How to Improve Operational Efficiency: Lessons in Real Operational Improvement

At Quanex, we know that true operational improvement requires more than new equipment, it requires a new mindset. Our Kent, Washington, facility, home of the Mikron brand vinyl window profiles, has undergone major operational transformations in recent years.

These changes weren’t just reactions to industry challenges, they were proactive efforts to improve how we serve our customers, streamline production, and drive continuous improvement across every level of our operation.

Start with “Why.” The Foundation of Operational Improvement

In manufacturing, operational efficiency starts with understanding cause and effect. You can’t fix what you don’t understand.

At our Kent facility, we faced a major challenge: excessive scrap. Initially, it seemed like aging extrusion equipment was to blame. But after deeper investigation, we realized that the true problem was mindset, not machinery.

To create lasting change, we shifted focus from “What needs fixing today?” to “How can we make things better long term?”

This mindset shift led to daily improvement meetings with all production staff, where challenges and solutions are discussed openly. This collaborative environment fostered accountability and encouraged innovation.

Investing in the Right Equipment

We also recognized that mindset alone wasn’t enough. In 2019, Quanex invested in ten state-of-the-art extrusion lines from Extrunet, an Austria-based leader in extrusion technology.

These new lines improved operator efficiency, reduced complexity, and enhanced product quality. But perhaps more importantly, they boosted team morale and engagement by making the job easier and safer.

It was a powerful reminder that operational improvement is as much about empowering people as it is about upgrading technology.

Planning Ahead for Enhanced On-Time Delivery

Scrap reduction wasn’t the only goal. To truly improve operational efficiency, we also had to change how we planned and executed production.

Previously, production was reactionary, we waited for orders before creating a plan. Now, we forecast and plan production monthly, involving sales, purchasing, and production teams to create a proactive strategy.

By aligning cross-functional teams and improving scheduling discipline, our on-time delivery rates reached upward of 98% as of early 2022. This improvement has been crucial amid ongoing supply chain challenges and shifting customer demands.

The Unexpected Benefits of Operational Efficiency

Every major process improvement comes with ripple effects. Our primary goal was operational improvement, to make products more efficiently and deliver higher quality faster.

But along the way, we discovered a powerful side effect: sustainability.

By upgrading equipment and improving process control, we now:

• Recycle more than 90% of the generated scrap
• Save nearly 1,500,000 kilowatt hours of energy annually, equivalent to powering almost 1,400 homes

Operational improvement doesn’t just drive productivity, it enhances sustainability, reduces costs, and creates a safer, cleaner environment for our teams.

Continuous Improvement: A Mindset for the Future

Operational improvement is never a one-time effort, it’s an ongoing journey. At Quanex, we continue to challenge ourselves to refine processes, improve collaboration, and strengthen customer relationships.

We encourage every manufacturer to do the same. Ask yourself:

“Is this the best way to go about our business?”

With commitment, teamwork, and a focus on long-term improvement, the answer will always move you closer to operational excellence.