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

全天候窗（AWW）是一家主要的门窗制造商，在加拿大有九个分支机构。由于AWW大批量生产多种类型的门窗，其生产过程涉及许多固有的复杂性。AWW正在寻求提高质量，同时扩大其产品范围，提高其运营效率，减少材料浪费和返工，并更新其评估程序。为了实现与生产相关的目标，研究将包括以下任务：(1)使用模拟和材料使用优化来改进生产线（包括详细的工作站分析和模拟以及工作中心绘图）；(2)提高自动化焊机和锯的效率；(3)窗制造的研究与开发（包括开发内部热测试和开发电动自动开窗）。通过该研究项目，AWW旨在消除新窗户产品外包热测试的低效做法，减少一半的返工，减少20%的材料浪费，计划并开始制造与智能家居平台集成的自动化窗户，并提高估算精度以减少库存差异。将自动窗扇制造集成到窗户制造过程中构成了一种新的技术解决方案，而热测试室的设计和建造以及进一步自动化生产过程的算法将有助于这些领域的现有知识库。可以预期，通过该项目，行业合作伙伴将受益于(1)提高生产率，(2)开发可负担且实用的自动化机械，支持操作流程，以及(3)开发高效且具有成本效益的建筑制造系统。预计该研究将通过降低生产成本和时间，提高质量和耐用性，为整个行业做出贡献。

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.