US 20070112451A1

(19) United States

(12) Patent Application Publication (10) Pub. No.: US 2007/0112451 A1
(43) Pub. Date:

Clayton et al.
(54)

GLASS DEMAND SCHEDULING SYSTEM

Publication Classi?cation

(51)

Int. Cl.
G06F 19/00

(52)

Us. or. .......................................... .. 700/100; 700/157

(75) Inventors: Byron Clayton, Sagamore Hills, OH

(US); Paul Dorsch, Warren, OH (US)

(2006.01)

Correspondence Address:

(57)

TAROLLI, SUNDHEIM, COVELL &

A method for optimizing material How and equipment

utilization in the fabrication of insulating glass units in a

TUMMINO L.L.P.
1300 EAST NINTH STREET, SUITE 1700

(73) Assignee: GED Integrated Solutions, Inc.

(21) Appl. No.:
Filed:

ABSTRACT

production operation. The method includes compiling a

plurality of orders and converting the plurality of orders into
production schedules for operating processes that fabricate
the insulating glass units over a prescribed period of time.
The method further includes releasing the production sched

CLEVEVLAND, OH 44114 (US)

(22)

May 17, 2007

11/652,747

ules to the plurality of processes used to fabricate insulating

glass units. The method also includes monitoring production

Jan. 12, 2007

Related US. Application Data

operations data produced as a result of the releasing the

production schedules to the plurality of processes used to

(63) Continuation-in-part of application No. 10/751,382,

used by the monitoring production operations having image

fabricate the insulating glass units and providing reports

?led on Jan. 5, 2004, noW Pat. No. 7,167,767, Which

readable indicia that are imaged for providing real-time data

is a continuation-in-part of application No. 10/646,

191, ?led on Aug. 22, 2003, noW abandoned.

for tracking material How to, from, and through the pro

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cesses used in the fabrication of insulating glass units.

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Patent Application Publication May 17, 2007 Sheet 1 0f 16

US 2007/0112451 A1

J2
14

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22

CUSTOMER FRONT E D

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ORDER ENTRY AND WINDOW ASSEMBLY SCHEDULING

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USH ORDERS

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REMAKE ORDERS

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SCHEDULES AND PPW

SCHEDULES AND PPW

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Fig-1

Patent Application Publication May 17, 2007 Sheet 2 0f 16

US 2007/0112451 A1

70

DEMAND REQUIREMENTS

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.

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22

314/64

CUSTOMER FRONT END SYSTEM

\ ORDER ENTRY AND WINDOW ASSEMBLY SCHEDULING

16\ w

REGULAR PRODUCTION
ORDERS

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______________ __6_6_.
DEMAND REQUIREMENTS

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GLASS ON DEMA

CENTRAL WORKSTA

28

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PROGRAHHABE DEVICE

cmzms UNES [1-15

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58

Patent Application Publication May 17, 2007 Sheet 5 0f 16

US 2007/0112451 A1

I6454WH

[PRODUCTION RUN SEQUENCE FROM SCHEDULING TERMINAL]

86/

88

9O

f
> RUN SIZE
PARAMETER
?

AUTOMATICALLY
SEGMENT RUNS

lG DEPT. QUEUE DISPLAY

AT THE CENTRAL WORKSTATION

PRoDUCTIoN RUN STATUS

FROM MACHINES

PRODUCTION RUN STATUS

AND REQUESTS FROM
SATELLITE woRKSTATIoNS

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AUTO GENERATED
LOW QUEUE CONDITION
100

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ALL DATABASES

110

MACHINES OR SATELLITE OPERATIONS

START NEXT PRODUCTION RUN

/-112
AUTO PRINT LABELS/REPORTS FOR FUTURE
PRoDUcTIoN RUN PER SETUP PARAMETER

oPERAToR MANUALLY PRINTS /14

OR DISPLAYS INFO

Patent Application Publication May 17, 2007 Sheet 6 0f 16

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Patent Application Publication May 17, 2007 Sheet 8 0f 16

222

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Fig.10

US 2007/0112451 A1

Patent Application Publication May 17, 2007 Sheet 9 0f 16

230

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Fig.12

US 2007/0112451 A1

Patent Application Publication May 17, 2007 Sheet 10 0f 16

231

232

230

231

230

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231

Fig.13
232

230

231

230

231

Fig.14

US 2007/0112451 A1

Patent Application Publication May 17, 2007 Sheet 11 0f 16

US 2007/0112451 A1

Patent Application Publication May 17, 2007 Sheet 12 0f 16

US 2007/0112451 A1

OPERATOR
PRESSES
FUNCTION
KEY

PRODUCTION RUN
SEQUENCE AND -314
STATUS DISPLAY

I
OPERATOR
PLACES

316

CORRECT #
OF CARTS

TEM PO RARY
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9

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STAGES
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SELECTS

FILLER

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OFF

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CHANGE \
SEQU.

Fig.16A '

322

Patent Application Publication May 17, 2007 Sheet 15 0f 16

US 2007/0112451 A1

mtg.

May 17, 2007

US 2007/0112451A1

GLASS DEMAND SCHEDULING SYSTEM

CROSS REFERENCE TO RELATED
APPLICATION

[0001]

The present application is a Continuation-in-Part

application of currently pending US. application Ser. No.:

10/751,382 having a ?ling date of Jan. 5, 2004 entitled
Glass Production Sequencing claiming priority as a Con
tinuation-in-Part of US. application Ser. No. 10/646,191,

arranging glass lites to be cut from stock glass sheets to

achieve the highest yield is called glass optimiZation.

[0007] Glass optimiZation is usually performed by a com
puter executing a computer program. The output from the
glass optimiZation process is a control program that is sent
to a computer-controlled cutting table. The glass optimiZa
tion softWare outputs a computer program that optimiZes one
or more production batches containing patterns of lites

entitled Glass Optimization ?led Aug. 22, 2003. The

present application claims priority to, and incorporates in
their entireties both of the above-identi?ed applications for

arranged on stock glass sheets. The cutting table automati

cally scores the glass according to each pattern. Each
production batch normally contains one or more glass layout
patterns that provide a loWer yield than desirable.

all purposes.

[0008]
FIELD OF THE INVENTION

[0002]

The present invention concerns a method and appa

ratus for controlling production run sequences of insulating

glass units.
BACKGROUND ART

[0003] WindoW manufacturers typically receive orders

that include a variety of different siZes and types of WindoWs
and/ or patio doors. The different siZes and types of WindoWs

and/or patio doors require different siZes and types of

These LoW Yield Patterns or LoW Yield Sheets

signi?cantly reduce the yield of entire production batches

resulting in higher manufacturing costs due to Wasted glass.
Waste is particularly expensive When manufacturing Win
doWs from increasingly popular specialty glasses such as
LoW-E or self-cleaning materials.

[0009] Today, there are several existing methodologies

used to increase glass yields. Unfortunately, each method
presents one or more problems to manufacturing operations.
The methods and their resulting problems are described
beloW.

[0010] a) Standard dimensioned lites called ?ller lites

insulating glass units (IGs) that are assembled into a frame

can be introduced to scheduled production batches to

or sash to form a completed WindoW or patio door at one or

?ll-in unused space on the stock glass sheets. The glass

optimiZation softWare determines Where ?ller lites can

more glaZing lines. The WindoW manufacturers separate and

group the orders for the IGs into regular or planned produc

be inserted When creating the initial programmed pat

tion runs. The regular or planned production runs are sched

terns. Because ?llers are inserted prior to the actual

uled to be manufactured in a certain sequence on a certain

manufacturing process, the number and type of ?ller

lites rarely meet actual production demand. Too feW

future date, usually Within one to three business days ahead.

[0004] Variables in the manufacturing process rarely alloW

the regular production runs to be manufactured in the exact

planned sequence. For example, rush orders for important

customers and remake orders that occur When IGs break are

?ller lites starve production lines While too many ?llers

create storage and quality problems.

[0011] b) Adding different siZes of large sheets can be
stocked to increase yield.

often prioritized, changing the sequence of the production

runs. The operational status of machines used to make the
components of the IGs may also cause the sequence of the

regular or planned production runs to be altered. Further,

demand ?uctuations, such as a shortage at one of the glaZing
lines may cause the sequence of the regular or planned
production runs to be altered. As a result, a supervisor of an

IG production line must constantly monitor each of the

manufacturing variables and modify the sequence of the
production runs accordingly.

[0005] Current methods employed by IG supervisors for

monitoring IG manufacturing variables and modifying pro
duction run sequences are sloW, inaccurate and confusing.

The existing methods typically rely on informal communi

cations, such as Word of mouth, handWritten documents and
manual data entry. Use of these non-automated forms of
communication often confuse operators, tie up machines and

[0012] This alloWs the glass optimiZation softWare to pick

the siZe of stock sheets that produce the best yield. Although
this method enhances yield, it also increases inventory space
and costs While decreasing throughput (more glass siZes to
shuttle in and out).
[0013] c) Certain cutting tables alloW the siZes and
types of lites from LoW Yield Sheets to be manually
entered at the cutting table controller With the siZes and
types of other of selected lites, then re-optimiZed to

increase yields.

[0014] Although these features provide ?exibility and

increase yield, they also cause the cutting table to remain
idle during the manual entry process.

[0015] This greatly reduces production throughput and

ef?ciency.

delay standard manufacturing procedures. Use of these

informal communication methods cause production ef?cien
cies to drop even further While neW employees are being
trained or neW machines are being commissioned.

[0006]

The glass lites that are needed to construct the IGs

are separated and grouped into scheduled production batches

or runs. For each production batch, the glass lites are further

grouped and arranged to be cut from large stock glass sheets

to achieve the highest yield. The process of grouping and

SUMMARY OF THE INVENTION

[0016] In accordance With one exemplary embodiment of

the claimed invention is a method for optimiZing material
How and equipment utiliZation in the fabrication of insulat

ing glass units in a production operation. The method

comprises compiling a plurality of orders and converting the
plurality of orders into production schedules for operating a
plurality of processes that fabricate the insulating glass units

May 17, 2007

US 2007/0112451A1

over a prescribed period of time. The method further

includes releasing the production schedules to the plurality

of processes used to fabricate insulating glass units. The
production schedules are accessible to users through a

computer netWork. The method also includes monitoring

production operations data produced as a result of the
releasing the production schedules to the plurality of pro
cesses used to fabricate the insulating glass units and pro

creating a material notice condition based on the monitoring

production operations data and altering one or more of the
production schedules based on the material notice condition.

[0019] These and other objects and advantages of the

system constructed in accordance With an exemplary
embodiment of the invention is more completely described

in conjunction With the accompanying draWings.

viding reports used by the monitoring production operations

having image readable indicia that are imaged for providing
real-time data for tracking material How to, from, and
through the processes used in the fabrication of insulating

glass units.
[0017] In accordance With another exemplary embodiment
of the claimed invention includes computer-readable media
having computer-executable instructions for performing a
method optimiZing material How and equipment utiliZation
in the fabrication of insulating glass units in a production
operation, the instructions comprising the step of producing
a plurality of production schedules for equipment and
assembly operations used to fabricate WindoWs and WindoW
components over a prescribed period of time. The instruc

tions further comprise releasing the production schedules to

the equipment and assembly operations used to fabricate
WindoW and WindoW components. The production schedules

BRIEF DESCRIPTION OF THE DRAWINGS

[0020]

FIG. 1 is a schematic representation of a WindoW

and/or door manufacturing facility;

[0021]

FIG. 2 is a schematic representation of a WindoW

and/or door manufacturing facility equipped With a system

for controlling production run sequences of insulating glass

units;
[0022]

FIG. 3 is a schematic representation of a user

interface by means of Which an operator controls production

run sequences;

[0023]

FIG. 4 is a schematic representation of a user

interface by means of Which an operator controls production

run sequences;

[0024]

FIG. 5 is a schematic representation of a user

are accessible to users through a computer netWork. The

interface by means of Which an operator controls production

instructions also comprise calculating production operations

run sequences;

data associated With the productions schedules. The calcu

[0025]

lating of the production operations includes using informa

controlling production run sequences;

tion from continuous real-time data collected from tracking

material and components through the equipment and assem
bly operations used to fabricate WindoW and WindoW com

[0026]

FIG. 6 is a How chart that illustrates one method of

FIG. 7 is a schematic representation of a cutting

station located Within a WindoW or door manufacturing

facility;

ponents.
[0018] In accordance With yet another exemplary embodi

[0027]

ment of the claimed invention is a method for controlling

of Which an operator sets up cutting operations at the FIG.

production schedules of insulating glass units, components,

1 cutting station;

and materials in equipment and assembly operations com

prising the steps of compiling a plurality of neW, remake,
and rush orders used to fabricate insulating glass units and
converting the plurality of orders into production schedules
for operating a plurality of equipment and assembly opera

[0028] FIGS. 9-15 are schematic depictions of glass sheets

illustrating layouts of lites to be cut from the sheets at the

tions that fabricate the insulating glass units over a pre

scribed period of time. The method further includes releas

ing the production schedules to the plurality of equipment

and assembly operations that fabricate insulating glass units,

the production schedules being accessible to operators and
management through a computer netWork and monitoring
production operations data produced as a result of the
releasing the production schedules to the plurality of equip
ment and assembly operations and real-time feedback infor

FIG. 8 is a schematic of a user interface by means

cutting station;
[0029] FIGS. 16A and 16B are ?oWcharts for optimiZing
lite layouts on glass sheets of a production run;
[0030]

FIGS. 17A and 17B are ?oWcharts illustrating a

process for managing and optimiZing material How and

equipment utiliZation through the production process of

FIG. 2 in accordance With the present invention; and

[0031] FIG. 18 illustrates a printing operation for a plu

rality of reports for providing information to the production
process of FIG. 2 in accordance With the present invention.

mation. The monitoring production operations data includes:

monitoring individual machine production rates used to

fabricate the insulating glass units; monitoring individual

machine completion rates used to fabricate the insulating

glass units; monitoring individual kanban arrival times hav

ing a knoWn amount of material used to fabricate the

insulating glass units; monitoring individual kanban con

sumption rates of the knoWn amount of material used to

fabricate the insulating glass units; and monitoring indi

vidual machine start times used to fabricate the insulating

glass units. The method further includes the steps of alerting

operators and/or management should the materials supplied

DETAILED DESCRIPTION

[0032] The disclosed invention provides an integrated

softWare and apparatus solution used in the manufacture of
WindoWs and/or doors for dynamically monitoring manu

facturing variables and controlling production sequences

using central production control Workstation 10 (FIG. 2).
[0033] FIG. 1 schematically illustrates a WindoW and/or
door manufacturing facility 12. The facility 12 includes a

to one or more of the plurality of equipment or assembly

front end system or terminal 14 Where orders for WindoWs

and/or doors are entered and WindoW assembly is scheduled.
The front end system 14 provides orders 16 to an insulating

operations fall beloW a prescribed material queue threshold,

glass unit (IG) production control terminal 18. The orders 16

May 17, 2007

US 2007/0112451A1

may include regular production orders 20, rush orders 22,

arroW 68. The front end system 14 and the control terminal

and remake orders 24. The rush orders 22 are orders that are

18 receive demand information electronically from the glaZ

ing lines as indicated by arroWs 70, 72 respectively. This

prioritized, usually due to a customer demand. The remake

orders 24 are entered When an IG 25, a component of an IG,
or a ?nished WindoW or door 58 is damaged. In the exem

plary embodiment, remake orders are provided directly to

information includes a number of runs 74 in a queue 76 for

each glaZing line. The control terminal 18 also receives

remake requirement information from the glaZing lines as
indicated by arroW 78. Additional remake information may

the central control Workstation 18 by an electronic commu

nication 19 from a glazing line or a WindoW component

be provided from one or more of the stations in the IG

processing station (FIG. 2). The regular production orders

department.

20 are orders that have not been tagged as a rush order or a

re-make order.

[0034]

The production control terminal 18 receives the

orders 16 as input and creates a sequence of runs of

insulating glass units to be produced at an insulating glass

unit (IG) department 26. In the illustrated embodiment, the

[0038] In the exemplary embodiment, the production con

trol terminal 18 is a controller or ancillary computer includ
ing a programmable device in communication With a pro

grammable device 80 located at each WindoW component

processing station and a programmable device 82 located at

the plurality of glaZing lines. In the exemplary embodiment,

IG department includes several insulating glass component

programmable devices 80 are electrically coupled to con

processing machines or stations that construct IG compo

nents and assemble the IG components to create IGs. In the

trollers of WindoW component processing stations that

include compatible machine controllers. This alloWs the
sequence of these WindoW processing stations to be altered
automatically. Compatible machines automatically run the

illustrated embodiment, the IG component processing sta

tions include a glass cutting station 28, a spacer frame
production station 30, a muntin bar production station 32, a

next production run in the sequence, if con?gured for Auto

muntin bar assembly station 34, a glass Washing station 36,

Sequencing. Such WindoW component processing stations

an IG assembly station 38, an oven 40, a gas ?ll station 42,

include the glass cutting station 28, the spacer frame pro
duction station 30, the muntin bar production station 32, and
the oven 40, in the exemplary embodiment. Non-compatible

and a patching station 44. Glass lites 46, spacer frames 48,
and muntin bars 50 are constructed at the glass cutting
station 28, the spacer frame production station 30, and the

muntin bar production station respectively. The glass lites,

spacer frames, and muntin bar grids 50 are assembled to
form IGs at the IG assembly station 38. The IGs are fed
through the oven/press 40, Which presses the IG to a
predetermined thickness and heats the adhesive/ sealant that
secures the lites to the spacer frame. The IGs are then ?lled
With an inert gas at the gas ?ll station 42 and patched at the

patching station 44. An IG department supervisor 45 is

responsible for managing each of the IG component pro
cessing stations to ensure that demands for IGs by a glaZing
department 60 are met.

[0035]

To simplify the disclosure of this inventive method

and apparatus, the term glaZing is to be interpreted as

installing a glass lite or IG in any WindoW or door compo
nent and the term sash is to be interpreted as any WindoW or

door component that surrounds a glass lite.

[0036]

Once patched, the ?nished IGs are placed on carts

54 in a staging area 56. The carts 54 in the staging area 56

form a visual kanban system 55, providing production

personnel With a visual signaling system by monitoring the
number of carts in the staging area assigned to an assembly

line in a glaZing department 60. More speci?cally, the IGs

are taken from the carts 54 and are assembled With WindoW

sash and frames or doors in the glaZing department 60 to

construct completed WindoWs and/or doors 58. Assembly of
an IG to a WindoW or door sash and/or a frame is broadly

referred to herein as glaZing. The glaZing department 60

includes several discrete glaZing lines 62.
[0037]

FIG. 2 illustrates a WindoW and/or door manufac

turing facility 12 equipped With a system 64 for controlling

production run sequences of insulating glass units. In the
embodiment illustrated by FIG. 2, the production control
terminal 18 receives orders electronically as indicated by
arroW 66 from the front end system 14. The control terminal
18 electronically sends and receives information to and from

the glass component processing machines as indicated by

machines utiliZe the satellite programmable devices 80 to

alert the operator of the neW production run sequence. Such
stations may include a muntin bar assembly station 34, the

glass Washing station 36, an IG assembly station 38, a gas ?ll

station 42, and a patching station 44.
[0039]

Referring to FIGS. 3-5, the status of the runs of

IGs, the status of the insulating glass component processing

machines, and the queue of insulating glass units to be
assembled at each glaZing line can be vieWed at the pro
duction control terminal 18 or Workstation. The screen

illustrated by FIG. 3 provides the IG supervisor With the

status of complete IG production runs, the status of runs of
IG components, and the status of completed IG runs in
queue at the glaZing lines. Column 400 provides the IG
supervisor With the overall status of IG production runs.

Column 402 provides the IG supervisor With the status of

runs of muntin bars that correspond to each overall IG

production run. Column 404 provides the IG supervisor With

the status of runs of glass lites that correspond to each
overall IG production run. Column 406 provides the IG
supervisor With the status of runs of spacer frames that
correspond to each overall IG production run. Column 408
provides the IG supervisor With the status of the IG runs of
at the gas ?ll and patching station. Column 410 provides the

IG supervisor With the glaZing line number or description

and the status of each completed IG production run at the

identi?ed glaZing line.

[0040] The screen of FIG. 4 provides the IG supervisor
With the status of the completed IG runs in the glaZing queue
of each glaZing line. On the screen illustrated by FIG. 4,
columns 412, 414, 416, 418 provide the status of each run
420 of assembled IGs in the queues 422 of glaZing lines 1,

2, 3, and 4 respectively. The stiphing and cross-hatching of

FIG. 4 corresponds to the legend shoWn in FIG. 3.

[0041] The screen illustrated by FIG. 5 provides the IG

supervisor With the status of each production run 424 in the
production run queue for each WindoW component process