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GE Appliances transforms a former refrigerator factory into a cutting-edge facility for water heater production

Water heaters are often overlooked until they stop working, leaving homeowners with cold showers. Recognizing the demand for these essential appliances, GE Appliances, a Haier company, recently invested $70 million in a state-of-the-art manufacturing plant in Camden, SC. The facility, which also serves as the company’s Center of Excellence for water heater manufacturing, underwent a massive renovation and retooling effort to increase production capacity. This article explores the transformation of the plant and the advanced technologies and processes implemented to create a world-class operation for manufacturing water heaters.

A Clear Perspective on Quality and Efficiency

GE Appliances has a clear perspective on the importance of producing top-quality, high-performing products. The company believes that designing factories that allow for safe and efficient manufacturing is key to achieving this goal. The Camden plant was designed with a focus on flexibility, allowing for efficient production and the ability to meet customer demands. The plant is equipped with advanced automation systems, including robots for material handling and processing, to ensure predictable, consistent quality in a safe and ergonomic environment.

Vertical Integration and Flexibility

Vertical integration is a key aspect of GE Appliances’ manufacturing strategy. The company starts with raw coils of steel and stamps out the major components of the tanks, giving them the flexibility to change production throughout the day if necessary. The Camden plant is vertically integrated, allowing GE Appliances to manage supply chain variation, control costs, and deliver high-quality products consistently. The facility can produce multiple tank sizes and both natural gas and liquid propane water heater repair near me on the same assembly line, thanks to its flexible, mixed-model process.

A Focus on Reliability and Quality

Water heaters are expected to perform reliably for a decade or longer, making reliability a crucial factor in meeting customer expectations. GE Appliances carefully considered quality, safety, and ease of manufacturing when designing and laying out the plant. The production process was centered around operators, with special attention given to ergonomics and ease of access to parts. The plant features a comprehensive quality process, including leak testing and end-of-line inspections, to ensure that every tank meets the highest standards.

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From Roll Forming to Assembly

The manufacturing process at the Camden plant begins with roll forming, where the tank bodies are created from raw coils of steel. Ports and the top of the tank are automatically welded, and the subassemblies are transferred to an overhead monorail conveyor. The flue and bottom head assemblies are joined on a separate welding line, and the tanks then go through a spray enamel process. After curing in a furnace, the tanks undergo leak testing and move to the main assembly area. The tanks are press-fit with the combustion chamber, fiberglass insulation is inserted, and the tanks are then uprighted onto a base pad. The assembly line is designed for ergonomic efficiency, with operators positioned at the correct height to interact with the tanks.

The Role of Automation

The size, weight, and configuration of water heater tanks necessitate the use of automation for operator safety and ergonomics. The Camden plant is equipped with over 35 robots, primarily used for material handling and welding applications. Automation is crucial in ensuring the safe and efficient production of water heaters. However, GE Appliances recognizes that people are the key to their success. The company has invested in training programs for employees, empowering them with digital skills, lean manufacturing principles, and production expertise.

Conclusion:

The transformation of the former refrigerator factory in Camden, SC, into a state-of-the-art water heater manufacturing plant is a testament to GE Appliances’ commitment to quality and efficiency. The $70 million investment and implementation of advanced technologies and processes have created a world-class operation capable of meeting customer demands and producing top-quality water heaters. The vertical integration, flexibility, and focus on reliability and quality highlight GE Appliances’ dedication to providing high-performing appliances for homeowners across the country.

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