Dunsteel case study
Efficiency is key to meeting budgets and ensuring accurate designs in the construction industry.
That’s why we helped Dunsteel with a groundbreaking project to automate the design process for their metal stairs in their 100+ tonne workshop.
Dunsteel is a 50-year-old, family-owned steel fabrication business at the forefront of prefabricated stairway design for large multistory buildings for leading building firms and architects.
Working with Dunsteel, we transformed a time-consuming manual process into a streamlined, automated solution that saves time and ensures compliance with Australian standards.
The challenge
Dunsteel approached us with a significant problem: their engineering team spent excessive time designing each set of stairs.
This slowed down their quoting process and impacted their ability to capture leads effectively. They needed a solution that could:
- Reduce engineering hours per stair set
- Improve quote turnaround time
- Provide instant, accurate minimum footprint calculations
- Ensure compliance with Australian standards
Concept and detailed designs
We began by analysing the current stair design process and Australian construction standards. This phase involved:
- Studying the Australian standards for stairwells
- Analysing the parametres that influence stair design
- Identifying bottlenecks in the current design process
Based on our research, we conceptualised an Industry 4.0 solution that would automate the stair design process. Key features of our concept included:
- Parametre-based design automation
- Minimum footprint calculation based on floor height and occupancy
- Automated generation of shop drawings
In the detail design phase, we:
- Developed algorithms to calculate the smallest compliant footprint
- Created a user-friendly interface for inputting key parameters
- Designed an output system that generates Excel-based shop drawings
Our team developed an innovative automation tool that innovates the stair design process using:
Automated design engine: The core of our solution is an algorithm that takes key parameters (floor height, people per floor) and generates a compliant stair design with the smallest possible footprint.
Instant quoting: The system allows Dunsteel to provide quotes and minimum footprints over the phone, dramatically speeding up the quoting process.
Automated drawings: The tool generates workable shop drawings in Excel format, eliminating the need for manual drafting.
Standards compliance: All designs automatically comply with Australian standards, reducing the risk of errors and rework.
Challenges
Our primary challenge was integrating our automation solution with existing software and models. We worked closely with external automation providers to ensure compatibility and rebuild models where necessary.
Results and impact
While the full implementation is pending, the framework we created has already yielded significant benefits for the company, including:
Improved lead capture: Providing faster quoting and immediate information significantly enhances Dunsteel's lead capture process.
Reduced engineering hours: The automation framework has the potential to drastically reduce the engineering hours required for each stair set.
Enhanced compliance: By automating compliance with Australian standards, the risk of design errors is minimised.
Recommendations for the construction industry
This project demonstrates the potential of automation in the construction industry. As the world moves towards more integrated digital solutions, projects like this will become increasingly common and necessary for maintaining competitiveness.
Based on our experience with this project, we offer the following recommendations to manufacturers in the construction industry:
Embrace automation: Look for opportunities to automate design and quoting processes to improve efficiency and customer service.
Cross-industry innovation: Look outside your immediate industry for solutions. Technologies from other sectors can often be adapted to solve construction challenges.
Prioritise compliance: Integrate regulatory compliance into your automated systems to ensure consistency and reduce risk.
Invest in digital transformation: While the upfront costs may be significant, the long-term benefits of digital solutions in terms of efficiency and competitiveness are substantial.
This case study illustrates the transformative power of automation. By developing a smart, standards-compliant automation tool for stair design, hone.pd demonstrated how technology can streamline processes, improve customer service, and drive business growth.
At our hone.pd, we're committed to pushing the boundaries of what's possible and bringing innovative solutions to age-old problems.
This project bridges the gap between traditional manufacturing and cutting-edge technology, paving the way for a more efficient, automated future in construction design.
Good design stands out. Get in touch with us today to kick-start your new product design project!