There are many types of water heaters: solar, electric, on-demand, storage-tank, gas, conventional, andtankless water heaters. You can even find coal and wood-fired water heaters. The global water heatermarket size will grow from $37.29 billion in 2023 to $40.94 billion in 2024.* We’ll look at applications of Lean and Six Sigma in water heater production and finish with a video of how water heaters are made.
Six Sigma for Defect Reduction in Solar Panel Water Heater Manufacturing
In a report titled “Analysis Of Defect Reduction Of Solar Panel Water Heater Production Process by Using Six Sigma Approach at Pt. Wijaya Karya Industri Energi” author Widya Yudha Putri discusses the use of DMAIC methodology to improve the quality of solar water heaters.
The report includes:
- Problem Statement and Scope
- Defect Data for all Products
- Pareto Chart of Defect Quantity Per Product
- General Process of Absorber Production
- Defect Data for Absorber Process
- SIPOC
- Fishbone Diagram for Aluminum Fin and Riser Pipe Defects
- FMEA for Aluminum Fin and Riser Pipe
- Improvement Recommendations
- Comparison Before and After Improvement
You can read the report here.
Transformation to Lean Production in Water Heater Manufacture
In a paper titled “Transformation to Lean Production system of a Water Heater company in Oman”
authors Mohammad Khadem and others discuss the use of Value Stream Mapping as the main tool used to identify the opportunities for applying various Lean techniques.
The paper includes:
- Water Heater Manufacturing Process Flow
- Current State Layout
- Improvement Scenarios
- Transfer Time Reduction
- Bottlenecks Process Reduction
- Increase Worker Utilization
You can access the paper here.
Applying Lean Methods to an Electric Water Heater Production Line
In a paper “Lean Production Applications in a Manufacturing Company” authors Ali Görener, Hümeyra Başer, and Ali Türkyılmaz discuss the application of Lean methods in an electric water heater manufacturing line.
The paper includes:
- Problem Definition
- Water Heater Production Times
- Improvement Objectives
- Production Cycle Times
o Before Kaizen
o After First Kaizen - Financial Improvements
Use the following shortened URL to download a copy of the paper.
Making Residential Water Heaters
See how water heaters are made in this video from How It’s Made.
You can watch the video here
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