Flexible and Efficient Light-Steel Framing Custom Assembly Lines

Industrial EquipmentGenesis

C4 is a complete just-in-time production line that encompasses assembly, conveyance and material handling of panels in the most cost effective, safe and ergonomic manner. The C4 line can be either implemented for Genesis Solution Providers or as Part of the Coil-to-Panel (CTP) production line combined with the Material Optimization Technology (MOT) for Genesis Licensees. The C4 line is a combination of lean assembly processes providing optimized productivity for typical and

individualized market sectors. Utilizing various levels of automation the C4 ensures that the highest standards of quality are consistently achieved. The line is designed to provide a flexible process flow to efficiently produce wall, floor and roof panels for the residential, commercial and institutional markets. C4 will automatically adjust to the specifications (height, length and number of connections) of a panel with no downtime making it the most flexible and efficient LSF custom assembly platform available.

A Turnkey Industrial LineLean, Customizable and Scalable

Industrial Line

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4 Real-time Production Tracking

Coil-to-Jobsite Product Traceability

Lean LSF Manufacturing

Flexible Process Designed to Efficiently Produce Wall, Roof and Floor Panels

ProductivityThe C4 equipment is designed around maximizing production up-time. Different levels of automation are available for each piece of equipment, but the output of the machine is never compromised. The C4 equipment requires a very limited amount of preventative maintenance and is easy to operate and troubleshoot. The C4 provides “smart” levels of automation where it helps to reduce labor head counts and adds capacity without compromising the efficiency of the machines.

C4: Genesis 4 Step Assembly Process

Labor OptimizationAs an industrial innovator Genesis constantly focuses on a lean manufacturing strategy whereby we endeavor to reduce all forms of waste and increase productivity. The waste of humane capital is one area of focus. The C4 equipment has been designed to eliminate all non value added work by the operators: walking, lifting, reaching and other material handling tasks. All conveyance and material handling equipment was developed to provide the safest and most ergonomic assembly environment for the operators, so their productivity is maximized.

As the sequenced components flow through the plant from the picking area or MOT output to final inspection and shipping, the production assembly steps of the kit into a finished product are fully traced. Hand held industrial scanning devices allow operators to scan the kit labels bar code as it enters and exits each C4 assembly station. This enables plant supervisors and management to track production in real time to measure productivity and implement focused action plans in areas that need improvement.

Coil-to-Jobsite Product Traceability

SequencingThis first stage in C4 can be used with cold formed steel material purchased from a Genesis licensee or in combination and synchronization with MOT. The Genesis Material Transfer (GMT) is the focal point of that link. It consists of a robust maintenance free 2-level sectional conveyor that allows panel kits to be loaded, conveyed and unloaded safely. After the panel kits have been produced they move in sequence for fabrication from the picking or MOT area to the pre-assembly and fastening areas.

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Live LoadingGEM rigidly controls the sequencing of the panels throughout the entire manufacturing process based upon a site delivery schedule. Panels can be grouped in work orders or by site block number to ensure that the panels delivered to site are those which are to be erected first. Prior to being loaded a final inspection takes place. Once the panels have been bundled and strapped into groups ready for dispatch (typically 6-12 panels) a custom lifting device attached to an over head crane loads them safely onto trucks within the plant.

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2 Framing - GFT for Rectangular PanelsThis is the second stage of C4 and is a key driver in the efficiency of the overall process. It provides the most reliable, cost effective and ergonomic off-site framing technology available in the production of LSF panels. The one piece of equipment provides a consistent process for squaring, bottoming out and fastening rectangle panels of infinite shapes and sizes to a high quality with no down time. The Genesis Framing Table (GFT) is an unrivalled solution to frame wall and floor panels (typically under 10 minutes per panel). It provides all tools and devices needed to quickly load and align components in place, fasten all connections with screws, without the need to flip the panels.

Framing - GFT for TrussesGFT for trusses is the solution to framing panels of irregular shapes (typically under 20 minutes per truss). Similarly to the GFT for rectangular shapes this unique table provides dimensional and angular “smart “ devices to allow operators to quickly position, clamp and fasten all components required for floor panels of irregular shapes and trusses of any kind (scissors, flat, mansard, jack, common, or complex). It is also possible to further enhance the speed of assembly by adding a complete laser system to the GFT as an upgrade.

3 SheathingThis third phase in C4 relates to the exterior sheathing of the steel panels. At this stage custom tables with lateral passage allow workers to convey the panels safely and with little effort from the fastening station via a pop up conveyor system. Here a combination of sheathing (dens glass, OSB, plywood, gypsum, rigid insulation, etc) can be cut to size and fastened efficiently and with relative ease. The jigs are combined with the latest nailing technologies for fixing multi-layer material such as dens glass and gypsum into steel members.

Sequencing

CTPC4-GMT4 GMT Conveyor System 4 lanes with Free Return

CTPC4-GMT3 GMT Conveyor System 3 lanes with Free Return

CTPC4-GMTP GMT Conveyor Power Return Upgrade (for GMT3 & GMT4 only)

CTPC4-GMT2 GMT Conveyor System 2 lanes with Free Return

CTP-SLC "Panel Kit" GMT Carts - Single Load

CTP-DLC "Panel Kit" GMT Carts - Double Load

Framing

CTPC4-GFT4 Framing Table Manual - 24' | 7.3 m H x 18' | 5.5 m L w/ Dual Overhead Gantry System equipped w/ Ergo-Tools

CTPC4-GFT3 Framing Table Manual - 18' | 5.5 m H x 18’ | 5.5 m L w/ Dual Overhead Gantry System equipped w/ Ergo-Tools

CTPC4-GFT2 Framing Table Manual 12' | 3.6 m H x 18’ | 5.5 m L w/ Dual Overhead Gantry System equipped w/ Ergo-Tools

CTPC4-GFTP Framing Table Automatic Fastening Upgrade

CTPC4-BLS2 Buffer-Lift Station Dual-Rail

CTPC4-BLS3 Buffer-Lift Station Tri-Rail

CTPC4-TRJS Semi-Automated 40' | 12 m Truss Assembly Table

CTPC4-TRJ Semi-Automated 60' | 18 m Truss Assembly Table

CTPC4-TRJP Semi-Automated 60' | 18 m Truss Assembly Table with Laser Layout System

CTP-AG Pneumatic Screw Guns c/w fittings & 50' | 15m Recoil Air Hose Reel

CTP-EDPD Electrical Drill c/w Power Driver Unit

CTPC4-TLD Truss Lifting Device Single

Sheathing CTPC4-SHT Sheathing Tables

CTPC4-SHTG Sheathing Fastener Gun GypFast

CTP-AG Pneumatic Screw Guns c/w fittings & 50' | 15m Recoil Air Hose Reel

CTPC4-SHTLD Sheathing Material Vacuum Lifting Device & Boom

Live Loading

CTPC4-ROR Uni-Directional Roller System

CTPC4-PLD Panel Lifting Device Single & Bundles

CTPC4-MKIT C4 Installation and Maintenance Tool Kit

Information Technology Hardware

CTP/CTJ-WNA Wireless Network Antennas

CTP/CTJ-BCS Wireless Barcode Scanners

CTP/CTJ-SWB Time Clock Barcode Swipe Card Reader

CTP/CTJ-CPRT ID Card Printer & Accessories

CTP/CTJ-LPRT Product Label Printer (incl. 96 Ribbons)

CTP/CTJ-LAB Label Supplies (Qty: 100,000)

CTP/CTJ-EXE Executive Dashboard Management Display

CTP/CTJ-PSD Plant Station Display

C4 Industrial Equipment

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Modular Expandable Portable

Quality CSA, UL & CE certified, full industrial safety-compliance Floor-Leveling adjustment incorporated on all industrial equipment Heavy duty, robust rollers on all conveyance products High capacity scissor lifts with 35% safety factor minimum Air filter and regulators on all pneumatically activated products Maintenance-friendly design providing easy maintenance access to machinery components without tear down or dismantling

Other Features Auto-quality clamping and squaring of wall and floor panels and trusses, including “bottoming-out” load monitoring

Superior Conveyance Built-in-ergonomic handles, devices and fixtures Dedicated Human Machine Interface (HMI) on each automated piece of equipment with start-up procedures, production status and user-friendly troubleshooting screens

Individual Line output of 35 to 42 wall or floor panels and 24 to 30 trusses per 8-hour shift with 6 operators

Flexibility Product Manufacturing versatility: wall | floor panel sizes up to 24’ | 7.3 m in height and 18’ | 5.5 m in length, truss span up to 50’ | 15 m

Single Minute Exchange Die: less than 1-minute machine change over, when required Compact, Modular, Portable machines, that fit into standard shipping trucks or containers, easy to install, re-arrange, move and re-deploy to another facility if required

Upgradable framing tables: Three standard sizes of framing tables are available. Smaller tables can be upgraded at any time on-site with minimum production interruption

No Flipping of Panels

C4 200 C4 300 C4 300+ C4 400 C4 400+

Number of Operators 7 17 13 22 17

Production Floor Space 8,000 - 11,000 sq.ft. 725 - 1,000 sq. m

15,000 - 20,000 sq.ft. 1,400 - 1,800 sq. m

15,000 - 20,000 sq.ft. 1,400 - 1,800 sq. m

23,000 - 29,000 sq.ft. 2,100 - 2,600 sq. m

23,000 - 29,000 sq.ft. 2,100 - 2,600 sq. m

Fully Upgradable Assembly Lines

Flexible Configurations Based on Your Market Penetration Objectives

C4 can be configured and customized based upon individual market penetration objectives and it can be expanded and upgraded at any time to increase the levels of automation. Genesis offers 5 pre-engineered turnkey packages that are clarified and compared in the C4 Models chart below. The C4 200 and 300 models are generally targeted towards Genesis Solution Providers to serve a specific market on one shift operation. The C4 300+, 400 and 400+ models are more geared towards Genesis Licensees as part of a complete Coil to panel (CTP) industrial set up integrated with Genesis Material Optimization Technology (MOT).

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200

C4 Models

C4 200 C4 300 C4 300+ C4 400 C4 400+

Volume (Combined wall/floor panels & trusses/8 hr Shift)Labor (Number of Workers)

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27

35

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94

114

129

156

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124

155

1 One shift of 8 hours, 50-minute break per shift, 95% efficiency2 48 weeks a year, 5 days per week

3 Assuming 35 sq.ft. | 3.25 sq.m total gross building area 4 Assuming 50 sq.ft. | 4.5 sq. m per average truss (25’ | 7.5 m long)

5 Assuming 100 sq.ft. | 9 sq. m per average truss (25’ | 7.5 m long)

C4 200 C4 300 C4 300+ C4 400 C4 400+

Daily Wall/Floor Panel Production1 35 70 84 105 126

Number of Panels Produced / Year2 8.400 16,800 20,160 25,200 30,240

Gross Building Area / Year3 294,000 sq.ft. 27,000 sq. m

588,000 sq.ft. 54,000 sq. m

706,000 sq.ft. 64,000 sq. m

882,000 sq.ft. 80,000 sq. m

1,050,000 sq.ft. 96,000 sq. m

Daily Truss Production1 12 24 30 24 30

Number of Trusses Produced / Year2 2,890 5,780 7,200 5,760 7,200

Gross Roof Area / Year (2' | 0.6 m spacing)4 144,000 sq.ft. 13,000 sq. m

288,000 sq.ft. 26,000 sq. m

360,000 sq.ft. 33,000 sq. m

288,000 sq.ft. 26,000 sq. m

360,000 sq.ft. 33,000 sq. m

Gross Roof Area / year (4' | 1.2 m spacing) 5 288,000 sq.ft. 26,000 sq. m

576,000 sq.ft. 52,000 sq. m

720,000 sq.ft. 66,000 sq. m

576,000 sq.ft. 52,000 sq. m

720,000 sq.ft. 66,000 sq. m

C4 Specifications (One Shift)

Labor vs. Productivity Summary Chart

Contact Us

C4 is a complete just-in-time turnkey production line that encompasses assembly, conveyance and material handling of panels in the most cost effective, safe and ergonomic manner.

For more information, please contact us at:

www.genesisworldwide.com

Email: info@genesisworldwide.com Toll Free (North America): +1.866.311.3711 Phone: +1 (905) 879.9000

10877 Keele Street, Bldg. A Vaughan, Ontario L6A 0K6 Canada

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