COLT-CALORIS PRODUCTION LINE
The increase in sales of Colt-Caloris has necessitated a major change to the production line and logistical processes, implemented by the Caloris line team at the Havant factory. This in turn has increased the capacity of Colt to handle bigger orders with shorter lead times.
The Colt-Caloris product is one of the most technically developed products that Colt manufactures. We are determined to strive towards "Zero Defects". This requires us to continually increase the number and effectiveness of these in-line tests. Two of those merit special attention.
Firstly, Colt has purchased a fully automatic "Galileo" refrigerant charging station. It performs automatic tests, i.e. double checks the system quality and vacuum, and can handle two different gases at the same time. Charging is achieved with an accuracy of 0.2 grams. The station uses three bar code sources to start its process providing full cross referencing of compressor serial number, refrigerant and quantity, thereby reducing the likelihood for human error as well as providing full historic information. Furthermore this information is electronically recorded providing a complete record of refrigerant consumption, as will be required by the forthcoming "F" Gas regulations (even though none of the Colt-Caloris range will be affected by these regulations).
Secondly, Colt has constructed a Test Chamber within the existing factory where the additional end of line test is conducted under climate controlled conditions. Every unit built needs to pass the rigorous requirements of this test chamber before it is dispatched. In addition to the in-line checks, units which have readings outside those set down by the QA process (even if only fractionally) are held back. Each unit undergoes a total of over 60 minutes of various checks before dispatch.
Two test stations inside the chamber are built in parallel to ensure continuous production. They incorporate the latest Caloris Test Program, with power metering and two sets of water flow manifolds, set up at exactly the right water flow according to the unit under test. The end of line test checks both the thermal and electrical performance of the unit between tight pre-set limits.
"This facility ensures that the situation no longer arises where units do not pass purely because the external environment is either too hot or cold", said Phil Harrington, who conducts the end of line tests. "In addition, we have been able to lower the tolerances in the software so that a tighter test may be performed on each unit, which allows us more easily to identify units that need to be investigated further."
"We now have greater and more reliable data on which to judge units," said Mark Puttock, Production Manager. "This will assist considerably should we ever need to examine units in the future as we strive ever nearer towards Zero Defects, and this feedback loop has in turn already led to product improvement."
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