Market visit analysis report with action plan.pptx

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

12. General Complaint Silvana Pedestal back side cutting not accepted Elana Basin Oval Shape not maintained White glaze require more whiteness Micro pinholes Corrective action Required approval for modification. Weight will increase by 4 to 5kg Loading setter will minimize the problem. Effect of L oad factor to be studied Immediate change of whiteness will create mis match with existing stock. Need approval, planning and communication with dealers 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