Fainger Engineering is a Dombivli-based engineering and valve manufacturing company established in 1975, known for its expertise in pressure and flow control solutions for industrial applications. The firm designs, engineers and supplies a broad range of products including safety relief valves, thermal relief valves, flame arresters, breather & tank blanketing valves, excess flow check valves and other flow control instruments used across oil & gas, petrochemical, chemical, pharmaceutical, power and process industries, backed by quality testing, customization and support services.
Before State:
Valves were assembled using a batch production system, with 12 fitters producing 1,200–1,300 valves per month. Frequent missing parts led to regular WIP accumulation and production delays.
After State:
Detailed study showed that with a 100% complete BOM, one valve can be assembled in under 15 minutes. After ensuring full-kit availability before release to assembly, a single fitter now produces 30 valves per day (≈750 per month). With 4 dedicated assembly tables and 4 fitters, monthly output increased to 3,000 valves in a single shift, compared to the earlier 1,200–1,300 valves with 12 fitters.
This reflects an approximate 140% increase in total productivity (from ~1,250 to 3,000 valves/month), while manpower reduced by 67% (12 to 4 fitters). Additional benefits include elimination of chronic WIP, predictable daily output, shorter lead time, improved floor discipline, and significantly better space utilization.
