JadeConsult – nipping production problems in the bud

The fenestration supply chain is one that has evolved into a comfortable rut over the last four plus decades as PVC-U and latterly aluminium has responded to the increasing pride and joy in home ownership and home improvement.

As taste and technology has led to a flurry of new product designs, incorporating those designs into efficient manufacturing has been a challenge faced by many at the back end of the supply chain.

Windows have gone from white squares that filled a hole, to property owners nurturing a domestic pride and deep desire to replace like for like, particularly when it comes to heritage windows, or for completing a more architecturally beautiful design that is increasingly the focus of slimline aluminium projects.

Product differentiation has become key for fabricators and installers across the UK. Fitting a houseful of beautiful windows is, first and last, the most powerful form of marketing asset for the entire supply chain – and one that we see in the pages of this very publication every month, with pictures of installations covering a wide range of building use and aesthetic style.

Yet every single one of those different windows has been through an intense process of production development to maximise efficiencies and product quality and performance. From the initial design of the profile, to the way in which a window is installed on site, every punch hole, every welded corner, every milled end needs to go through a process which needs to guarantee repeatable quality every single time.

Invariably, Jade is there to help troubleshoot production problems as and when they occur. Whether that is bottlenecks building up at certain parts of the production line, a recurring quality issue, or replacing worn out tooling, Jade has built its reputation on being able to sniff out the exact problem the moment they step into a window factory. Such is the power of the company’s knowledge and expertise.

And while troubleshooting will always be a core part of its business, the company is now wanting to help systems houses and their fabricators get ahead of the curve of potential problems arising further down the line by dealing with them before they even occur. This forms part of the company’s JadeConsult division – a service whereby directors Sean Mackey and Adam Jones will cast their expert eyes across a fabrication plant and future proof weak links against impending issues.

“Over the years we have worked with pretty much every major PVC-U and aluminium system, window and door brand, and machinery supplier, and there is not much that we haven’t resolved,” said Jade director, Adam Jones. “This gives us a unique insight into manufacturing methods across the UK and across the industry, and probably the most extensive insight in the industry as a whole. We have also evolved a method of working which protects confidentiality and ensures that every company is supported in a way that will never compromise its own identity and brand value.”

Whenever the word ‘problem’ is bandied about, fabricators can get worried about potential costs. The premise of Jade Consult is to ensure those potential costs are minimised, as well as the impact of production issues on future profits.

“Sometimes we have gone into factories and the solution is so obvious to us, having seen it 100 times before,” continued director Sean Mackey. “This might mean we have a ready made solution, or can resolve the issue with one of our uniquely designed stand alone machines. A problem that might have cost tens of thousands if left to develop and fester, could be resolved with a couple of grand, by us noticing it early enough to mitigate any further disruption to the production schedule”.

Jade has long since advised fabricators to keep on top of their tooling maintenance to protect themselves against production issues further down the line – JadeConsult is an extension of this, understanding the intricacies of every stage of the production line to make sure that nothing is left to chance.

“It might sound like we are teaching the industry to suck eggs,” said Adam Jones. “In reality, we are the only supplier that has a deep understanding of the entire manufacturing process across a range of products and machinery – we know what goes into creating, growing, nurturing and laying those eggs – and getting them safely to the shop in one piece! Our role is to, as much as possible, eliminate any broken eggs. Not an easy job, but one which we can do in collaboration with the systems houses and their fabricators!”