YKK AP AMERICA INC. — Operations Begin at New Macon Factory

Under the policy of "contributing to customers’ businesses, the global environment, and local communities through a commitment to safety and quality," the Macon Factory is focused on safety and quality in all of its operations, contributing to customers’ businesses and the local community, and being a plant where its employees can take pride in their work.

The factory has upgrades including a new hung window line for the production of the upcoming "StyleView^® Classic series," an improved product that will be launched in addition to producing the existing vinyl window products.  Production flow is designed to run from the west side of the building to the east side in order of extrusion of vinyl materials, processing of glass and windows, assembly, and shipping, creating a highly efficient integrated production system. Automation technology, which has been adopted in Japan for the APW Line for the production of vinyl windows, will be rolled out in the new factory to increase productivity by 212% from current levels. In addition, to ensure a safe and high-quality factory, improvements such as the development of a remote support system, the adoption of equipment specifications that can be maintained and managed by local operators, and in-process inspections that are not dependent on human operators, will be established.

To create an environment that is comfortable for workers, automation such as GTP (*1) technology will be added to reduce physically demanding tasks such as heavy lifting and picking in the production line, as well as during the warehousing and shipment processes. Additionally, the information infrastructure will be developed to help establish a "smart factory." 

In order to reduce CO2 emissions, the new building has increased natural light, and improved insulation of its roof and walls for better energy efficiency. Furthermore, energy-generation technologies will be phased in, in an effort to achieve carbon neutrality. The building design is scalable to accommodate additional automation, increased capacity, and future business and product expansion strategies. In addition, an emergency evacuation site has been secured to ensure the safety and security of employees in the event of natural disasters, such as  tornadoes that frequently occur in the southern United States.

*1: GTP stands for Goods To Person, and refers to a system of shelf-transporting robots that bring goods to the location of workers picking goods at distribution centers, etc., or a method of carrying out picking operations in which workers pick goods from a fixed location. Compared to a method in which workers walk while picking goods stored on fixed shelves, this minimizes worker movement, thereby reducing workload.

[Outline of the Macon Factory]

[Outline of YKK AP AMERICA INC.]