August 17, 2004
GAF Materials Corporation (GAFMC), North America’s largest manufacturer of commercial and residential roofing, reported that it used WinSPC to reduce manufacturing variance by 39.5%, attaining its ROI in 4 months.
Background
–Chris Valier
Business Intelligence Manager
GAF Materials Corp.
GAF Materials Corporation (GAFMC) is North America’s largest manufacturer of commercial and residential roofing with annual sales of nearly $3 billion. GAFMC’s Mt. Vernon plant manufactures residential and commercial roofing products. The Mt. Vernon plant has gained significant benefits using WinSPC.
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 properly processed asphalt. Incoming asphalt arriving from the refinery can have a notable fluctuation in characteristics from one branch to the next. 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
About DataNet Quality Systems
DataNet Quality Systems empowers manufacturers to improve products, processes, and profitability through real-time statistical software solutions. The company’s vision is to deliver trusted and capable technology solutions that allow manufacturers to create the highest quality product for the lowest possible cost. DataNet’s flagship product, WinSPC, provides statistical decision-making at the point of production and delivers real-time, actionable information to where it is needed most. With over 2500 customers worldwide and distributors across the globe, DataNet is dedicated to delivering a high level of customer service and support, shop-floor expertise, and training in the areas of Continuous Improvement, Six Sigma, and Lean Manufacturing services.