Common PVC which is polyvinyl chloride is strong but lightweight plastic that is used for construction work. Normally this type of material is used for manufacturing window frames, pipe work and other structures. This material is made softer and flexible by adding plasticizers. If no plasticizer is added then it is known as UPVC (unplasticized polyvinyl chloride). UPVC windows are popular these days because of its several characteristics. First of all this window is weather proof, storm proof and noise proof that makes it extremely unique thing. On the other hand, this window also has a strong insulating power. This type of window is capable to keep a room hot and insulated (Eskandari et al. 2017). In cold places most of the houses are built with UPVC windows equipped in them. Some other features of this window are there are anti rust and does not corrode. Besides, these windows require low maintenance and are durable. Manufacturing process of this UPVC window is a complex method. In order to understand that manufacturing process of UPVC windows, in this assignment we will focus on AAA windows which is a window manufacturing organization. This report will also find out how the organization is manufacturing UPVC windows and what process design they are using.
AAA Advanced Trusses and Windows were established in the year of 1986 by the Cements family. After that, the organization has expanded to a truss plant in Cranbourne in the same year. Besides, this organization is also a windows manufacturing organization that has its sites in 6 locations of South Melbourne. Till now, the organization is under the individual ownership of Clements family (Aaatrussesandwindows.com.au 2017). The mission of the organization is to offer a pleasant and personal experience to the consumers. This organization’s vision is to provide best products and installation experiences to the consumers. As per Vince Lambardi, AAA always looks to develop perfect products through excellent manufacturing method. This is the reason that this organization is selected to discuss about the manufacturing process of UPVC windows.
Manufacturing of UPVC windows start out as nothing more than plastic powder at the profile extrusion plant, namely unplastisized polyvinyl chloride (UPVC). In the next step, plastic powder is heated up and injected via a mold which is called as a die (Parrett 2015). It means that the PVX has taken its shape. After that, PVC is rapidly cooled by using water until it reaches to a length of 6m. Then it is cut and packaged.
In AAA windows, the operation related to the manufacturing of UPVC windows is slightly different. In the organization, UPVC windows are made from sections of profile. Later these are cut and joined together for the shape of the window. The flatness, square shape and straightness of the profile are maintained by the design characteristics of the profile and the tooling. After this method, the windows are fabricated from pieces of profile that have been cut to the proper size (Chanchlani and Keswani 2015). Later all these pieces of profiles are joined together using high-heat fusion welding or T-joint connectors. In the next step, steel of reinforced sections are fixed inside the UPVC profiles to deliver additional strengths, where needed.
Resources for manufacturing UPVC windows, which can also be called as primary inputs are power and water. Power is needed to run manufacturing machineries and to deliver lighting for the plant. On the other hand, water is needed for general reasons such cooling the screws for improving the shearing effects. AAA widows are currently using a cost effective method for catering the water to the plant by locating the plan near a river (Brown et al. 2013). On the other hand the management of the organization has also set up their solar panels to become self-sufficient on electricity. Some other critical inputs that are required for the manufacturing process include PVC Resin, impact modifier, stabilizer, filler, toughened glass, argon gas and polyisobutylene sealant. All these inputs provide an output which is the UPVC window.
In order to understand the current performance of the UPVC windows manufactured by AAA Company, it is necessary to discuss their process based on Deming’s 14 points.
The management of the organization has developed an aim for constant improvement in their products and services. That is why; the organization delivers free inspection sessions to each of their consumers (Krajewski et al. 2013). Operations related to continuous improvement are undertaken in 18 production facilities and research and development laboratories across 13 countries.
AAA windows Company is dedicated to continuously deliver UPVC windows that contain no defects. Currently the customer rating of the organization is 98% which clearly indicates that the management of the organization has successfully completed their goals. It means, their manufacturing processes and methods are performing well.
The manufacturing department of the organization depends on statistical control rather than mass inspection. Unlike other companies, UPVC frames developed by the AAA windows are fusion welded at corners.
The management of AAA windows is using its suppliers strategically to collect evidence about the quality of its UPVC windows.
The manufacturing team of the organization is constantly improving the processes of manufacture through innovation and creativity.
The management of the organization has always motivated its employees, especially those employees who are dealing with the consumers directly, to establish effective relations through continuous communication (Mahadevan 2015).
All the departments in AAA windows are working together to improve the quality of the organization. From the annual report of the organization, it is seen that the organization has experienced a 27% growth (USD 97 million) compared to USD 76 million in the year of 2014 (Goetsch and Davis 2014).
The management of the organization does not cater any type of methods and strategies that do not support its continuous improvement goals.
Statistical methods in manufacturing department, such as developing facilities near water reserves and establishing solar panels are implemented by the organization to improve quality and productivity.
Barrier to pride in workman ship is eliminated by the management of the organization.
Employees in each department of the organization are provided with proper training to make sure that they can keep up with new products and methods.
In its official website, and annuals report, the management of the organization has precisely defined top management’s continuous commitment to quality.
In all the manufacturing facilities, ample amount upgraded machineries and tools are provided by the management so that workers can perform their job comfortably
Some operational resources that are already mentioned in this report are PVC Resin, impact modifier, stabilizer, filler, toughened glass, argon gas and Polyisobutylene sealant. All these resources have its own operational function. PVC resin is known to have higher level of chemical resistance On the other hand, it is strong and resistant to water and scratch. Impact modifier is used to ensure the durability of extruded plastic where stabilizer tends to inhibit the reaction between two or more other chemicals (Mitra 2016). Fillers are another major resource in UPVC manufacturing process that helps to lower the consumption of expensive binder materials. Toughened glass is developed by controlled thermal or chemical treatment that increases its strength. Tampering method helps to put the outer surface into compression and inner surfaces in tension. Argon as is used to retain more heat than air. This air does not escape from windows and will not be topped up. Polyisobutylene sealant is used on the face of the spacer on each side and panes pressed against the pacer. Due to its good performance even in low temperatures, this material is used along with the other mentioned resources to improve the quality of UPVC windows (Slack 2015).
From the day-to-day experience of the manufacturing department of the organization, one thing is clear that the department is enriched with every bit of machineries are tools that are required to manufacture UPVC windows. Safety measures are placed properly in the facilities and that is why accident rates are almost nil in the company.
Rise in new housing production activities, especially of high-end segments is driving the requirement of UPVC windows in different countries (Subram et al. 2016). Because of its several benefits, the customers are looking to buy ore this type of indo which is allowing the UPVC window manufacturing organizations to expand it manufacturing units.
The management of AAA Windows wants its manufacturing department to develop quality UPVC windows with zero defects so that consumers can trust its products and items.
According to Karlsson, (2016), Job production which is also called as jobbing method means manufacturing custom work, such as a one-off product for a definite customer or a small batch of work in quantities generally less than those of mass-market products.
AAA Windows Company is also manufacturing the UPVC windows as per the requirement and demand o the consumers. They are not mass manufacturing as these type of windows are expensive than the normal windows and only a specific segment of consumers are looking to include UPVC windows in their houses (Buede and Miller 2016). On the other hand, the manufacturing process of UPVC window is a broad method and also a complex one. Therefore, it is important to have skilled workers in the manufacturing facilities.
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Objectives of Operations Performance |
Typical Process Design Objectives |
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Quality |
AAA Windows have all the required resources to manufacture UPVC windows. Therefore, the organization is capable of accomplishing specification of the UVC windows. Besides, their manufacturing department is also able to facilitate error-free processing. |
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Speed |
As al the required resources and machineries are present in the facilities of the organization, its manufacturing is capable to develop windows faster than some other organizations. |
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Dependability |
The manufacturing department of the organization is using best available resources to make the windows defect free. |
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Flexibility |
The method of constructing a UPVC window is absolutely not flexible. The entire process consumes 6 times more energy than the manufacturing process of a timber window. |
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Cost |
Cost of manufacturing a CPVC window is higher than any other window. As the process has several different steps and requires a lot of rate resources, manufacturing is cost is high. |
8.0 Conclusion
In the end it can be concluded that AAA Window organization is using proper and updated method for manufacturing UPVC windows in the facilities. As the organization has always focused on gathering proper resources and updated machineries, they are able to manufacture quality windows for its consumers. Besides, it is also seen that the organization has implemented proper safety and health measures in its workplace that have made sure number of accidents are nil. On the other hand, the manufacturing method of the organization can be compared as the jobbing process as the management has not implemented mass production method. It is true that demand of these types of windows is increasing. However, currently the demand is not much high because of its price. Therefore, the chances are high that in the future, when the demand will rise, the organization will upgrade is manufacturing department to meet the demand.
Reference
Aaatrussesandwindows.com.au, 2017. About Us : AAA Trusses and Windows. [online] Aaatrussesandwindows.com.au. Available at: https://aaatrussesandwindows.com.au/about-us/ [Accessed 23 Mar. 2017].
Brown, S., Bessant, J.R. and Lamming, R., 2013. Strategic operations management. Routledge.
Buede, D.M. and Miller, W.D., 2016. The engineering design of systems: models and methods. John Wiley & Sons.
Chanchlani, J., and Keswani, I. P. 2015. Cycle Time Reduction in Plastic Industry. International Journal of Technology, 5(1), 25-29.
Eskandari, N., Motahari, S., Atoufi, Z., Hashemi Motlagh, G. and Najafi, M., 2017. Thermal, mechanical, and acoustic properties of silica?aerogel/UPVC composites. Journal of Applied Polymer Science, 134(14).
Goetsch, D.L. and Davis, S.B., 2014. Quality management for organizational excellence. Upper Saddle River, NJ: pearson.
Karlsson, C. ed., 2016. Research Methods for Operations Management. Routledge.
Krajewski, L.J., Ritzman, L.P. and Malhotra, M.K., 2013. Operations management: Processes and supply chains (Vol. 1). New York: Pearson.
Mahadevan, B., 2015. Operations management: Theory and practice. Pearson Education India.
Mitra, A., 2016. Fundamentals of quality control and improvement. John Wiley & Sons.
Turner, B., Strong, R. and A. Gold, S., 2014. A review of melt extrusion additive manufacturing processes: I. Process design and modeling. Rapid Prototyping Journal, 20(3), pp.192-204.
Oakland, J.S., 2014. Total quality management and operational excellence: text with cases. Routledge.
Pahl, G. and Beitz, W., 2013. Engineering design: a systematic approach. Springer Science & Business Media.
Parrett, M., 2015. Window Performance and Sustainability. Windows: History, Repair and Conservation, p.233.
Seo, S., Kim, J., Yum, K.K. and McGregor, J., 2015. Embodied carbon of building products during their supply chains: Case study of aluminium window in Australia. Resources, Conservation and Recycling, 105, pp.160-166.
Slack, N., 2015. Operations strategy. John Wiley & Sons, Ltd.
Subram, K.S., Khan, M.N. and Srivastava, C., 2016. A Study of Marketing Mix Strategies on the Indian Upvc Window Market. CLEAR International Journal Of Research In Commerce & Management, 7(11).
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