For Essex-based Mason Projects, who began manufacturing high-end bespoke joinery solutions for the private and commercial market in the wake of a global pandemic, clear direction for the future and a plan to overhaul its original machinery within 18 months was at the heart of its business model. With the help of used machinery specialist, Ferwood UK, the company was able to invest in a Biesse Rover A CNC router and Holzma HPP230 Beam Saw to help them reach their production goals.
“We originally started our business in 2017 to work in partnership with two existing joinery companies but in a relatively short period of time, one folded and the other closed due to retirement,” begins Kerry Mason, Co-Director of Mason Projects Ltd. “We made the decision to start manufacturing bespoke joinery ourselves and took on the lease of our 15,000sqft factory in May 2020.”
“Budget was tight,” admits Kerry. “Most of our staff members came from the other two companies, as did some of our equipment. In theory, we could start manufacturing from day one but we soon ran into problems due to the age of our machines. Some were over 20 years old. This is where Ferwood came in.”
The family-run business couldn’t afford new machinery – nor could they afford to wait for a machine when faced with longer than normal lead times thanks to the pandemic but Ferwood’s Ferwood Functional buying option – which sees used machinery function tested before being installed to reassure customers the machine they are buying is in good order – ticked the box.”
“Ferwood’s offering really worked for us,” admits Kerry. “We had zero confidence in buying a machine from eBay and certainly didn’t want the hassle of arranging all the logistics that came with buying a machine from a private seller or auction site. Ferwood not only had machines in stock and available to view, but they could also test the machine and do all the heavy lifting – leaving us to get on with our day jobs.” Kerry adds, “Their prices also meant that we could spread our budget more widely and invest in other machines and areas of the business.”
The need for modern machinery with updated technology was a huge factor for the ambitious company. Paul Mason, Co-Director of Mason Projects says, “We had an operational factory but we needed it to work efficiently. We needed to work smart in order for our company to move forward. For us, this meant stepping away from the manual imputing of data directly onto the machines - which ultimately saw us doubling our workload after creating the original design files in our office – and being able to transfer data from the office directly onto our machines.”
Kerry and Paul wanted to replace their failing Busellato Jet 3000 CNC router and their unreliable Holzma beam saw. They worked with Ferwood UK to narrow down some options that offered them the technology they needed, whilst giving them the technical specification required to fit today’s budget and tomorrow’s growth plans.
Paul says, “We had a rough idea what we wanted but the team were great at explaining each of the machine’s core processes and limitations. They were honest and that immediately gave us confidence in them. They also had a great selection of machines in stock and could deliver and install each machine quickly. They even offered us training.”
Working predominantly with 8 x 4 MDF, as well as Medite and Egger board measuring 18mm thick, a Biesse Rover A 4-axis pod and rail and Holzma HPP230 Beam Saw were the best fit for Mason Projects.
“The difference when each machine was installed was like night and day,” admits Paul. “Both machines have massively changed how we work and have significantly reduced production times and human error. Jobs that would have taken us a day due to our aging technology can now take us a couple of hours. This has had a massive knock on effect throughout the business and has given us much needed flexibility on the factory floor.”
Working in tandem, the new machines have allowed the company to take on bigger projects and maintain strong profit margins. Kerry explains, “We’ve recently finished a project that saw us create hundreds of wardrobes for a housing developer consisting of 121 new homes. This saw us produce large quantities of carcasses. They needed to be consistently accurate and cleanly cut before being moved to the CNC and edgebander. This is where the beamsaw really came into its own. It was so much simpler to programme and quicker and more precise when performing each cut cycle.”
Production times have also reduced. “Recently, we were asked to complete a large, last minute job that required work to commence immediately,” says Kerry. “We wouldn’t have been in a position to do this before – we simply wouldn’t have had the time – but our new machinery means this kind of ad-hoc job is possible to fit into our existing production schedule with minimal interruption, giving us more opportunities to grow our business.”
Then there’s been the completion of more challenging projects. “We were commissioned to make a beautiful bar in someone’s annex,” says Kerry. “To create the look of a compound curve, we made multidirectional fins that were faceted to create the look of curves on the CNC. It was stunning. With the new machines in place, the project was designed, manufactured and fitted within 12 weeks. This project wouldn’t have been financially viable to do on our old machines due to the amount of time it would have taken to complete the programming and intricate machining. Now, we’re only restricted by two things: imagination and budget.”
Kerry continues, “The machines were a necessity, not a luxury but they’ve certainly paid us back more quickly than we expected and have allowed us to take on larger, more profitable projects we may have struggled to complete before. They’ve also significantly reduced human error, the need for human intervention - both in the office and factory floor – and have helped us start to streamline our production. It’s also given us an opportunity to embrace new software like BSolid, Cabinet Vision and Cabinet Works and incorporate a new barcode system into our processes to increase efficiencies.”
Kerry concludes, “As a company, we’re not afraid of change and we wanted to invest in the right machinery to help us grow. Ferwood have given us the tools we needed to make every success of our business. Once both machines were installed, we saw revenue increase by 35%. Now, we’re working towards doubling our capacity in the next four years. Our growth plan is steady – we know what we need to do – and by working with like-minded companies such as Ferwood, we have every confidence in knowing we’ll reach our goals.”
