Overview
Milgard Windows, a leading manufacturer of windows and doors, faced major inefficiencies in sorting, staging, and loading their products for delivery. Their process involved multiple handling steps, heavy metal carts, and significant labor-intensive work. The implementation of Deltarack, an innovative wood racking system, revolutionized their operations—reducing product damage by 90%, optimizing warehouse space, and improving overall efficiency.
We spoke with Warren Lee, Director of Operations at Milgard’s Temecula, CA facility, to understand how Deltarack has transformed their logistics.
The Challenge
Before adopting Deltarack, Milgard’s window handling process was cumbersome and inefficient:
- Manual Labor-Intensive Handling – Windows were loaded and unloaded multiple times before reaching the truck.
- Heavy & Inefficient Metal Carts – Traditional 8’x4’ metal carts were difficult to maneuvre and inefficient for loading.
- High Product Damage & Labor Turnover – Frequent handling led to significant damage, high remake rates, and warehouse staff turnover.
- Limited Truck Capacity – Traditional methods restricted the number of windows per truck, increasing transportation time.
According to Warren Lee, these inefficiencies were a growing concern:
“Before Deltarack, our warehouse and delivery process required too many touches. We had significant handling damage and high labor turnover. We needed a solution that could simplify our operations while maintaining product quality.”
Milgard needed a cost-effective, durable, and scalable solution to streamline their workflow, minimize damage, and improve delivery efficiency.
The Solution: Why Milgard Chose Deltarack
Milgard discovered Deltarack while researching alternative racking solutions for their vinyl windows. Traditional metal racks were not a viable option due to cost and compatibility concerns.
Warren Lee and his team were introduced to Deltarack during a visit to a supplier’s facility. After an initial conversation with Dave Thoman from Deltarack USA, they quickly began testing the product in their plant.
Key Reasons for Choosing Deltarack:
- Durable & Cost-Effective – Deltarack provided a sustainable and affordable alternative to metal racks.
- Improved Handling – The design allowed for easier maneuverability and palletization of windows at the production line.
- Direct-to-Truck Efficiency – Enabled true “direct-to-truck” loading, eliminating multiple handling steps.
- Customizable & Scalable – Easily adapted for different product lines and scalable for expansion across multiple locations.
The Results: Dramatic Efficiency & Cost Savings
The impact of implementing Deltarack was immediate and transformational:
90% Reduction in Product Damage
- Product damage on trucks decreased significantly, minimizing remake rates and improving customer satisfaction.
- Milgard is exploring ways to use Deltarack for glass storage to further reduce damage rates.
Warren Lee emphasized the impact on damage reduction:
“Since implementing Deltarack, we’ve reduced product damage on trucks by 90%. That’s a major win for our operations and our customers.”
Increased Truck Capacity & Warehouse Optimization
- 15% more warehouse space freed up due to streamlined storage.
- Truck capacity increased from 120 to 200 windows per truck, significantly reducing transportation time.
Enhanced Workflow & Employee Satisfaction
- Reduced manual handling improved workplace safety and reduced warehouse turnover.
- Drivers and warehouse staff reported a better work experience with the simplified loading process.
According to Warren Lee, the new system has created a “win-win-win” for employees, drivers, and customers:
“With Deltarack, we’re eliminating six or seven handling steps per window. That’s huge in terms of labor efficiency, product integrity, and overall workflow. Our drivers love it, our warehouse team loves it, and most importantly, our customers see the difference.”
A Game-Changer for Manufacturing Logistics
According to Milgard, Deltarack has completely changed their approach to window handling and delivery:
“We’ve been using over 100 racks daily for months, with almost no deterioration. Deltarack is an extremely durable and sustainable system. It’s a true game-changer for our business.”
Looking ahead, Milgard plans to expand Deltarack’s use across multiple plants, further optimizing logistics and maximizing efficiency.
Conclusion: Why Manufacturers Should Consider Deltarack
For manufacturers looking to cut costs, reduce product damage, and streamline logistics, Deltarack offers a proven solution.
- Affordable & Scalable – A fraction of the cost of metal racks with long-term durability.
- Massive Damage Reduction – 90% reduction in handling damage, minimizing remakes.
- Direct-to-Truck Efficiency – Eliminates unnecessary warehouse handling steps.
- Increased Truck & Warehouse Capacity – Optimizes space, increasing shipment loads per trip.
“Deltarack has been a game-changer for us. Deltarack USA provide top-tier customer service, adapting the product to our needs and helping us improve every step of the way. We look forward to continuing this partnership and expanding its use across our operations.”
Warren Lee, Director of Operations, Milgard Windows, Temecula, CA
