Tag: IG

Bringing in Outside Perspectives

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Commercial glass manufacturing isn’t easy work—it takes expertise, dedication and the ability to streamline operational efficiency across the board. Many of us pursue continuous improvement efforts, striving to achieve greater consistency and quality every day.

But our jobs, like any other hobbies or work we pursue outside of the fenestration industry, fall at risk of becoming rote tasks when we do them every day. We know our operations inside and out—and sometimes that’s the problem.

You’ve probably heard of the expression about giving something “a new set of eyes.” Outsiders can catch errors you’ve overlooked, things you’ve gotten used to. It’s why I always have my blog posts proofed before they’re posted! 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, for instance, one common source of unseen trouble that I ran into frequently when I was regularly walking customer plant floors: the glass washing station, which represents around half of an IG line’s preventative maintenance tasks, and as such 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 an automated glass washer in the field that has been incorrectly calibrated, with the cleansing brushes barely or not even coming into contact with the glass itself. Water temperatures might also be 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: Secondary sealants play a critical role in the longevity of commercial IG, and the proper mix ratio and consistent mixing of two-part sealants is critical for achieving desired long-term performance. As we continue to drive efficiencies through automation, the volume of sealant pumped through these delivery systems increases. That means check valves, mixer tubes and seals will all wear more quickly. Worn components may not initially show visible problems within the IG, but if the sealant mix ratio or consistency is off around the perimeter, your desired cut rate and performance may be in jeopardy. An outside perspective from your sealant or equipment supplier may be just the ticket to help identify improvements and adjustments here.

Plant floor audits highlights the value of bringing outside perspectives onto your plant floor to help identify issues that might be occurring without your realizing. Whether it’s a vendor whom you trust or some other third party, giving your operations a “new set of eyes” can 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.

Be open to the possibilities, and I’d encourage all manufacturers to consider where they can be finding fresh perspectives in a market that demands continued improvement.

How to Overcome a Labor Shortage

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There’s a similar story being told throughout the building and construction industry. I wrote about it in my last post and why it’s time to start thinking differently about IG production on a broad scale.

Of course, I’m talking about the skilled labor shortage. It was a hot topic at the GANA BEC Conference, which I attended in early February. Though the conference primarily targets commercial glass and curtainwall installers, many conversations mirrored those we’ve been having in the manufacturing space recently. How do we attract new talent? How do we transfer decades of institutional knowledge to a new generation of workers?

While it’s true that advancements in technology have enabled glass fabricators to weather the labor shortage in certain ways, we’re not immune to the labor shortage. Recruiting and retaining skilled workers remain critical challenges for any glass fabricator—and anyone in the fenestration industry at large.

Easier said than done, right? Especially when recruiting millennials to manufacturing positions—across all sectors—has proven an uphill battle. According to the Wall Street Journal, there will be an estimated 2 million unfilled manufacturing jobs by 2025, and it’s millennials who must be convinced to fill them.

Part of what we’re facing here is a perception problem. It’s become apparent that traditional manufacturing and installation jobs are unattractive to a younger generation, so it’s up to us to engage with these potential employees to show them the benefits and change that perception. There is money to be made, there are good incentives, and there is room for growth for those willing to put in the effort.

Also, as later noted in the Wall Street Journal piece, “For millennials choosing careers today, the most sought-after industry is technology.” It’s here that I sense another way in which the fenestration industry’s strengths may play well to the oncoming challenge.

We’ve seen how technology is transforming our industry, as high-speed automation has revolutionized some of our traditional manufacturing processes, allowing us to maximize labor in the face of a shortage. There are emerging ways to optimize these systems, taking advantage of new software solutions to streamline our processes from beginning to end. Robotics and automation itself require specific, technical know-how.

We need to communicate that our industry is one that is moving forward, looking ahead, and utilizes new and emerging technologies. For both recruiting and retention purposes, it’s worth considering partnerships with trade schools or universities to extend your influence with potential employees and as an investment in your current ones.

An investment, yes—but a worthwhile one to make as we forge ahead. What I found at the BEC Conference was a sense of camaraderie. Yes, though competition is fierce, we’re working together and sharing best practices to overcome a shared challenge. Our industry is alive and ready for growth, and there’s something in that for all of us.

Joe Erb is a commercial sales specialist at Quanex Building Products.

This Side of Uncertainty: Tackling 2017’s Challenges

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Lacking a working crystal ball, nobody truly knows what 2017 has in store for the commercial glazing industry. As the new presidential administration begins its term, there is a good amount of uncertainty in terms of investment in the building and construction space that may or may not be made, along with policy changes that may or may not come to pass.

The Labor Shortage. For one, the building and construction industry overall continues to grapple with a labor shortage that threatens efficiency and margins, with many players competing for a shrinking pool of skilled labor. Whether you’re a glazier, an IG fabricator or a window manufacturer, finding and retaining the right people continues to pose a significant challenge.But while we forge into the new year with a bit of “wait and see,” there are a few things we do know for sure—and there are a few ways we’re beginning to see the industry address them.

But over recent months, I’ve sensed a rising effort in our industry to invest in our workers as we figure out how to potentially operate with fewer of them. Consider the Insulating Glass Manufacturers Association (IGMA’s) ongoing IG workshops, two-day seminars providing hands-on training on the technical ins and outs of IG manufacturing. USGlass magazine’s Nick St. Denis attended the IGMA workshop late last year and reported back on his findings. In short, the workshops offer detailed, exhaustive information for IG fabricators and others in the industry.

It’s this kind of investment and education that will continue to help our industry deliver high-quality, high-performance solutions that our customers demand. If we, as an industry, continue building and incentivizing high levels of skill and expertise in a new generation of workers, we can bolster the skill levels we need to continue succeeding and innovating well into the future.

Seizing Opportunity with New Technologies. It seems like commercial IG fabricators have been talking about automated technology for a little while now—and with good reason. High-speed automated lines have helped fabricators realize significantly larger volumes (and larger units) while reducing labor. Processes that once required 12 line workers may now require three or four, enabling organizations to allocate their most skilled workers to high-value tasks throughout their plant.

But as more fabricators continue to invest in high-speed automation, it’s becoming increasingly clear that to maintain a competitive edge, fabricators need to begin thinking differently about the overall operations of their plant. When more companies can deliver high-quality IG units at increasingly high volumes, what’s setting your business apart?

As 2017 gets underway, I believe we’ll begin seeing these efforts take shape by innovative manufacturers and fabricators in the commercial glass space. Whether it’s a focus on high-margin, high-value products, new ways of thinking about plant layout, and beyond, anticipate moves from fabricators looking to sharpen their competitive edge.

And I’ll be here to offer my thoughts and insight on these movements along the way. I’m excited with the opportunity to author this blog for USGNN.com™; watch this space for my thoughts on glass technology, industry trends and ways in which fabricators can move forward confidently in a changing industry.

Joe Erb is a commercial sales specialist at Quanex Building Products.