Modern Data Solutions for Glass Manufacturing

In glass manufacturing, every fraction of a second and every square inch of material counts. Despite the industry’s critical need for precision, many plants still rely on outdated processes and guesswork, resulting in inefficiencies and missed opportunities.

Over the last few years, modern data collection tools have shifted from a ‘nice-to-have’ upgrade to an absolute necessity for staying competitive in the industry, leaving many plant managers wondering, ‘How can glass manufacturers with legacy systems leverage these tools to improve efficiency and reduce waste?

The Current State of Data Collection in Glass Manufacturing

Despite significant advancements in other manufacturing sectors, glass production remains one of the last to fully adopt comprehensive data collection methods.

“Most glass manufacturers today still manually write down production data or don’t collect it at all. Transitioning to technologies like barcoding, RFID, and automated systems is essential to gather and analyze data effectively,” said Barry Brian, owner of DRM, highlighting the company’s understanding of the unique challenges facing the glass industry. “We know how important it is for every piece of equipment to work together, and we take pride in helping manufacturers make it all fit.”

Tracking throughput, monitoring processing times, and identifying bottlenecks are challenges that data collection helps address. This data provides the insights needed to improve operational efficiency and monitor quality, such as reducing glass defects and ensuring products meet high-quality standards throughout the process.

Technologies Driving Data Collection

Implementing automated data collection requires a suite of specialized tools. These technologies enable manufacturers to capture real-time insights and turn them into actionable improvements. Among the most impactful are:

Barcoding Systems

Barcoding offers a straightforward way to track production by scanning labels on raw materials, semi-finished products, and finished glass pieces, providing immediate updates on inventory and production flow. By replacing manual tracking methods like handwritten logs or spreadsheets, barcoding offers manufacturers a straightforward and reliable entry point into data collection and automation.

RFID (Radio Frequency Identification)

RFID technology elevates tracking by enabling wireless monitoring of glass batches throughout the facility. “RFID is especially useful for tracking batches of glass. It’s critical for ensuring traceability, particularly when managing returns or recalls,” stated Brian.

Vision Systems

Vision systems are another vital technology, playing a key role in quality control by detecting defects such as cracks, chips, or blemishes. “Vision systems reduce waste and rework while providing real-time quality control. When integrated with data collection, they generate detailed reports that enable continuous improvement,” Brian explained.

Real-Time Dashboards

Collecting data is only half the battle; presenting it effectively is equally important. Real-time dashboards provide plant managers with clear visualizations of key metrics, such as throughput, downtime, and quality performance. For instance, a dashboard might show a sudden increase in downtime, enabling managers to address the issue immediately and avoid costly delays. These tools enable quick decision-making to minimize disruptions.

Overcoming Challenges Through Integration

Integrating data collection tools into existing systems can feel impossible, especially for plants relying on legacy equipment. Skilled system integrators simplify this process, ensuring minimal disruption and providing invaluable support.

Reflecting on industry events, Brian noted, “There’s a real gap when it comes to system integrators in the glass industry. Our goal is to bridge that gap by helping manufacturers understand how these tools can transform their operations and providing them with the knowledge they need to invest confidently in their future.”

Plant managers often face the frustration of investing heavily in new equipment, only to discover challenges integrating with existing systems. “That’s why we focus on ensuring everything works together smoothly to deliver the data manufacturers need,” Brian explained.

Integrators assess current systems and identify the best strategies for implementing data collection technologies without disrupting ongoing operations. The controls engineers ensure that data from various sources, such as barcodes, RFID, and vision systems, flows seamlessly into a unified platform for comprehensive analysis.

The Business Case for Glass Industry Data Collection

How can real-time insights help improve quality? How does enhanced traceability minimize risks? Data collection offers solutions to these challenges and more.

• Improved Quality: Real-time insights and vision systems ensure products consistently meet high standards, minimizing waste.
• Enhanced Traceability: RFID enables tracking across the entire product lifecycle, from raw material to delivery, which is important for managing recalls.
• Data-Driven Decisions: Dashboards and analytics empower managers to identify issues proactively, reducing downtime and improving productivity.
• Scalability and Adaptability: As market demands shift, robust data collection systems make it easier for manufacturers to scale operations and adopt new technologies.

Together, these benefits make data collection a necessary pillar for modern glass manufacturing, driving operational success and long-term growth.

Data Collection: A Foundation for Success in Glass Manufacturing

For glass manufacturers, embracing data collection is no longer optional. The industry’s future lies in leveraging technologies like RFID for traceability, vision systems for quality control, and dashboards for real-time monitoring.

“As a partner to glass manufacturers, our goal is to help educate them on the benefits of data collection,” summarized Brian. “For over 30 years, we’ve built relationships based on trust and results. We’re not just here to sell a service—we want to help manufacturers see the potential in their operations and guide them through solutions that make a tangible difference.”

Data collection technologies are reshaping the glass industry, offering manufacturers the tools they need to optimize operations and stay competitive. By working with experienced partners who understand the challenges and opportunities of integration, manufacturers can take confident steps toward a more efficient and innovative future.

If your glass manufacturing facility is ready to take the next step toward efficiency and innovation, DRM is here to help. Contact us to learn more about how our expertise can guide you toward success in a data-driven future.