Door and window manufacturing takes expertise, dedication and the ability to streamline operational efficiency across the board. Most of us are on continuous improvement journeys, with the goal of achieving greater consistency, quality and efficiency every day.
But like any other routine, our jobs fall at risk of becoming rote-like tasks when we do them every day. You probably know your production line like the back of your hand—and sometimes, that can be the problem.
That brings me to today’s tip: Consider a new perspective.
You’ve probably heard about the importance of looking at something with “a new set of eyes.” Outsiders can catch errors you’ve overlooked and things you’ve gotten used to. In fact, it’s why I typically pass these very blogs to a colleague before I submit them.
The same is true of your plant floor. Third parties can catch errors you might be missing or areas that can be improved as you work toward higher efficiency and consistency.
Take one common source of unseen trouble that I run into frequently when I’m on my customers’ plant floors: the glass washing station, which represents a significant amount of an IG line’s preventative maintenance tasks, and as such is one of the most critical tasks on the line. Glass cleanliness can lead to lasting aesthetic issues as well as performance problems like seal failures. Water quality, water temperature and the machine’s overall general cleanliness must be constantly monitored to avoid issues.
Nevertheless, it’s not uncommon to find a glass washer that has been incorrectly calibrated, with the cleansing brushes barely or not even coming into contact with the glass itself, or instances where the water temperatures are off. These might seem like small or relatively inconsequential issues, but they can have an impact on your overall quality goals. And, often, quick fixes can be performed to issues like that on the spot.
Another example: Insulating glass sealants play a critical role in the longevity of your finished windows, and proper application is essential. This process is increasingly automated on today’s shop floors, and that means the volume of sealant pumped through automated delivery systems increases. As a result, check valves and seals will all wear more quickly than manual processes. Worn components may not initially show visible problems within the IG, but if the sealant fill ratio is off around the perimeter, performance may be in jeopardy. An outside perspective from your spacer, sealant or equipment supplier may be able to help identify improvements and adjustments if you’re running into trouble.
Finally, plant floor audits highlight the value of bringing outside perspectives onto your plant floor to help identify issues that might be occurring without notice. Whether it’s a vendor you trust or some other third party, they may be able to help identify some of these details, and it can make a big impact. Likewise, beyond specific fixes, there might be unidentified areas of opportunity on your plant floor, and a third party might be able to spur new ways of thinking.
In short: Be open to the possibilities. It can be beneficial for all manufacturers to consider where they might find fresh perspectives on the journey towards continuous improvement.
John Ryba is the technical services director for Quanex.