As the demand for sustainable, energy-efficient building solutions rises, the smart glass manufacturing industry is faced with increasing challenges of scaling production and maintaining consistent quality, requiring new thinking on manufacturing and process optimization. Viralsinh Solanki, a leading figure in this domain, stands out for transforming these challenges into opportunities.
An IT guru with a strong background in both manufacturing and information technology, Solanki’s experience ranges from Deloitte to FedEx Express and View Inc., where he played a major role in developing and implementing advanced manufacturing execution systems (MES). He specializes in improving productivity and guaranteeing quality control and sustainability through innovative IT solutions tailored to the unique needs of electrochromic (EC) glass manufacturing.
Solanki’s work focuses on combining advanced technologies with traditional methods of production, ensuring transparency of real-time data, and efficient allocation of resources. His impact on the smart glass industry has been remarkable, contributing to both technological advancement and environmental stewardship.
Inspiration and Vision
Solanki’s inspiration to work in manufacturing stems from his desire to engage with tangible products and processes. Unlike the typical roles of software developers, his choice to venture into software development was based on his desire to see what he could make physically before it was shipped into the market. Besides his love for greener technology, which made him join View Inc., Solanki joined the glass-manufacturing company not only because its objective was aligned towards the development of environmentally friendly smart windows that would reduce energy consumption and greenhouse gas emissions but also because these windows blocked over 90% of solar radiation, thereby significantly enhancing building energy efficiency.
“Software developers play a vital role across all industries, but I have always had an inclination towards working in a manufacturing facility because you can see the products, touch them, and feel them through your hard work at the plant before they are shipped out,” Solanki recalls. “Besides that, I have always been an advocate of green technology and using technologies that are good for people and the planet.”
Addressing Industry Challenges
Until Solanki introduced his innovations, the smart glass industry had significant challenges, primarily with regard to scaling production and maintaining consistency in quality. For example, when shifting from R&D to large-scale manufacturing of electrochromic (EC) glass, there were difficulties in achieving the needed precision. There is inadequacy in conventional manufacturing systems to handle EC technology-specific needs, leading to low efficiencies and high defect rates.
A significant challenge was the integration of advanced information systems into the complex processes required for EC glass production. The lack of any customized solution made manufacturers struggle with problems such as data management, real-time monitoring, and process optimization. This resulted in persistent concerns about meeting both quality standards and high throughput levels.
Conceptualizing MES for Electrochromic Manufacturing
Solanki’s biggest contribution at View Inc. was conceptualizing a manufacturing execution system (MES) that met the unique demands of producing electrochromic (EC) glass. Traditional MES solutions had to address particular issues associated with EC technology, which is characterized by flexibility and precision. In addition, Solanki’s vision for an MES that seamlessly works within the EC manufacturing process played a role in transitioning View from a research facility to a fully automated manufacturer.
“In manufacturing, it’s all about speed, quality, and throughput,” Solanki says. “These three combinations have put my work at different levels and have made me think of automation, data integrity, increasing processing time, yield improvement, and labor and material costs. View was moving from R&D to a fully automated company, but these ingredients are essential to scale up any manufacturing company.”
Real-Time Production Management
Real-time production management is a major role of MES developed by Solanki. The system ensures that accurate monitoring and documentation of transformation from raw materials to finished products are carried out by capturing data from machines, sensors, and operators. This gives stakeholders the opportunity to identify constraints, minimize downtimes, make timely decisions, and therefore lead to optimal production planning and scheduling.
“The primary purpose of an MES is to track and document the transformation of raw materials into finished products in real-time,” Solanki explains. “It captures data from different sources, such as machines, sensors, and operators, thereby providing up-to-date information about the status of production activities.”
Improving Quality Control and Compliance
Enforcement of quality control procedures and adherence to strict standards are among the most critical tasks that an MES performs. The system monitors key metrics, takes real-time data, and facilitates traceability, thus producing high-quality output. These structures have become paramount in smart window manufacturing, where accuracy matters most.
“An MES provides real-time visibility on production processes to monitor operations for stakeholders in order to identify bottlenecks, minimize downtimes, and make informed decisions promptly,” Solanki points out. “By facilitating optimized production planning and scheduling, MES systems ensure efficient resource allocation, workload balancing, and on-time deliveries, therefore leading to higher profits.”
Overcoming Transition Challenges
View’s journey towards implementing MES was wrought with numerous challenges. Introducing it into legacy systems required detailed preplanning exercises coupled with extensive customization efforts. This seamless integration is largely credited to Solanki, who ensured all these systems exchanged data smoothly with their synchronized functionalities. The role he played in managing 24/7 IT support while training supervisors during the transition phase helped them overcome initial operational hurdles.
“The integration aspect became extremely complicated given that we had begun running orders through legacy systems that were already work-in-progress, hence preventing transferring them into MES because of the various manufacturing histories involved,” Solanki notes. “It was not easy for any of the departments, including but not limited to operations and IT. I played a key role in modeling, configuring, and leading the implementation as well as training supervisors, managers, and area leads on how to use MES.”
Expertise and Impact
What differentiates Solanki from others is the fact that he possesses knowledge in both information technology and manufacturing. This expertise enables him to create software solutions that are directly relevant to the practical needs of manufacturing operations. As part of his work at View Inc., he collaborates closely with process engineers, quality assurance teams, and production supervisors so that IT solutions are more than theoretical concepts—they can be used on the shop floor.
“As an individual in my role, there are many software engineers who share the same opinion about IT,” Solanki believes. “Unlike most people, after working with View, I have a completely unique background because I am not only an IT developer but also a problem solver in the manufacturing industry. You can touch and feel your products every single day, and see your hard work right before you.”
The Future with Smart Glass
Solanki’s work for View Inc. is not confined to increasing manufacturing efficiency; it also involves building a sustainable future. MES-facilitated smart windows made by View are making significant contributions towards reducing energy consumption and greenhouse gas emissions. These windows automatically adjust themselves depending on how intense the sunlight is; consequently, they increase the user’s comfort and productivity by maximizing natural light while minimizing heat and glare.
“By blocking out 90% of solar radiation entering buildings, these smart windows cut down on energy consumption and greenhouse gas emissions,” Solanki states. “For every View installation, there is a smart building platform that includes power, network, and communication infrastructure that can be upgraded over-the-air to deliver new capabilities and performance improvements throughout the life of the building.”
Viralsinh Solanki’s innovations in the field of manufacturing, and more specifically in the smart glass industry, demonstrate that the integration of IT with manufacturing brings many positive changes. He has revolutionized the concept of MES at View Inc., taking it to enviable heights in terms of efficiency and productivity. In addition, such an approach has significantly advanced the cause of sustainable technology. At the moment, one can only marvel at the strides he has made. His story is a beautiful example of how the world can be changed by a few hardworking men and women in their fields and the global concern for the environment in particular.
