Building Products Manufacturing

Building products manufacturing is a very unique industry. It spans residential, commercial, and industrial sectors and includes products as diverse as pavers, shingles, insulation, glass, cabinetry, doors, and fasteners, to name a few. This results in an unusually wide range of manufacturing processes, within an industry that often features significant regional competition and multiple manufacturing sites in order to produce products closer to their final destination - reducing transit and other logistical costs.

Engineering and IT resources are often shared amongst sites even while continuous improvement processes remain an essential tool for controlling costs. Vorne XL is ideal for this type of environment as it scales easily from machine to plant to enterprise, creates visibility across regional sites to keep the business coordinated and cost-efficient, and is truly fast and easy to implement. XL provides critical insights for effectively driving process improvement and actualizing change with 100+ metrics and 20+ data dimensions.

Other benefits of XL that customers love include no software to install, no servers to maintain, no recurring fees, and no contracts. Instead, you get unlimited users, free technical support, a 3-year warranty, and free software updates. All in an inexpensive, off-the-shelf product.

Building products manufacturing facility.

Driving Improvement for Building Product Manufacturing

Our building products customers strive to make something more durable, eco-friendly, or cost-effective than their competitors. It is critical to be able to optimize the process while maintaining the product quality that their customers require.

The Vorne XL Productivity Appliance empowers building products manufacturers to monitor their processes in real time, improve throughput, and maximize efficiency, all while preserving the integrity of their products. XL drops onto your existing process, making it a quick and easy solution that requires little to no changes on the line. This is a unique and critical advantage of Vorne XL.

Key Benefits for the Building Products Industry

Vorne XL is completely agnostic to the type of equipment in your manufacturing process. This is a huge advantage as you can easily apply XL to any process and get the same deep wealth of information. XL includes I/O to integrate with your process, a scoreboard for your operators, and built-in reporting for your managers. Even better, it easily and incrementally scales from machine to enterprise. Monitor your preform block pavers and ovens, mills, saws, planers and grinders, cold headers or extruders, and other equipment with one solution, quickly seeing benefits such as:

Simple Setup XL can be installed by your existing team with minimal involvement of your IT department, with no expensive external resources or equipment necessary.
Intuitive Unified Interface Benefit from instant, plant-wide production visibility through web-based reporting. Ensure your team has effortless access to the data they need without introducing or requiring complex infrastructure.
Plant Floor Display and KPIs Eliminate over or underproduction by displaying real-time KPIs and production targets, empowering operators to produce exactly what is needed at the time it is needed.
Automated Alerts Be proactive in managing your lines with metric alert notifications by email and/or text to the right personnel, escalating when necessary.
Visibility on Tangible Losses Identify, discuss, and take action based on powerful production KPIs. Pareto your downtime by reason. Express OEE in terms of lost time. Establish your continuous improvement roadmap with ranked Top Losses and much more.

Metrics, Dimensions, and Dashboards

Vorne XL provides you with an incredible data foundation and an outstanding suite of reporting tools to effectively drive your continuous improvement, lean manufacturing, and digital transformation initiatives. With XL you get immediate access to over 100 highly accurate and actionable metrics and 20 data dimensions - in real time and for deep retrospective analysis through historical reporting. There are dozens of built-in reports, and you can easily create your own reporting dashboards.

30%

Labor Savings, 31 Day Payback

G.K. | Continuous Improvement Manager | Global Food Service ProviderWe purchased a Vorne XL display to help us monitor production rates and apply lean manufacturing tools to one of our many value streams. By efficiently working to takt time, we have been able to eliminate waste and improve productivity, while maintaining our commitment to quality. We have calculated a 30 percent labor savings on our pilot project which yielded a 31 day payback. Since the pilot we have installed another two XL displays. As you can imagine, we will be continuing to add more Vorne displays!

22%

OEE Improvement

Pascal Bourdages | Plant Manager | NovatechWe have XL on a 90-day trial and have already seen a 22% improvement in our OEE score. We are keeping our trial unit and will be adding our next unit shortly!

100% ROI

In Just Minutes

M.B. | Manufacturing Engineer | Commercial Building Products ManufacturerEach operator in our plant does just a small piece of the completed product and previously had no idea of how their work affects the final output. This was before the displays. Now, anyone can look down the line and see the real-time production output in large numbers. We were truly surprised at the effect the displays had on our productivity. Some areas actually achieved a 20% increase in on-time quota. We have seen gains everywhere we've put the displays and are now convinced of the value. As matter of fact, we've proven 100% payback of the display cost in just minutes of improved productivity!

10%

Production Increase

P.P. | Facility Engineer | Premium Door Products ManufacturerThanks for an excellent product! We've installed six Vorne XLs now and the results have been great. Our supervisors love seeing real-time production data at their PCs and the Excel reporting tool provides ready access to information we can use to further improve the process. The six lines with XLs have consistently shown 5% and often 10% increases in production.

Best

Productivity Monitor Around

Max W. | Manufacturing Engineer | Building MaterialsWe tried multiple other productivity monitors and Vorne XL is the best, hands down. It is customizable for any of our production lines, easy to standardize from line to line and the user interface makes it simple and fast for operators to use. Their tech support is unmatched too!

99.5%

Count Data Collection Time Improvement

G.D. | Bindery Manager | High Volume Catalog PrinterHaving the data collected from the Vorne displays allows my supervisors to focus on machines that are running bad and to leave the good ones alone. The bottom line for us is that we cannot effectively react to what was done yesterday. Now, people on the line are always looking to see if their line is number one and do what it takes to make their line perform. No doubt we would not have the efficiency gains that we've achieved without the visuals. It used to take our supervisors 35 minutes to collect the count data for their 9 machines now they have it in 10 seconds!

94%

Downtime Reduction

S.T. | Plant Engineer | International Glass Products ManufacturerThe Vorne displays definitely generate a competitive interest on the plant floor. Until we put the displays up it was not uncommon to see 160 minutes of shift downtime. Now that operators can see the downtime in real time it is down to just 10 or 12 minutes per shift. Also, one of our production shifts just broke the all-time run rate for the line.

15%

Downtime Reduction

L.C. | Manufacturing Engineer | Global Auto Parts SupplierTwo years ago we brought in the Vorne XLs as part of our lean program. We wanted to measure and improve efficiency on seven lines. OEE gave us a reliable way to measure our progress and also a tool for identifying areas where we can improve. Over this time we have increased our OEE by an average of 20 points and our downtime is down by 15 to 20%. Vorne has been with us every step of the way. We are proud that we have improved and also that we are maintaining our gains. Vorne has been a trusted partner in our journey, providing us the tools and support to help us improve our productivity.

127%

Target Rate

A.C. | Manufacturing Consultant | Manufacturing Consulting FirmWhen we installed Vorne displays showing target and actual production rates, the target rate for one of the lines was inadvertently set higher than was planned. One of the engineers set the target rate to 180 pcs/min for a part that was scheduled for 140 pcs/min. A few hours later when the plant manager glanced at the display, he was amazed to see the actual performance at 178 pcs/min. The line was running at 127% of plan simply because the goal was there! The Vorne displays showed us that our team members can outperform our own expectations. After we started visual management using the Vorne displays, the lines are showing record productivity numbers.

115%

Of Plan

C.T. | Lean Improvement Team | Global Imaging Products ManufacturerWhen we brought in our first XL, we introduced it to our associates in small groups and explained the idea behind working to Takt Time. After three days our team was producing at 115% of plan and set a new production record. At the end of the shift our plant floor team broke into applause! That's why every line is getting an XL.

30%

Labor Savings, 31 Day Payback

22%

OEE Improvement

Building Products Manufacturing

Driving Improvement for Building Product Manufacturing

Key Benefits for the Building Products Industry

You're In Excellent Company

Learn More About Vorne XL

Metrics, Dimensions, and Dashboards

Vorne XL User Success Stories

Building Products Specialties