Hensen Robinson Modernizes Its Fabrication Workflow With Cloud+

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Learn how Cloud+ brought a uniform workflow for both pipe and sheet metal fabrication.

“I was happy to be able to work with PypeServer to come up with software that is useful to the “dry side”. This software has been working very well in our shops and field.”

– Derek Miller, VDC Ventilation Designer

CASE STUDY

Q&A Interview With Derek Miller, VDC Ventilation Designer at Hensen Robinson Company

How Henson Robinson Unified Multi-Trade Fabrication with PypeServer Cloud+

About Henson Robinson Company

Henson Robinson Company is a premier mechanical, plumbing, roofing, and HVAC contractor known for handling complex commercial, institutional, and industrial projects. To maintain the high level of precision and service their clients expect, Henson Robinson recently modernized its fabrication workflow by coming online with PypeServer Cloud+. While PypeServer has long been the industry standard for automating heavy piping workflows, Henson Robinson has uniquely broken new ground by leveraging the platform to bring that same model-driven efficiency to their high-volume sheet metal and ductwork operations.

Below is an interview with Derek Miller exploring Henson Robinson’s journey toward a fully integrated, multi-trade shop.

To kick things off, could you tell us a bit about Henson Robinson Company, the types of projects you specialize in, and your role in overseeing the fabrication operations?

VDC/BIM Mechanical Duct Designer. With this title it becomes more than just creating a 3D Model. I manage the duct database, provide training for piping database to fellow co-workers. I developed the model-to-shop workflows and tracking for both of Henson Robinson’s duct shops. I work closely with the project managers/field superintendent/field foreman and shop foreman through all stages of preconstruction to final install. I’m the point of contact when there are issues pertaining to anything technology related to our duct shops.

I have been in the Sheet Metal union since 2012. I spent from 2012-2016 as an apprentice, then worked 2016-2020 on various projects as a journeyman; foreman; and Test, Adjust and balance Technician. In June 2020 I started my journey into the VDC world. The projects we work on in our VDC Department can be as little as 1,000 SF to 80,000+ SF.

A few projects I have worked on are the Illinois State Capitol North Wing Renovation (Springfield, IL), IDOT Labs (Springfield, IL), Sarah Busch Lincoln Hospital renovations (Mattoon, IL), Ubben Basketball Complex (U of I).

In the fabrication world, sheet metal and piping have historically operated as two completely different animals with different workflows, software, and machine languages. What led your team to challenge that tradition and look for a single platform to bridge them both?

Currently we are unifying them under one platform which is PypeServer. This will help manage workflows in one software instead of having different practices for each shop. This helps with implementation and training across the board instead of teaching each trade to do something different.

Let’s look specifically at the sheet metal side. Before PypeServer Cloud+, what was the exact path a piece of ductwork or a complex transitional fitting took from the VDC model to the actual cutting table? Where were the hidden time-wasters in that process?

Instead of exporting out one package at a time and having to flip through folders to get to the correct folder you want to export them, I can export multiple packages now. When we export now every piece of duct gets a QR code attached to it where we can track the process of each package and bring up sheets with the scan of a Tablet/phone or computer. Instead of manually inputting each batch into a spreadsheet to track now once the VDC Department exports it automatically sets the status which takes away from button pressed and mouse clicks which saves a lot of time on bigger projects.

PypeServer built its reputation on the “wet side” automating complex pipe profiles. When you first realized they offered a solution that could handle the “dry side” nesting and sheet metal cutting, what was your initial reaction, and what features convinced you it was legitimate?

I was very surprised with PypeServer wanting to tackle the duct side. Duct is a more complex system with custom fittings and offset so all the information needs to be exported, or it will cause big problems for the shops and fields. I was happy to be able to work with PypeServer to come up with software that is useful to the “dry side”. This software has been working very well in our shops and field.

Hensen Robinson chose PypeServer for its ability to support both pipe and sheet metal fabrication with a single, uniform workflow. This gives them real-time tracking for every project from model to installation.

Now that you are live, how does having a single cloud-integrated queue change the daily dynamics for your Shop Leads who have to coordinate both pipe cutting and sheet metal fabrication simultaneously?

At Henson, we can track progress of projects from the model exportation through the install phase. The first big project we are tracking now is in progress. Once we have more information on where the project and shop are, Henson will use this to shift production from shop to field based on where it’s needed the most.

Introducing software to a busy sheet metal shop can face resistance from operators used to legacy nesting programs. How did your cutting table operators react to the Cloud+ interface, and what did the actual learning curve look like during the transition?

The shop and field will always be skeptical of anything newly implemented, the best thing we can do is work with the guys side by side and show them what we are gaining from the software. The shop is handling it very well; the shop foreman and I have been working closely with each other to simplify the implementation of this software A few learning curve issues will always come up but this has been very smooth. Henson has only implemented it with one duct foreman so far and we are still working together to make sure everything is smooth.

Looking at the sheet metal bottom line, where has Cloud+ delivered the most noticeable operational victory? Are you seeing it in optimized sheet layout and less scrap material, or is the real win downstream because the assembly tables aren’t waiting on parts?

The main thing we are seeing ROI wise is the tracking of the packages through the shop. Before this was an excel sheet that could have typos or missing information and would cause timely phone calls.

Do you consider Cloud+ to be a good value for your business, and how do you see this partnership supporting Henson Robinson’s growth and technological goals moving forward?

I see this partnership being valuable for Henson Robinson moving forward. PypeServer works well with us to develop and make software that we will utilize every day in both shops. This has been a game changer for tracking through our Shops. Instead of using an excel spreadsheet we are using a software that can track the percentage of fabrication that’s exported, in fabrication, awaiting delivery, delivered, and installed.

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