GAF Material Corporation

GAF Material Corporation

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GAFMC raises the roof on increased product reliability and productivity with WinSPC


Background

GAF Materials Corporation (GAFMC) is a $1.1B privately-held company that offers a broad spectrum of residential and commercial roofing systems and materials. GAFMC’s Mt. Vernon plant manufactures
residential and commercial roofing products. The Mt. Vernon plant has gained significant benefits using
WinSPC.
“WinSPC integrated easily into our processes and helped improve product quality and reliability. Since, implementing WinSPC, we have seen a variance reduction of 39.5%.”

Chris Valier
Low Slope Manager, CQA
GAF Materials Corp.


Challenge

GAFMC’s Mt. Vernon plant manufactures roofing for residential and commercial use. One of the key ingredients in producing reliable, long-lasting shingles is a properly processing asphalt.
Incoming asphalt arriving from the refinery can have a notable fluctuation in characteristics from one branch to the n ext. GAFMC adjusts for differences in the batches during the oxidation process to establish consistency.
GAFMC realized SPC tools were required to monitor and analyze the oxidation process to achieve its goals.

Implementation

GAFMC employees chose WinSPC for the following reasons:
  • WinSPC is easy-to-use and the most intuitive SPC system they could find
  • WinSPC gives the most efficient presentation of data for their operators and supervisors
  • WinSPC allows for easy integration with past, present and future systems
  • WinSPC is compatible with multiple SQL databases which fits with their future expansion plans

Results

GAFMC has achieved greater control over its oxidation process costs in the manufacturing process.

Benefits

GAFMC cited the following benefits achieved with WInSPC:
  • Increased end-product reliability
  • Reduced variance by 39.5%
  • Attained ROI in 4 months
  • Increased productivity and reduced downtime

>>Next: Loos & Co., Inc. reels in scrap and rework with WinSPC


 
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