Poka-Yoke - A Window Manufacturer's Response to Leakage and Quality Control

Please note: The attached file below contains a paper from the BEST5 conference that is linked to a conference presentation in pdf format. Open with Adobe Acrobat for best results.

Replacement windows installed in commercial and residential buildings are subject to potential quality control issues during fabrication, shipping, storage, and installation. Quality control procedures employed by the manufacturer during fabrication may not be known or understood by the Architect. Proper employment of these procedures are imperative to achieve specified performance levels. In situ window testing performed at a building that included replacement of 990 windows (consisting of over 6,250 individual sashes) revealed multiple fabrication deficiencies related to sealant and gasketed joints, as well as window assembly component fabrication and orientation. These deficiencies were not initially identified by the manufacturer through their quality control procedures and resulted in an extensive investigation, on-site remediation, and testing program. This paper presents the findings developed through this case study and provides recommendations for assessing manufacturers’ quality control plans, methods to quickly identify quality control lapses, and enhancing quality control procedures to prevent re-occurrences.