UK kettles use three types of heating element.
Elements may fail if damaged in use or by excessive scale build up. Scale can also cause the kettle to become increasingly noisy.
The specification below provides the recommended improvements needed to improve product durability. They are ranked from bronze to gold based on the effectiveness of the change in improving durability, with bronze being the minimum and gold being the maximum.
Concealed elements; institute quality control procedures; provide instructions for scale removal
X-ray inspection of heating elements; low noise textured surfaces
Improved reliability of components can reduce early returns and improve brand reputation which, in turn, can lower business costs and increase long-term sales.
To calculate overall cost savings for your business, use the WRAP cost/benefit analysis tool (currently in draft form and available on request).
Weld control contacts to bus-bar
Use bus-bar connections instead of cords. These use less parts (e.g. no crimps) and are quicker to attach.
New design testing
Testing will identify fatal flaws. Independent kettle design assessment and durability testing can be obtained free of charge from some manufacturers of kettle controls if sales volume are sufficiently high.
Good quality control and change control should be standard procedures.
X-ray inspection can be sub-contracted if not available at factory. 100 elements can be inspected in one day so the cost per kettle if, e.g. 0.1% of elements are checked to ensure batch quality and consistency will (we estimate) be ca. $0.01 per kettle.