Our roof window components are selectively imported to source the best quality parts from the most cost effective and resourceful markets.

Keylite's production factory is cited in Zambrów, Poland. This location delivers the following benefits to maximise the efficiency of our manufacturing process:

• Skilled manufacturing labour
• Readily available raw materials
• Slow grown, high quality timber
• High volume, high quality glass producer

Currently 2,500,000 metres of timber are processed annually to manufacture our Keylite roof windows.
 

Laid end to end, this would stretch from Zambrów to Cookstown!
 

Approximately 75,600m² of glass is also utilised annually. This amounts to the stretch of 7 football pitches. Due to Poland's high volume of these readily available high quality materials, Zambrów is the ideal location for our factory.

The first stage of our timber production process removes the rough surfaces along the exposed edges of the raw timber by passing the lengths through a planer moulder.

The lengths of timber are then marked either side of a knot or blemish where an Opti-Cut machine will create the specific elements of a window. Guaranteeing optimal use of the timber every time.

The timber is then graded on a scale of 1-3, with 1 being the highest quality. Grade 1 timber will be utilised for all visible surfaces. 

Lengths of timber are laminated together to form larger and stronger blocks for structure. The visible grains along the timber lengths are placed in alternating alignments to add tensile strength to the newly formed glulam.

The newly laminated timber is planed for a second time along all four sides once again to smooth down all exposed edges.

Once the glulam has been planed, the timber is put through a double-end tenoner to shape the profile of the roof window sections and insert milling holes.

Vacuum impregnation protects the timber against insects and any fungal decay, guaranteeing our materials a long service of life. 

The process is identical up until the internal finish coating for all timber windows. A clear lacquer is applied to our Natural Pine Windows while our White Finish roof windows are coated with a primer and finished with a white polyurethane based paint. 

The timber frame and sash profiles are first assembled to create the structure for the roof window. Once the frame has been thoroughly checked for square-ness, the additional components such as the glazing, metal and plastic mechanisms and thermal collar are then installed to construct a complete roof window.

From final assembly, we inspect 100% of all roof windows. A dedicated QC inspector is stationed at the end of each assembly line and carries out a multi-point check on all critical functional & aesthetic aspects. An ID serial code is then assigned to each window for traceability before the window is thoroughly cleaned and securely packaged. 

Keylite’s PVC extrusions are produced externally to suit the profile of our roof window designs. These extrusions are delivered into our Poland factory in 6 metre lengths.

Once the extrusions have arrived in our factory, the respective components are cut and created in preparation for the assembly stage.

Before the roof window can be assembled, all PVC components must be milled. This process introduces all the necessary pre-drilled holes ready for the construction of the roof window. A QC inspector is present in carrying out random in process checks on all PVC operations. The QC team look for trends and ensure corrective and proactive actions are implemented to drive a ‘right first time’ culture.

Steel supports will then be fixed onto the components once all parts have been successfully cut and milled accordingly.

The construction of our PVC components will repeat the assembly procedure of a timber roof window. The window sash and frame will be assembled prior to the installation of all additional components such as the glazing and any metal and plastic mechanisms.

From final assembly of our PVC range, the final quality inspection procedure remains the same as aforementioned. 100% of all roof windows are checked by a dedicated QC inspector. Multi-point checks are carried out along the assembly line before the window is given a unique serial code and packaged ready to be shipped to market.

Quality Control checks are not only carried on our roof windows.
 

Samples of our inbound goods, raw materials and plastic and metal components are inspected using an ‘8 Disciplines’ report to understand the root cause of any complexities to ensure adequate CAPA (Corrective and Preventative Action) is put in place.

 

8D reports are used to communicate any issues with components to our suppliers. Samples of our flashing kits and loft ladders are also regularly quality checked utilising the same reporting methods.

In addition to the in-process and final quality check procedures, we carry out random ‘open-box’ audits on samples of goods from our distribution centres. We also carry out the following routine quality testing on our components:

 

1. Accelerated UV Testing
2. Accelerated Salt Water, Weather Testing
3. Cycle Testing of Window Opening/Closing for 20 Years use
4. Cycle Testing of Blind Function
5. Impact Testing of External Forces

 

These checks are all part of our exhaustive quality assurance process which aims to deliver the highest levels of quality every time.

Keylite’s Microsoft Navision software manages our stock levels and automates the replenishment of fast moving goods.

 

Supply chain planning ranges from strategic, long term as well as short term actions in order to achieve our 98.5% OTIF target.

 

This closely measures of the volume of orders which are delivered On Time and In Full.

We employ a range of supply chain tactics to ensure complete visibility in our quest for 100% OTIF:

 

Long Term

- Forecasting & Capacity planning

 

Medium Term

- Stock Purchase Orders & Ranging Reviews

 

Short Term

- Made to Order Goods based on Special Purchase Orders

Since Keylite's establishment, sales have increased year on year. As a result, we have experienced positive correlation alongside our production capacity.

The demand within market drives not only our levels of production but also the divide between our roof window range.

 

Currently, White Finish windows have the greatest output followed by PVC and Pine Finish windows.

 

* Based on 2019 figures