Case Study: PGT Industries boosts production and avoids expansion with Mitsubishi Electric Iconics Digital Solutions' GENESIS Productivity Analytics

PGT Industries cuts labor and energy costs 20% with Mitsubishi Electric Iconics Digital Solutions

PGT Industries, a leading U.S. manufacturer of impact-resistant windows and doors, faced projected demand exceeding production capacity, which threatened revenue growth and prompted plans for a costly plant expansion. Their challenges included hidden operational inefficiencies and the need to integrate data from numerous existing equipment systems. To address this, they turned to Mitsubishi Electric Iconics Digital Solutions and its GENESIS Productivity Analytics software.

The solution involved implementing the GENESIS suite to measure Overall Equipment Effectiveness (OEE) and integrate disparate data sources, revealing previously hidden operational losses. As a result, Mitsubishi Electric Iconics Digital Solutions helped PGT Industries cancel its planned expansion, achieve production targets while reducing operations from seven to five days a week (cutting labor and energy costs by approximately 20%), and drive a cultural transformation focused on OEE. The discovered capacity exceeded expectations, and the system was expanded from monitoring 12 to approximately 80 assets.

PGT Industries