Efficiency improvement for a window manufacturer through automation, process improvement, and waste reduction

点击翻译按钮获取中文摘要

All Weather Windows (AWW) is a major window and door manufacturer with nine branches across Canada. Its production process involves many inherent complexities, as AWW produces multiple types of windows and doors at a high volume. AWW is seeking to increase quality while broadening the range of its product offerings, increase its operational efficiency, reduce material waste and rework, and update its estimation procedures. To achieve the production-related goals, the research will encompass the following tasks: (1) production line refinement using simulation and material usage optimization (including detailed workstation analysis and simulation and work centre mapping; (2) Efficiency improvement of automated welders and saws; and (3) research and development for window manufacturing (including development of an in-house thermal testing and development of motorized automated casement windows. Through this research project, AWW aims to eliminate the inefficient practice of outsourcing thermal testing of new window products, to reduce rework by half, to reduce material waste by 20%, to plan and begin fabrication of an automated window casement for integration with smart home platforms, and to increase estimation accuracy in order to reduce inventory discrepancies. The integration of automated window casement fabrication into the window fabrication process constitutes a novel technical solution, while the design and construction of a thermal testing chamber, and algorithms to further automate the production process, will contribute to the existing knowledge base in these areas. It can be expected that through this project the industry partner will benefit through (1) improved productivity, (2) development of affordable and practical automated machinery support for operational processes, and (3) the development of an efficient and cost-effective construction manufacturing system. The research can be expected to contribute to the industry in general by decreasing production costs and time, and by increasing quality and durability.