Market visit for Sanitary Ware report and action plan

1. Market Visit Report
Visiting Area: South reason( Khulna, Jessore,
kustia, Magura, Chuadanga and faridpur)
Attended: 1. Mr. Shaharier
2. Mr. Matlubor Rahaman
3. Mr.. Aziz
4. Mr. Sujon

2. Market Complain (A grade products-2014)
Sl
No:
Defects No of complain
(Pcs)
1 Broken
2 Waist Curve 8
3 Water Leakage &Rim
Punch problem of WC
2
4 Warpage of Asian Pan 1 (General)
5 Tap Hole & Wall
Setting Punch
1
6 Epoxy Problem 4
7 Grading problem 3

3. Market Complain (A grade products-2015)
Sl
No:
Defects Nos(Pcs)
1 Waist Curve 1
2 No Seat & Cover Hole
WC
1 No Seat & Cover Hole of marcela WC
3 Warpase of Asian Pan
& WC
4(General) Lotus pan & Orchid pan, Verso WC
4 Tap Hole & Wall
Setting Punch
1 Crown basin
5 Epoxy Problem 3
6 Grading problem 3 Octavia basin (BCR & bad shape), Cooling crack
through BCR (Repaired by Body Epoxy)

4. Market Complain (B grade products-2014)
Sl
No:
Defects Nos (Pcs)
1 Waist Curve 1
2 BCR (Poor Grading) 4
3 Inlet Punch crack not
repaired
1(General)
4 Soft Body Epoxy
application
4 Resin & Hardener Not mixing Properly
5 Epoxy Problem 19
6 Grading problem 12 Wavy Glaze flow of WC rim, Too match spk (4),
crawling , Pin hole in Sump area.
7 Scratch on glaze
surface
4 Poor Handling

5. Market Complain (B grade products-2015)
Sl
No:
Defects Nos (Pcs)
1 Oval Waist Curve 1
2 BCR (Poor Grading) 1
3 Inlet Punch crack not
repaired
(General)
4 Soft Body Epoxy
application
Resin & Hardener Not mixing Properly
5 Epoxy Problem 2
6 Grading problem 2 Wavy Glaze flow of WT Lid, Glaze Removal ,
7 Scratch on glaze
surface
1 Poor Handling
8 Hair Crack & broken Balance

6. Sorting errors
Possible causes:
• Due to space constrain WIP products control
difficulty
• Shortage of experienced sorters
Action plan:
• We have started second check of every piece at
the sorting table and WIP products are graded
after completion of repairs.
• One of the best practice of other companies is
all pieces centralized sorting is being done in
“A” shift every day. Benefits are
 Low manpower,
 Good supervision,
 WIP products control
 Production departments effective follow up
on defects,
 Effective delivery planning,
 Minimize accounting errors
Requirements
• 600 sqm PLACE
• Experienced sorters

7. Asian pan rim bending
Possible causes:
• Soft condition of product due to variation in mold
dryness, slip drying.
• Misbalancing while releasing due to small flat seat
at bottom
Action plan:
• Casting production should level rim part
after releasing.
• QC will audit the process
• Random Level check will be started at
sorting
Requirements
• Checkers

8. Waste hole deformation
Possible causes:
• Soft condition of piece
• Misbalancing while releasing
Action plan:
• Casting production should level the
bevel area with the template.
• QC will audit the process
• Finishing people should check with
gage every piece
• Green ware inspection people should
check with gage random
• Sorting will check fitting every piece
Requirements
• Gages

9. Marcela seat hole block & hole area
raised surface
Possible causes:
• Due to plug system there is inconsistency in surface
level, plug depths and some hallow cast inside plug
area
Action plan:
• From the top as the hole is open it assumes
that hole is thru. All the pieces gage check
will be implemented at casting and sorting
• Customer comparing Marcela with Versu at
the seat fitting area, the level at seat hole of
Versu is plain than Marcela. This was due to
Versu is solid cast and Marcela is hallow
cast. This can be modified.
Requirements
• Approval for Case modification

10. “B” Grade repairing errors
Possible causes:
• Non availability of shed for repair processing
• Working under poor lighting in nights and raining
situations
Action plan:
• Irrespective of the orders daily “B” grade products
processing will be done under shed
• Receiving from order to until packing will be done by
QC team.
Requirements:
• 20 x 15 x 3 Mtr shed
• Tarpaulin for covering repaired products
• Formalities and man power arrangement for processing
and packing

11. General Complaint
1. U Shape of verso WC sump not
maintain.
2. WT and Lid not matching (Lid
is bigger in size)
3. WC rocking on floor. (Specially
Verso)
4. Flush mechanism inlet valve
frequent problem also
maintenance difficult
5. Crown basin not fit on the
pedestal
6. Water leakage of Basin
7. Waist problem (Gap remain
between waist and basin)
8. Pan not properly fit with the
Tiles (specially Lotus pan)
Corrective action
1. Casting finishing improvement
should be done.
2. Required approval on design
modification
3. Required foot grinding machine
4. Easy maintenance inlet valve
sourced. Required approval to
introduce
5. Design corrected. Case is under
progress
6. Immediate action shifting the back
holes to upper side. Silvana, Crown
models corrected cases are under
progress
7. In casting process deformation
correction with gage, Inspection and
sorting checking with gage
8. In casting process leveling after
release and in sorting level check
with template

12. General Complaint
1. Silvana Pedestal back
side cutting not
accepted
2. Elana Basin Oval
Shape not maintained
3. White glaze require
more whiteness
4. Micro pinholes
Corrective action
1. Required approval for
modification. Weight will increase
by 4 to 5kg
2. Loading setter will minimize the
problem. Effect of Load factor to
be studied
3. Immediate change of whiteness
will create mis match with existing
stock. Need approval, planning and
communication with dealers
4. Variation of volatile matters from
raw materials, Glaze thickness,
Design curves, Kiln loading
position, Heat circulation between
the products, Oxyzen availability
all the time of volatile matters
burning will leads to Micro
pinholes. A continue study and
process improvements will be
carried out.

13. Verso WC problem
U shape of Sump not maintained

14. Verso WC problem
Rocking on floor

15. Foot grinding machine

16. Back Side Cutting not accepted