Italian technecian Recomandations on our issues.
Body Department.
ISSUE
1.Under fire & Over fire
2.Micro pin holes & improve Glaze texture.
3.For improve casting rate
Casting Department.
ISSUE
Purging air pipe position
Pin holes & Blibs
shortage of slip during casting
Big air bubble on top part(Marcela wc)
All water closets bowl cracks,
All water closets foot cracks
Water closets front side rim bad finish
All Asian Pans catching cracks
Vivana water closet foot cracks.
Isabella WC corner cracks
Flat Urinal corner cracks
Water Tank pin holes & blibs
Water tank body cracks.
Verso water closet sump cracks
Verso wash basin big tap hole side crack
Marcela water closet water leakages
Cooling cracks (Silvana ped)
Inspection & Spraying Department.
ISSUE
Pin holes & Blibs
Clay droppers(CDR)
All inspection related issues
Recomandation
Walstonite introduction in glaze composition(Minimizes).
Walstonite introduction glaze composition.
increasing residue %.
Recomandation
Final of the BCL slip pipe
New filling system
Filling of big tank with disk system
1st 10 minutes slow filling and then normal filling
Reorganisation of shifts
Study on mould filling pipes in BCL slip line
Increasing line angle and slip pipe little high that the rest
Covering(Filling) of fall pieces gaps with clay.
To clean immediattely after the lateral mold onces open up
Covering(filling) of top side body parts gap with clay
To modify mold to diminish thickness of wall of the piece
Reduce gap between foot core & body part.
Reducing back core drying and Talc powder application
Application of Talc powder at core part corners.
Introducing purging air pipe at final of line slip pipe.
proper cleaning of moulds after and before casting
Avoiding slip leakages in the mould and casting process.
Good water fingering and merging of plate with sump.
Maintain sufficient thickness.
Application of Talc powder for Plaster pin & slow releasing
Proper setting of plaster pin in the mould
Maintain sufficient thickness.
Recomandation
After Inspection every piece cleaning by blowing air with air
gun and clearing appeared pin holes & blibs.
Increasing of air blowing time(To allow clay particles to go out)
Proper checking and clearing of clay particles from the piece
after inspection.
Increasing lighting, even side of booth.
 Kiln Department.
ISSUE Recomandation
Introducing perforated slabs for top deck.
Allow more heat to go out(In that case top pieces will get
Under fire in Kiln-2 sufficient heat).

Moulding Department.
ISSUE Recomandation
Improve the supervision.Introducing finishing of moulds after
releasing from the case in single cavity moulds. Try to
introduce cement in case making to get good case surface.
Poor finishing of mouls Case production with resin.

Improve the supervision.Proper case maintenance.proper

finishing. Proper calmping of moulds during production.case
Poor fitting of Moulds production with resin
More weight of moulds. To maintain 60 mm wall thickness of moulds.

Mould dis placement Modification of mould carriers with mould size.

 Body Department.
Check list
N/A
N/A
N/A

Casting Department.

Need to provide air purging pipe at final area for all lines.
Trained all super visors & workmen. Required every day all lines checking during mould filling time

Required every day all lines checking for big air bubbles and to change the pipes.
N/A
Required every day all lines checking during mould filling time
Results not favourable.
Required every day all WC lines checking during mould preparation time
Required every day all WC lines checking during piece releasing operation time.
Required every day all WC lines checking after body parts fitting.
Modified moulds(8 pieces) in line number-47.samples under progress
Reduced gap in the moulds and the results found good.
Followed the instruction 30% improvement only found.
Started Application and results found good, same continueing. Casting part found good.
Privided air purging pipe in line no- 33, Trails under progress.
Required every day all WT lines checking during mould preparation time
Required every day all WT lines checking during casting time
Results found good.Required every day verso WC lines checking after merging & fingering.
following casting slip holding time and green piece weights
Required every day Marcela lines checking during mould preparation & pin releasing time
checked the setting, found gap between pin & mould.5 moulds casting with proper setting.
Following green piece weights with standards on daily basis.

Inspection & Spraying Department.

Check list
Need to check process implimentation and need to train up people regarding checking and clearing of
surface defects(pin holes, blibs & Bcr)

Need to check, the way people air blowing and need to train up people regardin air blowing time

Monitoring the inspectors during air blowing and cross checking the inspection finished pieces.
work under progress.
 Kiln Department.
Check list
Need to check one car on trail basis with perforated slabs.

need to check one firing by adjusting the chimny heights

Moulding Department.
Check list

Need to check Case mould maintenance and production mould quality and production supervisor must
ensure the quality of moulds produced in his shift.

Need to check Case mould maintenance and production mould fitting and production supervisor must
ensure the fitting of moulds produced in his shift.
work under progress.

Need to start carrier modification at more displacement observed areas. Already Orchid pan trails under
progress.