Customer
A leading US manufacturer of gas and electric hot water heaters.
Application
Production leak and pressure testing of water heaters.
Challenge
The manufacturer was experiencing multiple challenges in their manufacturing process. The first challenge was twisting on the male “plug” or “tip” into the tank and achieving a reliable seal every time. The second was the safety risk and potential for worker injury posed by the physical effort required to make the coupler connection at the testing station. A third challenge to overcome was unacceptable takt-time due in large part to the significant time required to make and break the test connections.
Project Goals
- Reduce/eliminate ergonomic issues and safety concerns.
- Increase the speed of the takt-time at the testing stations
- Improve sealing reliability at the tank connection points.
Solution
FasTest supplied their TwistMateTM quick disconnect plugs to provide effortless, reliable, and leak-free sealing of the tank. For the pressurized charge line, FasTest developed a custom-sized RQD connectors that eliminated the ergonomic and safety issues. A green indicator ring on the RQD provided an additional safety feature that helped ensure a proper connection is made every time.
Results
The customer realized a significant improvement in safety and reduction in ergonomic issues in their leak and pressure testing process that was much appreciated by the operators. In addition, the tank connection time was reduced by over 75% and connection leaks were virtually eliminated.
