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 of windows was well established in the early part of the previous century. The factory line approach was considered an vast improvement over individual hand construction. The mechanization of the line has continued to evolve to near total robotic methods.
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.
Changing a sash profile is one of the most time consuming issues that modernization has be able to reduce. Instead of closing down a manufacturing line for days, a computerized program can shift the movable cutting knives in a modern plant in minutes. The entire production line can be ready in just a few hours or sometimes even less.
As the processes have changed, the facilities that house them have changed as well. Guild halls have become vast automated structures that cover acres. The increases in efficiency have decreased the waste products that need disposal. Turn-around times are such that as-needed shipping has become common.
Modern manufacturing processes for wooden sash windows have improved the availability and decreased the cost of production. Efficiency and flexibility are at new all time highs. And while the craftsman will always have his niche, the production line is here for the needs of millions.
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