March 24, 2023 | Intercept

Maximizing Efficiency and Profits: Benefits of Boosting IG Productivity



Increasing Insulating Glass productivity from 800 insulating glass units per shift (more than the practical maximum capacity of a vertical line IG process) to about 1800 insulating glass units per shift (which is about half the production capacity of an Intercept® line IG process) can have significant benefits across multiple operations’ management areas, including overall-efficiency, financial, human resources, equipment maintenance, and sustainability.

The Intercept® Insulating Glass manufacturing process is designed to produce up to 6 IG units per minute with 7 people. That is 10 seconds per cycle for Double-pane insulating glass units under 49” and 20 seconds per cycle for Triple pane Insulating glass units or oversized units. Check this GED blog article out for more information on how many people it takes to operate an Intercept® line.

Why Improve IG Productivity?

By increasing Insulating Glass productivity, the company can manufacture more insulating glass units per shift, which can result in increased windows and doors output, better capacity utilization, and higher efficiency in the manufacturing process. The improved overall efficiency can lead to a reduction in the time and cost required to produce each unit, and the company can fulfill orders in a shorter time frame. This, in turn, can lead to a better customer experience, more satisfied customers, and increased sales.

Scaling for Seasonality

Seasonality is a common challenge for the windows and doors manufacturing industry, as the demand for insulating glass units can vary significantly throughout the year. During peak seasons, the company may need to produce more insulating glass units to fulfill customer orders, while during low seasons, the demand may decrease, resulting in idle equipment and reduced workforce utilization.

Increasing productivity can help the company to better manage seasonality by improving its capacity to produce insulating glass units efficiently during peak seasons and adjusting the production level during low seasons. By optimizing its processes and equipment, the company can produce more insulating glass units per shift without increasing its workforce or investing in additional equipment. This can help the company to meet the demand for insulating glass units during peak seasons without overburdening its workforce or incurring high labor costs.

Overall, by increasing productivity, the windows and doors manufacturing company can better manage seasonality and adjust its production levels efficiently to meet customer demand.

Higher Revenues and Profits

From a financial standpoint, increasing productivity can result in higher revenues and profits for the company. With a higher output, the company can reduce the cost per unit and improve its profit margins. Additionally, the increased productivity can enable the company to meet the demand for insulating glass units without investing in additional equipment or increasing its workforce, thus reducing capital expenditures and labor costs. As a result, the company can allocate resources more effectively and generate more cash flows, which can be reinvested in the business or returned to shareholders.

Champion Windows is an example of a key customer that was able to more than double IG production on one line that they didn’t need to man a second line to meet daily production goals.

customer testimonial

Reduced Overtime or Additional Shifts

From a human resources perspective, by improving Insulating Glass productivity, employees can work more efficiently and reduce the need for overtime or additional shifts, resulting in a better work-life balance for employees. Additionally, employees can develop new skills and experience in handling new equipment, processes, or technologies, leading to personal and professional growth opportunities. Improved productivity can also increase employee morale, job satisfaction, and loyalty to the company, which can reduce turnover rates and recruitment costs.

Fewer Equipment Breakdowns and Unplanned Downtime

Increased productivity can lead to better equipment utilization and reduced idle time. The company can also schedule maintenance activities during downtime, reducing the risk of equipment breakdowns and unplanned downtime. By maintaining equipment in optimal condition, the company can reduce repair and replacement costs, improve safety, and ensure that the equipment is used efficiently.


Increasing overall production effectiveness can lead to more efficient use of energy and reduce energy consumption per unit produced. The company can optimize its equipment and processes to reduce material waste and the percentage of remakes. Improved energy efficiency can also result in lower energy bills, reduced carbon emissions, and a positive impact on the environment.

In summary, increasing Insulating Glass productivity can bring benefits across multiple areas, including financial, human resources, equipment maintenance, and sustainability. These benefits can lead to improved bottom-line profitability for residential windows and doors manufacturing operations.

How to Improve IG Productivity?

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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.