Quality (and cost) control

”The bitterness of poor quality remains long after the sweetness of low price is forgotten,” is a quote widely attributed to Benjamin Franklin, one of the Founding Fathers of the United States. As consumers we have all had a disappointing experience where a discounted or budget product has failed to live up to expectations. 

But in a business where the cost of quality can be more than purely reputational, via expensive remakes and callouts, blind and curtain manufacturers are constantly striving for greater quality in order to win over new consumers. WFA spoke to four leaders in the window furnishings manufacturing space about their recent efforts to improve the quality of their output. 

Viewscape: A reputation for quality

Andrew Rundle, General Manager of Viewscape, says the company has always had an excellent reputation for quality.

“One of the reasons our retail partners align with Viewscape is because of this fundamental manufacturing pillar and we all believe the Australian consumer expects this from locally manufactured products.” 

“One of our core values is continuous improvement and we apply this directly to our Quality Assurance and its part of our DNA.” 

“We consider quality right from the specification of componentry all the way through to the grade of cardboard we use for shipping our products in.” 

“Our commitment to quality goes beyond rigorous systems, processes and standards. We also invest heavily in bespoke equipment to solve industry issues and drive excellent repeatability in the manufacturing process.”

Rundle says that over time Viewscape has developed a number of versions of roller blind centric equipment to enable excellent blind performance at the window. 

“One piece of kit is an automated base rail machine. The machine provides brilliant repeatability and ensures no fabric distortion as fabric is sleeved into a base rail.” 

“The system also addresses the reduction in puckering. The automated process removes mechanical fastening between the spline and fabric.” 

“Fabric and spline can behave independent of each other, therefore not being affected by significant heat gain in the window allowing fabric to sit flatter on the blind.”

Post manufacture, every roller blind manufactured at Viewscape is placed on a hoist to undergo a series of quality assurance checks and tests.

“One of those checks is to ensure that the base rail of the blind sits parallel with the roller blind itself,” Rundle says. 

“We use a laser levels which are calibrated daily with the hoist to give our manufacturing operators a control mechanism to check that both the blind and base rail are level.”

“The hoist represents a workstation that conducts a variety of quality assurance checks imperative for producing blinds that have excellent performance on the window and are aesthetically pleasing free from imperfections.” 

“Viewscape is focused on ensuring we provide our retail partners bullet proof reliability with the quality of product delivering the ultimate satisfaction to the end user.” 

Rundle adds that the hoist allows manufacturing operators to test the blinds operations in a simulated environment like a window. 

“This allows for any balancing required to optimise blind performance and longevity. A number of other checks are completed at the workstation relating to fabric performance including tolerance checks for cupping, V’ing and puckering. We also inspect all plastic and aluminium componentry to ensure it meets our quality specification and standard.”

Rundle adds that Viewscape recently commissioned drilling equipment for shutter manufacture that drills multiple hole types and sizes in the shutter stile, allowing for precise assembly and prefect repeatability of hole location. This ensures louvers open and close without spring back.

“The performance of a shutter is very much based on its accuracy of manufacture.”

Ziptrak: Custom-made Excellence

Marc de Maaijer, Managing Director, Ziptrak Pty Ltd says that the heart of the company’s manufacturing strategy lies in its investment in custom-made machinery, engineered to consistently produce our unique componentry to a high standard. 

“Two key examples of custom made machinery at Ziptrak are our spline manufacturing machine and our SuperSpring assembly machine,” de Maaijer says. 

“Operating with precision, these machines adhere to the exact specifications of our manufacturing process, resulting in a high quality, superior product, every time.”

“Our company has worked hard to align all manufacturing processes with ISO 9001 requirements, leading to enhanced product quality, increased customer satisfaction, and potentially greater operational efficiency.”

Other quality and cost savings come from the company’s commitment to sustainability, a commitment Ziptrak has made to every area of its operations for more than 24 years. 

“Our blinds stand as a testament to this dedication, with essential components crafted from aluminium, a material that supports environmental responsibility through its ability to be recycled multiple times.”

“Another area we strive for excellence in is waste reduction throughout our supply chain; optimising pack sizes and carefully selecting environmentally friendly, degradable, and recyclable materials.” 

“It’s important for us to work with companies that help us to achieve our goals for both sustainability and high quality.”

“Maximising space in shipping containers for interstate and overseas orders, reduces multiple deliveries and the associated carbon they produce from transportation.”

Quality at Ziptrak starts with the company’s collection of custom made machines that produce the products they design in-house and extends to the components used. 

“We use high quality purpose-made plastic parts that are strong, durable, and resistant to wear and tear,” de Maaijer says. 

“These plastics are carefully chosen for their strength, impact resistance, and UV stability, ensuring our blinds last for years, even with daily use and sun exposure.”

“Made from high quality material for flexibility and strength, our unique spline (not a zip!) securely holds the blind skin into the tracks. Our spline makes installation and adjustment effortless, improving both functionality, durability, wind performance, and appearance.”

“Naturally resistant to corrosion and wear, Ziptrak aluminium frames are designed to withstand the elements and daily wear and tear, ensuring long-lasting performance and longevity. What’s more, aluminium is 100% recyclable, underscoring our dedication to environmentally friendly practices.”

The quality process begins at the R&D stage for Ziptrak. 

“Manufacturing begins with design, a pivotal phase where we meticulously craft the blueprint of our products.”

“We use a range of technologies and materials to produce our parts, selecting the best option to meet our product and quality requirements.” 

“Prototyping and small production runs are made using our in-house plastic and metal 3D printers, before our production of components is transferred to technologies that can handle large quantities.”

“We’re always looking to integrate new and cutting-edge manufacturing technologies, such as metal injection moulding, robotics, and composite materials, into our production processes.”

Before each product leaves the Ziptrak factory, it undergoes a rigorous quality control process. 

“Our quality control protocols include raw material inspection, production process monitoring, testing and validation, inspections and audits, and taking action from customer feedback.” 

“We consistently review and refine our production quality control protocols to adapt to new technologies, materials, and feedback from our Ziptrak network. 

“The whole Ziptrak team is involved with supporting quality control practices. The Quality Control Manager directly reports to the Managing Director and presents findings in our weekly management meetings.”

Norman: Commitment to Kaizen

Peter Boyle from Norman, explains that the company employs a unique blend of manufacturing processes inspired by the Toyota Production System (TPS) to ensure the highest quality window furnishings.

“Our commitment to ‘Kaizen’ – or continuous improvement – ensures that every aspect of our manufacturing evolves to meet and exceed quality standards.”

“Additionally, through practices such as ‘Nemawashi’ we garner support from all stakeholders before implementing new techniques or processes.” 

““Hansei” is ingrained in our culture, fostering a proactive approach to recognising and rectifying mistakes swiftly, thereby maintaining the excellence of our products.”

Boyle says that innovation is a cornerstone of Norman’s manufacturing ethos. 

“Our commitment to excellence is evident in the integration of cutting-edge materials and technologies into our window furnishings.” 

“From the world’s best-selling shutter, Woodlore, to the advanced shutter motorisation of G4 PerfectTilt, and the revolutionary invisible louver tilt system of EasyTilt, we continually push the boundaries of innovation to offer our customers unparalleled quality and functionality.”

Boyle says customisation and personalisation are central to Norman’s manufacturing process. 

“Through our partnership approach with retailers and our adherence to TPS philosophies, we ensure that every customer’s unique requirements are met.” 

“Whether it’s through bespoke design options, innovative operating systems like SmartRelease and PrecisionLift, or a custom shaped shutter for that odd window, Norman empowers customers to create window furnishings that reflect their individual style and preferences.”

“Quality control is paramount at Norman, as evidenced by our industry leading RGA (Returned Goods Authorisation) rates.” 

“By adhering to long-term improvement mindsets and embracing the philosophy of ‘Genchi Genbutsu’ (go and see for yourself), we proactively identify and address any deviations from our high standards, ensuring that every Norman product delivers trouble-free performance and customer satisfaction.”

External testing drives BM Blinds

Michelle Macready, Sales Manager at bm Blinds, says that the growth of the vertical sheer market within Australia has cemented the company’s commitment to quality, service and excellence.

 “This commitment to quality has been perfected over the years with in-house testing that backs up any external testing done by our suppliers,” Macready says.

“There are some things that make BM Blinds vertical sheers stand out from other wholesale manufacturers such as the use of stainless-steel spacer links within our tracks.” 

“Having previously tested plastic spacer links and finding that they can often buckle and warp over time, we continue to use the stainless-steel links ensuring years of trouble-free use.”

Macready says BM Blinds’ dedicated production team views each order individually, ensuring that the spacing between the links appears even and avoiding messy bunching at one end. 

“They are also conscious of the stacking requirement of vertical sheers and use techniques to minimise and virtually eliminate any gaps.”

“Even our wands have been specifically engineered to ensure they are robust and easy to use. The fluted and symmetrical nature of our wands makes rotating your vertical sheers a breeze and the option of a solid wand stops bending on longer drops.”

“The way each hanger is fastened to the Vertical Sheer fabric has also been perfected over the years and we have been able to prevent the hangers from becoming dislodged during transport.” 

This may seem like a small issue to overcome however Macready says months of trialing various techniques has resulted in much quicker installation times for their retail customers.

“Our customers have also enjoyed speedy lead times as these manufacturing processes have been streamlined to enable maximum benefits for our customers with minimal delays.”

“It is a culmination of these small, yet vital improvements that have improved our quality and maintained consistency in the vertical sheer market and propelled BM Blinds as the leading vertical sheer wholesale supplier in NSW.”