Fixture development for door manufacturing in water heater and Lean production in small scale industries

Abstract

To gain more business and profit each industry needs to work hard for their best practices. Customers want finest quality products, instantaneous supply at reduced cost.  To get any plan to improve product, industries must concentrate on what the customer wants. Lean practices help to reduce waste in each area leading good quality product, reduction in lead time with an optimum utilization of resources. In small scale water heater manufacturing unit, it is very difficult to optimize resource utilization and reduce lead time. Traditionally door manufacturing for water heater requires two operators as well as tedious sequence of operations and holding leading to discontinuity in alignments. It creates bottleneck situation in production flow resulting in longer lead time and customer complaints. To securely locate and support the work, ensuring that all components by means of fixture will continue conformity and interchangeability. It improves smooth operation and quick transition of part to part and economy of production through less skilled operator and growing conformity across a production track. Economically the most valuable function of the fixture is to reduce labor cost. Holding the work piece one operator can be eliminated. Frequently reduces the complexity of the process allowing for unskilled workers to perform it. In the steps of manufacturing of water heater includes assembly of doors of combustion chamber of wood fired water heater which can be simplified by the use of fixture. With the help of proposed work Fixture development have enable small scale industry to reduce eliminate on operator for one process and reduced lead time which helped to improved productivity and optimum utilization of resources.