Modern manufacturing processes for wooden sash windows are now among the most automated of manufacturing processes. It has only been in the last century that mass production has had any impact on sash windows at all. Window sashes before the early part of the 20 Th century were cut by hand.
Each sash was handmade and required hours of work and hours of training. Usually a single master craftsman would pass his skills on to one or more apprentices. They in turn would practice the proper construction and carving of the sash. It was a lengthy process.
Today, a cutting edge, modern factory can change sash specifications in a matter of minutes. Just a few key strokes can reprogram dozens of robotic stations to perform the same tasks that would have required hours to set up in factories only few decades old. Now employees learn computer programs rather than how to sharpen a cutting tool.
Mass production is nothing new to sash manufacturing. As early as 1900 the idea of mass producing sash parts in a factory was well established. From there the mechanization of mass production increased rapidly until robots handle the majority of actions in some plants.
Because historical restoration often requires authentically produced, window sashes, the need for the skilled master craftsman will likely continue. Any house on the National Registry of Historic Homes would need the services of many such craftsmen. Of course the cost is enormously greater as well.
Window sash styles come in a huge number of profiles. It used to require hours of physical labor to change the cutting knives of factory equipment when one job was complete and another was to begin. The more modern factories can now instruct movable jigs to slide into the proper profile design in record time. The days of closing down while retooling are nearly gone.
The facilities for construction have evolved over time as well. Vast automated factories can cover acres of ground. The efficiency of these behemoths is greater as well, lessening the need for waste handling. With robotics and other modern processes, as-needed shipping is becoming the norm. Gone are the guild halls when it comes to quality control.
Such flexibility and efficiency have transformed the cost of manufacturing and the availability of products around the world. From single blade cutting tools, handled by master craftsmen, the modern manufacturing processes for wooden sash windows have truly advanced. The future can only add to that upward trend. Robotics and automated warehousing will only increase the level of efficiency and product availability.
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August 30, 2010 by Craig Beck