and has also created 30 new roles at the site, supporting local employment.
The specialist door manufacturer redesigned the factory layout as part of a wider efficiency drive across the entire business. The extra production line, enhanced by AI technology, will not only boost output but also streamline workflow in tandem with the company’s new Sheffield site.
Strengthening the company’s ability to support customers in navigating an increasingly demanding market, further helping to deliver fire-compliant doors for multiple projects with tight time schedules, Dom Gaffey (VP, GM UK France and Export at JELD-WEN UK), explained: “The additional line will greatly support our abilities to deliver at scale, but that’s just the tip of the iceberg.
“It’s a true investment, not just in terms of capacity, but also for efficiency and productivity. We’ve integrated advanced technology into our new line, as well as carefully considered sustainable solutions, all with the purpose of bettering our production at scale.”
Dom continued: “The whole line will run seamlessly from end to end, which is unique compared to other production lines across our European footprint. This means we will be assembling, pressing, trimming, inspecting, packing and stacking the doors in one single piece flow, producing five doors per minute.”
AI optimisation will perform autonomous quality checks as part of the process. Every door in production passes through a camera system which uses self-learning to identify any potential defects and segregate them.
Dom added: “By optimising operational efficiency, we have also created a more productive, healthier working environment for our teams. Increasing output helps to reduce costs and, thanks to more efficient resource allocation, minimises waste.
“Being able to produce and deliver at increased scale will put us in a strong position to meet future demand in the markets which we serve.”
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