Automation in window manufacturing has become a buzzword that’s hard to escape. It’s a concept we hear about daily, often touted as the solution to a multitude of industry challenges—from labor shortages to the quest for higher efficiency. However, as with any technological shift, it’s essential to approach automation with a clear understanding of its implications and a well-thought-out plan. Recently, we came across an article discussing automation in our industry, but it missed the mark on a few key points. This oversight underscores the need for a deeper understanding of the historical context and technological nuances that shape our industry.
One of the most critical aspects often overlooked is the role of historical innovations, particularly in insulating glass (IG) technology. The term “Warm-edge” spacer, for instance, wasn’t just a marketing term—it was coined by PPG, now known as Vitro, to describe the Intercept® Spacer system. This system, developed by GED Integrated Solutions, set a new standard for efficiency and performance in window manufacturing. Understanding these benchmarks is crucial when evaluating new equipment and automation solutions. These innovations were not arbitrary; they were the result of years of engineering and refinement, setting a foundation that current technologies continue to build upon.
When considering automation, it’s not enough to simply adopt the latest technology. It’s vital to determine the right level of automation for your specific processes. Terms like equipment, software, and robotics are often used interchangeably, but they represent different facets of automation that must be aligned with your business objectives. Automation should not be pursued for its own sake but should be implemented as part of a strategic plan that addresses specific needs—whether it’s enhancing safety, improving product quality, or managing costs more effectively.
The decision to automate should be driven by clear objectives. The acronym SQDC—Safety, Quality, Delivery, and Cost—provides a useful framework for setting these goals, with Safety always taking precedence. Once your objectives are clear, the next step is to explore what can be automated through machinery and software. But it’s also important to consider the cost of capital. The allure of automating everything can be strong, but it’s crucial to ensure that your investments will yield a solid return on investment.
Labor scarcity and aging equipment are two of the most pressing reasons to consider automation now. When unemployment rates are declining, labor costs are rising, and as equipment ages, the cost of maintaining it increases. Fortunately, the cost of automation, particularly in robotics, has been decreasing, making it a more viable option for many businesses. However, the challenges of automation extend beyond the initial investment. For example, ROI calculations often fail to account for soft costs such as improvements in quality, space utilization, and warranty reductions. These are significant benefits that, although difficult to quantify, should be considered when evaluating the overall value of automation.
Automation also brings challenges and threats, particularly if your business isn’t adequately prepared. It’s essential to identify the point where labor and machinery work best together, rather than assuming a turnkey solution will eliminate the need for human involvement. Automation doesn’t mean replacing people; it means finding the optimal balance where both human and machine contributions are maximized.
As automation becomes more sophisticated, the role of people in the process remains critical. One of the main concerns voiced by industry professionals is the complexity and cost of robotics, as well as the need for skilled labor to manage these systems. However, automated equipment can often be easier to operate and maintain, provided it is designed with user-friendly interfaces and supported by robust training programs.
Another important consideration is the adaptability of your production. Seasonal fluctuations in demand mean that your equipment needs to be capable of handling peak periods without being overburdened. Planning for capacity that can accommodate these variations without exceeding sustainable levels is crucial.
In conclusion, automation in window manufacturing should be approached strategically, with a clear plan that aligns with your business goals. It’s about right-sizing your automation—choosing the solutions that best meet your needs rather than opting for the biggest or most complex technology available. This is something we have started calling “Intelligent Automation” or the best mix of man and machine. By understanding the historical context, carefully planning your strategy, and considering both the tangible and intangible benefits, you can make informed decisions that will enhance your operations and set your business up for long-term success.
Written By: Ashraf Hussein
Ash has 10 years of experience working in the North American fenestration industry. As the Product Marketing Manger – IG, Ash manages all commercial activities for GED IG products. These products include glass cutting systems, Intercept® spacer fabrication systems, glass washers, ovens, assembly systems, gas filling systems and other associated products. His expertise lies in product development and sales and customer support programs as well understanding IG manufacturing use among customers.