October 2009 The October kick off meeting for Section 619 ASQ was hosted by Darryl Hopkins , Quality Assurance Manager of VPI Quality Windows. The first part of his presentation demonstrated how the new ultraviolet reflecting coating can both save energy and reduce fading caused by sunlight. He then showed a video explaining the SUNCLEAN/SOLARBAN windows operation. This is the glass that has the no clean technology provided by integration of chemical elements on the glass that react with sunlight and water to sheet of the dirt while reducing the ultraviolet energy entering the house or business. No more going up high on ladders to clean windows.
Darryl has implemented many improvements in the process and procedures used for making the windows. One of the first changes he made was to implement a computer program that lays out the cuts in a sheet of glass to minimize the waste resulting in a major cost savings to VPI. As part of the Quality improvement program, with input of the employees he posted charts that show such things as on time deliveries , returns for defects, material delivery and material waste tracking so that all of the employees can see how their action affect the bottom line. He has regular meeting with key people to discuss the data. Darryl got the names and phone numbers of the installers and regularly calls to find out the condition the shipment arrived in, any installation troubles and just how they feel about VPI products. This has resulted in very high customer satisfaction as they know that they can call him with any problem they may have and get rapid results. He has just recently had a training room built in which the employee on the first day of the job get instruction on all aspects of the material used to build the windows, the labeling to track the windows and hands on training for the tools used to build the windows. This has resulted in a major reduction of on the job injuries by creating safety conscious employees. Darryl was able to accomplish all of this because of the full support he has from the top management down including the employees.
On the tour of the plant we were shown how the windows are built from the cutting of the glass to the final packaging for shipment. Darryl is very proud of the fact the VPI is ISO certified. Every station has reference sheets the operators can refer to if needed. Shipping damaged or defective parts are isolated and analyzed before being released for repair. The item must then be signed off before it can then again be shipped. The major features he pointed out are that they use all foam structural spacers reducing energy cost and providing long life to the window. They also use full round sealing rather than half round some other manufactures use.
Thank you Darryl for showing us how your dedication to improving VPI quality has contributed to a Major local company‘s recognition for Quality windows even thru this down turn in the economy.
David Lewis
Secretary
