Manufacturing and processing: Operations dashboard for glass processors
An operations dashboard for glass processors that shows breakage and remakes by workstation, glass type and cause, so it becomes clear where panes are being lost.
Which figures glass processors really need.
Breakage comes with glass processing: a pane runs when cutting, an edge chips when grinding, a pane breaks in the tempering furnace because of an invisible inclusion. But there is a difference between breakage that comes with the job and breakage with an avoidable cause. Many glass processors do not know how many panes are remade and why. Does it happen mostly with one glass type, with thin panes with cut-outs, on one edging machine or because of wrong customer sizes? Every remake costs glass, machine time and a place in the next tempering batch, and pushes deliveries back. Without an overview it stays a string of separate frustrations.
Operations dashboard for glass processors
Example- 1
Classify breakage and remakes
DoneWe agree what counts as breakage and which causes are distinguished, such as cutting error, edge damage, furnace breakage, transport damage and customer size error.
- 2
Link job cards and cutting plans
In progressThe dashboard reads sign-offs and rejections per pane from the job cards, with workstation, cause and glass type.
- 3
Look for patterns
NextNotable combinations rise to the top, such as more edge damage on one machine or more furnace breakage at a certain thickness.
From scattered figures to one overview.
Classify breakage and remakes
We agree what counts as breakage and which causes are distinguished, such as cutting error, edge damage, furnace breakage, transport damage and customer size error. We also fix at which workstation a pane is written off. Those agreements are shown alongside the dashboard.
Link job cards and cutting plans
The dashboard reads sign-offs and rejections per pane from the job cards, with workstation, cause and glass type. A remake is linked to the original pane, so you can see how much extra glass and time an order cost. If a cause is missing, that is shown plainly.
Look for patterns
Notable combinations rise to the top, such as more edge damage on one machine or more furnace breakage at a certain thickness. From the dashboard you click through to job cards and panes. The production manager can see, for example, whether breakage relates to a batch of glass from one supplier.
Figures from your own work.
At glass processors breakage is often only recorded as a remake in the order system, without a cause. Cutting plans sit in the cutting optimisation, glass batches on a separate stock list. The dashboard reads from job cards, the order system and inventory, with no separate data entry, so the picture builds up without extra typing on the floor. The production manager owns the list of causes, operators own their reports and production engineering owns reading in the measurement sheets.
Count breakage in panes or square metres
A small pane and a large partition pane each count as one breakage, but the cost differs greatly. Counting in square metres gives a better picture of lost glass, counting in panes of lost handling. The dashboard can show both; we agree which figure leads in meetings.
Show customer errors separately or together
A remake caused by a wrong customer size is a different problem from breakage in your own production. Together they show total loss; separately they show where you have influence. Seeing customer errors separately also shows whether the measuring guidance or the sheet check could be improved.
Look per supplier or only internally
Furnace breakage from inclusions or stresses in the glass can relate to a supplier or batch. That is only visible if batches are recorded with each pane. Doing so lets you raise what you see with a supplier on solid ground rather than on instinct.
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Read the storyWhich figures we put on the dashboard.
At the start, breakage and remakes per workstation, glass type and cause are on the dashboard, with a click through to job card and pane. We check it together on a period when production ran normally and on a week when strikingly many panes broke in the furnace, to see whether the dashboard traces that back to thickness or batch. Glass batches and the split by customer errors you add once causes are reported reliably.
View pricingSupport and updatesGood to know.
Explore pricing and optionsCan we tell furnace breakage from earlier damage?
Yes, if the pane was checked and signed off before tempering. If it then breaks in the furnace, the cause lies in the furnace or the glass itself. Without that check there is no telling whether a small edge chip was already there.
Does the dashboard show what remakes cost?
It shows per order how many extra square metres of glass were used and which processes were repeated. If you want, it can value those at your own cost prices. It does not forecast savings, but it shows where the loss sits.
How do we get operators to enter a cause?
By making reporting quick: a scan of the pane and a pick from a short list, with a photo optional. And by showing in team meetings what happens with the reports. When operators see their reports lead to a fix, they keep filling them in.
Can we share the dashboard with our glass supplier?
Part of it, such as furnace breakage per batch, can be useful in a conversation with a supplier. Share a summary explaining how breakage is defined, not the full dashboard. That stops numbers without context taking on a life of their own.
What often connects to this.
- Digital job cards for glass processorsDigital job cards for glass processors that show the final measurement sheet for each pane, with edge finish, holes and cut-outs, and record every process and check as it is signed off.
- Website for glass processorsA website for glass processors that explains glass types, edge finishes and work such as drilling and cut-outs by application, so a glazier or interior fitter knows what to specify.
- Enquiry form for glass processorsAn enquiry form for glass processors that asks for dimensions, thickness, glass type, edge finish and the position of holes and cut-outs, so nothing needs changing once the glass is tempered.
See where the work drifts.
Start with a short intake. Then we schedule a call to show the software with your services, team and way of working.
WhatsAppinfo@vorlyo.com Operations dashboard for glass processors: breakage and remakes by workstation, glass type and cause, traceable to job card and cutting plan.
- Classify breakage and remakes
- Link job cards and cutting plans
- Look for patterns