Cutting Defects, Not Corners: Waudena's Quality Revolution

A Three-Year Turnaround

In 2022, internal unit defects were a persistent challenge, with rates as high as 13% in some months. But by 2023, that number dropped to 3.9%. In 2024, it fell again to 1.2%. And now, in 2025, Waudena is holding steady at 0.9% year-to-date, with August closing at just 0.5%, the second time this year the team has hit or surpassed that mark.

Compared to August 2024’s 1.4%, this represents a 64% improvement, the largest monthly drop of the year. January came in second with a 60% decrease.

The People Behind the Progress

This success is no accident. Waudena’s strategy centers on “quality at the source,” a philosophy championed by Danny Dillon, Quality Control Lead. “We had to shift the culture,” Dillon explains. “It’s not just about speed; it’s about doing it right the first time.”

That mindset is now embedded across every stage of production, with dedicated team members leading the charge.

First, comes wood prep. “We set the tone. If we catch issues here, they don’t become problems later,” said Dan Hurlbert.

Then comes door picking. “It’s about making sure the unit is built exactly as the customer expects,” said Luke Krause.

Next? Glass prep. Richard Jacome says a small misalignment can affect the whole unit. “We double-check everything before it moves on.”

Then comes jamb assembly. “If the jambs aren’t square, nothing else fits,” said Keith Klein.

We’re getting close to the end of the line (literally). Next up is another check and packaging. Dave Staubs says “we want to make sure it’s protected, clean, and exactly what they ordered.”

And everything gets a final quality check by Craig Schroeder. “If something’s not right, it doesn’t leave the building,” he said.

Each area uses a standardized checklist developed with input from the team, ensuring that whether someone’s been on the job for 20 years or 20 days, they’re inspecting with the same level of precision.

Smart Tools, Smarter Processes

Technology has played a key role in Waudena’s quality evolution. Automated systems like the MTC machine in wood prep allow for precise jamb preparation with minimal manual input. Visualizers show team members exactly what a finished unit should look like, eliminating confusion and reducing errors.

“We’re even adding features like active/inactive bore hole indicators,” says Dillon. “It’s faster to see it than read it, and that saves time and prevents mistakes.”

These tools not only reduce defects, they also improve efficiency and reduce warranty costs.

Fixing the Right Problems

In 2024, the top service and warranty issues were stain variation (15%), jambs out of square (13%), and crooked glass frames (12%). In response, Waudena introduced jigs, stain samples, and more rigorous inspections. The result has been a noticeable drop in those issues in 2025.

A Culture That Owns Quality

What makes Waudena’s approach stand out isn’t just the tools or the processes, it’s the people. From wood prep to final inspection, every team member understands their role in delivering a flawless product. They’re not just checking boxes; they’re taking pride in their work.

As Dillon puts it, “If a defect makes it through prep, paint, and install before we catch it, we’ve already lost time and money. Doing it right the first time is always worth it.”

With a defect rate now sitting at 0.9%, down from 1.3% this time last year, Waudena has achieved a 31% year-over-year improvement. It’s a testament to what’s possible when innovation, ownership, and pride in craftsmanship come together.