The Irish glass processor and IG producer Douglas Glassworks is currently undergoing an innovation process which, within just a couple of months, will render the company one of the most modern and customer-friendly Irish glass producers. Apart from a thorough renovation of the machinery, Douglas Glassworks are counting on the comprehensive, networked application of German software supplier ALBAT+WIRSAM which shall make them more flexible, produce a better yield, and improve the quality.

Networked Production

At the end of this renovation process, Douglas Glassworks will have achieved a nearly paperless, fully networked production and a comprehensive registration of operational data. Breakout display XTV will show the men at the breakout tables both the cutting patterns and the rack on a large-sized monitor. By means of barcode registration, the current production status of each sheet is reported to the central database so that all departments – as well as all enquiring customers – can get information on the present situation (‚where is my sheet?’).

Omitted processing steps are expensive and normally render the sheet in question practically worthless. A sheet for instance which is put into the furnace without the required hole or edgework, can be thrown right into the waste glass container. This is why, by means of the barcode-controlled ALCIM monitoring system, the users at every workstation check the sheets prior to processing for correct sizes and completeness of the previous processing steps. For Douglas Glassworks, this is a new dimension of processing-safety which saves a lot of time and money.

After processing, the sheets can be reported complete or broken by each of the workstations. Breakage reports will be instantly transferred online to the premium optimiser XOPT-ON which will immediately initiate, automatically of course, a remake – despite the mishap, the order can be shipped, on time and complete. These new features will be installed by the end of 2006.

Perfect Organisation – High-Quality Product Range

Since the day Ronnie Douglas founded the company in 1978, the focus has been set on quality and optimum compliance with customer’s requirements. According to the current managing director, Raymond Douglas, the family business takes special price in reliably supplying the expected quality, together with responsible, specialist service. This can be achieved only with reliable, responsible staff: The approximately 40 members of the Douglas team will therefore support the current innovation process – which, in many aspects, means a complete reorganisation – and, together with the ALBAT + WIRSAM project team, turn it into a roaring success.

"ALBAT+WIRSAM", says managing director Raymond Douglas, "have not just sold us the software. We have been impressed by the conscientious, individual consulting. All this is part of a tailored concept which will improve a lot of our processes, from technical and commercial order entry up to the direct packing of sheets and thorough route planning".

Above all, Douglas Glassworks is a glass processor who, apart from a wealth of know-how, are equipped with the optimal technology – be it bevelling machinery, several CNC processing centres or a state-of-the-art TAMGLASS toughening furnace used for products that are supplied to the native furniture industry, manufacturers of sanitary products, Specialist steel fabrication companies and interior designers. A most interesting fact is that on many of the machines used for glass processing, flagstones are processed as well – mostly granite kitchen worktops which, apart from the necessary cut-outs, undergo intricate surface processing such as the carving of drain boards.

Another speciality of Douglas Glassworks is the production range for EVASAFE® laminated safety glass which includes patterned glass for interior design, using coloured films or different types of functional film. EVASAFE® laminated can also be used in IG units and opens up a multitude of creative possibilities such as fitting design elements between two layers of film. Production of this laminated glass is completed under vacuum at approx. 1300 C.

High-Tech IG Production within the ALCIM Network

The plan is to increase IG production. The existing IG line will therefore be joined by a second one. Both lines will be fully integrated into ALBAT+WIRSAM’s production control system ALCIM, for a speedy and constant production flow. At the start of the line, the monitoring system ProdTV shows loading direction and bottom edge of every sheet. The man at the machine knows the exact sheet structure at any time – this prevents a loss of time and material because of wrongly assembled IG units where, for instance, the outside of a patterned sheet points inwards.

A fixed scanner on the line reads the labels of each passing sheet and reports the data via ALCIM to PackTV packing optimisation. The man at the end of the line knows exactly which sheet to put onto which rack. Again, the customer is the one to profit most of this technology: Wrong shipments with omitted or wrongly packed sheets become scarce because most of the sheets can be directly put onto “their” racks. Tedious searching and re-sorting in the shipping area – this antiquated process during which many a sheet has been damaged in the past – is no longer necessary.

The shipping personnel use radio scanners to register the labels of the packed sheets. From this, ALCIM2000 creates cargo lists which show the completeness of the shipment and, if required, the sequence of sheets on the racks. A further step allows barcode registration at other processing terminals which give precise information on the status of the individual sheets such as: 'edgework completed' or: 'broken in the toughening furnace'.

About 700 high-tech IG units will be produced per shift, on two lines. Most of the customers are joiners and window installers from county Monaghan but it goes without saying that Douglas Glassworks are supplying other customers too. The growth in the IG area will be mainly due to high-quality functional and ornamental glass such as toughened, laminated, or patterned glass combined with Low E and gas filling. What with the EVA-produced laminated glass, this glass producer from county Monaghan offers a comprehensive product range for all sorts of requirements.

Perfect Order Processing with ALFAK

The more varied and high-quality the product, the more important becomes an efficient, specialised order processing system that can handle the enormous product depth and diversity of the flat glass industry. The currently used order processing system has been coping only insufficiently with those requirements. When Raymond and his IT specialist Mervyn Taylor took a closer look at ALFAK, they soon realised that the basic package can be easily adjusted to the individual circumstances and demands at Douglas Glassworks. Quick input right from a stack of faxes works as effortlessly as the construction of a technically complex sheet. The graphic surface fits seamlessly into the familiar WINDOWS environment. All operating elements are where they belong; nothing is hidden in cryptic sub-menus. The system can be operated by mouse or keyboard, whatever the user prefers. In case of queries, the competent team at A+W UK are always glad to help and answer any question right away.

A Innovative Family Business – Perfectly Organised

Douglas Glassworks offer a comprehensive product range of IG, safety glass and processing which is now being extended and updated. All this is founded on an enormously healthy family business, managed with a lot of business courage.

The current reorganisation and modernisation is based on a well thought-out, many-faceted, compre¬hensive concept which can only be hinted at by slogans such as: will to cooperate, will for innovation, service culture, and customer orientation. For the technical realisation of this concept, so Raymond Douglas, the cooperation with the IT and consulting partner ALBAT+WIRSAM UK has been significant.

With this new commitment, Douglas Glassworks have set the points for remaining one of the most efficient and versatile companies in the Irish flat glass industry.

We have been impressed by the conscientious, individual consulting. All this is part of a tailored concept which will improve a lot of our processes, from technical and commercial order entry up to the direct packing of sheets and thorough route planning