Reduce Field Failures with OptiPatch Automated Fourth Corner Patching
OptiPatch is an automated fourth-corner patching system that eliminates costly field failures caused by improper sealant application and reduces the need for patching workers.
OptiPatch applies sealant at the right pressure and temperature to every unit every time. It automatically pulls each unit partially out of the rack, patches and then indexes it back into the rack, eliminating manual handling damage.
You push a rack into the indexer queue and walk away. OptiPatch advances the rack, partially pulls the unit out of the rack, fixtures it, finds the corner, applies the required layer of sealant at the right pressure and temperature, returns the unit to the rack and continues until all units in the rack are sealed. It patches units at 10 seconds each and advances the next rack automatically.
Payback is less than 12 months for most companies and can be less than six.
The Patching Payback Calculator
Want to better understand how automated patching will work for your operation? Use the IAS robotic patching payback calculator. The calculator allows you to control all the factors in your cost: current and estimated replacement rates, unit repair cost, production volume and labor cost.
On average, one to two percent of insulating glass units fail in the field. Direct cost to replace a unit in the field runs from $150 to more than $300. The fourth corner patch is not the only reason units fail, but is near the top of the list. OptiPatch could help reduce your field failures by up to half.
Example
A fabricator produces 1,000 IG units per shift, five shifts per week. Field replacement averages $200 per unit. With OptiPatch, they can reduce their field failure rate from two percent to one and patching labor from two workers to one at a fully loaded cost of $35 per hour.
Labor savings per shift would be $280. Reduction in patching field failures per shift saves $2,000. Total savings are $2,280 per shift, $45,600 per month and $547,000 a year. Payback is 11 months.