In manufacturing, every minute counts—a small delay can throw off an entire day of production, and when products are custom-built, those delays can be expensive. The same is the case in window manufacturing, where each window is often made to specific measurements. If something goes wrong, it’s not just a minor issue—it can stop the whole process.
Many professionals are helping to solve these problems by working in the background, using software and data to keep things running. Among them is an Enterprise Systems Lead at a major window company, Ravikumar Palanichamy, who has recently played a key role in fixing a common challenge with glass parts arriving out of order.
Glass for residential windows is fragile and made in many different sizes. It needs to arrive at the factory in a specific sequence so it matches up with each window being made. But suppliers don’t always deliver the glass in the right order. Sorting it manually takes a lot of time and creates more chances for damage. To fix this, the professional’s company looked at installing a new glass sequencing robot.
But before spending the money, they decided to test it first using a digital simulation. That’s where the professional came in. Sharing his experience, he added, “During the preliminary budget evaluation, the vendor proposed a detailed simulation of the robot’s operational process, highlighting its potential to enhance efficiency and reduce processing time. Prior to final budget approval, stakeholders greenlit a proof of concept to validate the approach.”
Since then, the robot has made a big difference. It reduced labor needed for glass sequencing by 72% and defects from handling dropped by 83%. And the number of times each glass piece is touched during the process has been reduced by a third. Of course, none of this would matter if the robot got bad instructions. That’s why the team also built a system to double-check the sequencing data before each shift. This check runs 16 hours in advance, giving the factory time to fix any mistakes before they become costly problems.
In another major project, Palanichamy helped launch a new extruder plant in Texas. This plant produces lineals—key parts used to build window frames. His job was to set up the IT systems that support the production line, helping the company make one of its biggest investments in over 10 years.
Through his work, he has also seen a key difference between commercial and residential glass manufacturing. Commercial glass usually follows standard sizes. But residential windows are more customized, which adds complexity and requires more flexibility from both the machines and the people behind them.
They believe that bringing more of the process in-house—what’s known as vertical integration—could help companies manage that complexity better. By using smart software, solid planning, and accurate data, he has helped reduce errors, save time, and avoid expensive downtime.
To summarise, it’s evident how digital twins and smart software are quietly revolutionizing manufacturing by preventing costly delays and errors. Through simulation, data validation, and strong IT planning, professionals like Ravikumar Palanichamy are proving that the real power behind production lines isn’t just in the machines—it’s in the minds ensuring everything runs smoothly behind the scenes.
