Robotic Wall Sheathing Cell: Automating Prefabricated Wall Manufacturing
Robotic Wall Sheathing Cell: Automating Prefabricated Wall Manufacturing
SCADAware engineered a four-robot wall sheathing system that automatically positions, nails, and cuts OSB panels on prefabricated wall frames, increasing production throughput while reducing manual labor.
Wood Component Manufacturing
Advanced Robotic Automation
Custom Software to Maximize Flexibility
Productions, Ergonomic, and Quality Improvement
Automation Project Overview
Industry: Food & Beverage Manufacturing
Project Overview
SCADAware partnered with Rehkemper & Son, Kawasaki Robotics, Mitsubishi, and Güdel to develop an advanced robotic wall sheathing cell for prefabricated building component manufacturing.
The system automates the placement, fastening, and trimming of oriented strand board (OSB) sheathing on preassembled wooden wall frames.
Four Kawasaki industrial robots mounted on Güdel linear tracks work together to handle sheathing panels, drive fasteners, cut window and door openings, and remove scrap material.
SCADAware developed custom software to interpret electronic wall designs and guide the robots through the operations required for each unique wall configuration.
The solution reduces labor-intensive manual operations while improving the productivity and consistency of wall assembly.
The Challenge: Automating a Labor-Intensive and Variable Manufacturing Process
Prefabricated wall manufacturing traditionally requires workers to position large sheets of OSB sheathing over wooden wall frames, fasten the material to underlying studs, and cut openings for windows and doors.
These operations are physically demanding and require accurate placement of fasteners and cutting tools.
For Rehkemper & Son, recruiting workers for these labor-intensive processes had become increasingly difficult. The company also wanted to improve production efficiency and remain competitive in the prefabricated construction market.
One of the greatest technical challenges was the natural variability of wood.
Wooden studs may be warped or positioned slightly differently than their nominal dimensions. Once OSB sheathing is placed over a wall, the underlying framing is no longer visible.
The robotic system therefore needed more than conventional programmed movements. It required a way to align the actual wooden structure with the electronic wall design so robots could accurately place nails and cut openings without damaging the finished assembly.
The SCADAware Automation Solution
Four-Robot Automated Wall Assembly
SCADAware integrated four Kawasaki BX250L industrial robots into a coordinated wall sheathing system.
Each pair of robots travels along a Güdel TrackMotion linear rail positioned beside the wall assembly table, providing the reach needed to work along large prefabricated wall sections.
The robots perform multiple operations using interchangeable end-of-arm tooling, including:
Picking and positioning OSB sheathing panels using vacuum tooling
Fastening sheathing to the wooden framing
Cutting window and door openings
Removing cut sections and transferring scrap material
These coordinated operations automate multiple labor-intensive steps within the wall manufacturing process.
Custom Software Compensates for Wood Variability
Unlike repetitive manufacturing processes where every part is identical, prefabricated wall construction requires the ability to handle unique wall designs and variations in framing material.
SCADAware developed custom software that interprets electronic wall designs and determines the required fastening and cutting locations.
The wall is positioned and squared on an adjustable assembly table. Servo-controlled positioning fingers straighten individual studs to align the physical structure with the electronic design.
This allows the robotic system to accurately locate framing members beneath the OSB sheathing and execute the required fastening and cutting operations.
By combining digital design information with mechanical positioning and coordinated robotic movement, SCADAware developed a solution for a manufacturing process that is difficult to automate with conventional fixed robot routines.
Precision Motion Across Large Wall Assemblies
The system incorporates four Kawasaki BX250L robots mounted on two Güdel TrackMotion Floor-3 linear tracks.
Each track measures 15 meters in length and provides a 12-meter working stroke, allowing the robots to operate across the wall assembly process.
The combination of industrial robotics, precision linear motion, and custom positioning mechanisms enables the system to handle large wall assemblies while maintaining the accuracy required for fastening and cutting operations.
SCADAware coordinated these technologies into a complete automated production cell, integrating robotic motion with material handling, wall alignment, tool changes, and production sequencing.
Technology & System Architecture
Mechanical Engineering & Design
Complete mechanical design of the custom storage, retrieval, structural, and material handling systems.
Servo-Controlled Wall Alignment
Automated positioning mechanisms straighten and align wooden studs before sheathing is installed.
Operator Interfaces
Record confirmed HMI terminals or SCADA workstations and their role in plant operations.
Multi-Function Robotic Tooling
Interchangeable tooling supports vacuum panel handling, fastening, cutting, and scrap removal
Kawasaki Industrial Robots
Four Kawasaki BX250L six-axis industrial robots perform sheathing placement, fastening, cutting, and material removal.
Güdel TrackMotion Systems
Two 15-meter TMF-3 linear tracks provide a 12-meter working stroke for coordinated robot movement along the assembly table.
Automated Material Handling
Integrated conveying equipment positions wall frames and supports movement through the sheathing process.
Integrated Production Controls
Coordinated controls manage the sequence of wall positioning, robotic motion, sheathing installation, fastening, and finishing.
Project Results & Customer Benefits
Project Results: Improving Productivity in Prefabricated Construction
The automated wall sheathing cell demonstrated how advanced robotics can improve a traditionally labor-intensive manufacturing process.
By automating sheathing placement, fastening, cutting, and material removal, the system reduced the manual effort required to complete prefabricated wall assemblies.
According to the published project case study, the automated system increased daily linear footage production by 25% without a loss in quality.
The combination of custom software, precision motion control, and coordinated robotic operations also provided a flexible approach to processing wall assemblies with different dimensions and configurations.
The project demonstrated the potential for robotics to help building component manufacturers address labor availability challenges, improve production consistency, and increase manufacturing capacity.
Higher Production
Track Length
Working Robots
Max Wall Length
Production Equipment, Controls, and Operator Interfaces
Automation Project Gallery
Industrial Automation Expertise for Manufacturers
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Whether you manage a plant, oversee operations, or engineer manufacturing systems, SCADAware can help you assess your automation challenges and plan the next steps. Contact the team to discuss your production goals and project requirements.