As an emerging state, the lodging industry in Bangladesh have progressed significantly in recent old ages, that inspired the ceramics industry besides to hasten investing into the industry. Fu-Wang Ceramics Industries Ltd. is a BBB rated company in the ceramics industry of Bangladesh. While there are other participants in the industries playing competitory, the evaluation reflects the constituted place of Fu-Wang Company in the tiles industry in Bangladesh with its prospective domestic markets. While the evaluation factors important experience of the boosters reflected in marketing success of the company and good recognition history, the evaluation is constrained by weak fiscal place. This possibly a ground of increasing investing in engineering and in fabricating procedure optimisation stage.
Fu-Wang Ceramic Industry Ltd. ( FWCIL ) was incorporated in May 1995. FWCIL is engaged in fabrication & A ; selling of assorted types and sizes of Floor Tiles and Glazed wall tiles. As quoted by the president of the company, Mr. Hsu Chin Hua, “ The Management of Fu-Wang Group is ever followed QSP ( Quality, Services and Price ) for their each & A ; every merchandise ” . Fu-Wang industry limited is confronting increasing demand of the consumers countrywide. The company is utilizing imported natural stuffs, Italian machineries and extremely experient Chinese technicians and applied scientists in production who are argus-eyed to run into the altering gustatory sensation and pick of the consumers by supplying the touch of brilliant proficient excellence in physical building and visual aspect of tiles. Fu-Wang already has a well-equipped studio for design development which enabled to present the epicurean glassy floor and wall tiles by utilizing latest publishing engineering foremost of all time in Bangladesh and utilizing optical maser cut engineering for all Homogeneous tiles.
The types of tiles produced and supplied by Fu-Wang Ceramics are Glazed Floor Tiles ( 31cm X 31cm ) , Glazed Floor Tiles ( 20cm X30 centimeter ) , Design Glazed Floor Tiles ( 31 centimeter X 31 centimeter ) , Glazed Wall Tiles ( 20cm X 30 centimeter ) , Luxury Ceramic Wall Tiles ( 25cm X 36cm ) , Homogeneous Floor Tiles ( 30cm X 30cm ) , Homogeneous Floor Tiles ( 40cm X 40cm ) , 20 Series Split Type Exterior Tiles, Border Tiles, Luxury Ceramic Wall Tiles ( 31cm X 45cm ) , Luxury Ceramic Floor Tiles ( 31cm X 31cm ) , and Luxury Ceramic Floor Tiles ( 42cm X42cm ) .. The sister concern Hua-Thai produces premium quality Hua-Thai tiles, which grabs important market portion in Bangladesh entirely. The instance intends to look into the assorted methods that are used by Fu-Wang and its sister concern Hua-Thai in running their production and fabrication operations and quality control steps.
As mentioned before, Fu-Wang has five separated lines for production ; it works difficult to do all assortment of tiles available in the market. Fu-Wang introduces the epicurean glassy floor and wall tiles by utilizing the latest printing engineering foremost of all time in Bangladesh and utilizing optical maser cut engineering for all Homogenous tiles. Deploying advanced mechanism and engineerings Fu-Wang is bring forthing same quality as European tiles and offering low-cost monetary value to all valuable Bangladeshi consumers for comfy hygienic and manner alien house life. Because of its first-class quality Fu-Wang has achieved the ISO-9002 enfranchisement in 1998. Thus Fu-Wang makes a revolution in regard of tiles market and among the users of Bangladesh. At present Fu-Wang tiles are exported to India, Pakistan. Bhutan and Taiwan due to quality colour and assortment.
The Fu-Wang Management Team is committed in leveraging their experiences to take Fu-Wang to greater highs by guaranting top line grosss with dynamic capablenesss. This Management Team is alone in being able to visualize the demand of the concern by conveying in a mixture of advanced engineering solutions know-how and revamping the organisational make- up for maximal profitableness. The corporate direction of the Company is consisted of 7 managers. The Managing Director of the Company is the Chief Executive, who assumes all duties for planning and controlling of the Company. Other managers and extremely qualified and experient forces assist him. This mix of people of Fu-Wang Ltd. are relentless to supply unparallel service to their clients, come up with seasonably and advanced merchandises and services and to heighten the capablenesss of their people while stressing on the latest engineering.
To recognize the procedure optimisation landmark, set by Fu-Wang Ceramics, the elaborate production procedure is necessary to be laid out. Taking Fu-Wang ( Wall-tiles ) fabrication procedure into consideration, as a benchmark. Fu-Wang tiles purchase the natural stuffs from Mymensingh. Then white clay and ruddy clay are crushed and put in the ball Millss. in this phase ( W ) crushed clay is assorted with H2O to bring forth ceramic clay. Once the ceramic clay is produce, it is so stored in the faux pas ( X ) . It can hive away 30-ton clay. Magnet extractor ( Y ) extracts the magnets form the clay. Spray drier ( Z ) dries the clay and gives it a pulverization signifier. This mill has 6 silos. Each silo can incorporate 70 dozenss of clay pulverization. Silos are used to hive away the clay pulverization for pressing. 6 silos are connected to two pressing machines ( A ) . A pressure machine is a hydraulic machine. Under this machine there is a home base.
This home base contains the surface design of the tiles. Clay pulverization from silo is poured into this home base. This machine presses the pulverization with 250 ton hydraulic force per unit area. Then the pulverization gets the needed form. Then it is delivered to the conveyor belt. The mill has one 3-layer drier ( B ) . Dryer is used to dry extra wet from the surface of the natural tiles. Startup clip for this drier is 20 proceedingss. The capacity of this drier is 645 square pess. After drying the natural tiles are delivered to the conveyor belt and it reaches to the dust storm. Manual surface dusting ( C ) is a manual procedure. One individual is in charge to clean the upper surface country of the tiles. The following stage ( D ) pours colour on the surface of the natural tiles.
Glaze spray ( E ) is used to glaze the surface of tiles. In the undermentioned phase ( F ) side glaze is minimized. This mill has five roller printing machines ( G ) . These pressmans print the surface design one by one in five phases. After chilling the manual review takes topographic point where the quality accountant inspects ( H ) each and every tiles and expression for textures jobs, deformation, topographic point, border interruption and colour utilizing their ain judgement. The Accumulator ( I ) militias the tiles for firing. After glazing, the tile must be heated intensely to beef up. Kiln ( J ) fire the tiles. Cooler fan ( K ) used to chill the discharged tiles. Then finished tiles are inspected ( L ) to look for any border interruption. Tiles are so manually packed ( M ) . Each battalion contains 10 tiles. Then the battalions are taken to the stock list.
The precedency diagram of Fu-Wang Wall Tiles fabrication procedure shows a straightforward diagram as signifier the precedency relationship it is clear that each undertaking has to travel after the earlier 1. This procedure starts with undertaking W that is the Ball mill step and divide terminals with undertaking M that is the packaging measure. We have calculated all the clip based on one SFT of tiles end product footing. We know that Cycle Time is the longest processing clip of the procedure. At this point Cycle Time is 2.49 sec, highest processing clip at undertaking J ( Kiln ) . Entire activity clip is the summing up of the full undertaking clip and at this point it is 18.29 sec. Gettable end product of the procedure is 34,699 SFT tile per twenty-four hours. Idle clip in each station is the fluctuation between the undertaking clip of that demanding place and rhythm clip. In this procedure entire idle clip is 24.01 sec, which provides 56.72 % idle clip. And use of this procedure is 43.27 % .
Proposed production procedure of Fu-Wang Wall Tiles:
Desired Output = 60,000
Required CT = Total Time Available/Desired Output
Figure 2: Proposed Precedence Diagram of Fu-Wang Wall Tiles
Findingss for proposed procedure of Fu-Wang Wall Tiles:
a ) CT = 1.24 Sec
B ) Output = Total Time Available/CT
= 24 * 60 * 60/1.24
= 69,677 square pess per twenty-four hours
degree Celsius ) Entire Activity Time = 0.43 + 0.34 + 0.58 + 0.69 + 1.17 + 1.17 +1.16 + 0.87 + 0.87 + 1.16 + 0.87 + 0.58 + 1.16 + 1.16 + 0.87 + 1.24 + 1.24 + 1.00 + 1.16 + 0.58 = 18.3 Second
vitamin D ) Total Idle Time = 0.81 + 0.9 + 0.66 + 0.55 + 0.07 + 0.07 + 0.08 + 0.37 + 0.37 + 0.08 + 0.37 + 0.66 + 0.08 + 0.08 + 0.37 + 0 + 0 + 0.24 + 0.08 + 0.66 = 6.5 Second
vitamin D ) % Idle tile = Total Idle Time / ( CT x No. of Stations )
= 6.5 / ( 1.24 x 20 )
= 26.20 %
e ) % Utilization = 100 – 26.20
= 73.79 %
As of the penchant relationship it is evident that grouping of undertaking is non executable. Bottleneck of current procedure is step A, C and J. As a consequence our suggestion of this procedure is to infix one Pressing machine, one manual dust storm and one Kiln as parallel Stationss at measure A, C and step J. This jutting procedure will supply a Cycle Time of 1.24 sec. As a consequence it will decrease the entire idle clip. This awaited procedure will supply 26.20 % inactive clip and Utilization of 73.79 % . Therefore this proposed procedure will supply about 30 % extra use degree than the bing procedure
Problem work outing session 1
Hua Thai ( Floor Tiles ) Manufacturing Procedure: The chief natural stuff of the floor tile is ceramic clay. Fu-Wang tiles imports ceramic clay signifier Malaysia. Each bag of ceramic clay pulverization contains 1.05 ton. Ceramic pulverization is lifted to silos. This mill has 3 silos. Silos are used to hive away the ceramic clay pulverization for pressing. Out of three, two of them run continuously and one of them is kept as a dorsum up. Each silo can keep 42 dozenss of ceramic pulverization. The description of the procedure follows. Each silo is connected to one pressure machine ( A ) . A pressure machine is a hydraulic machine. Under this machine there is a home base. This home base contains the surface design of the tiles. Ceramic pulverization from silo is poured into this home base. This machine presses the pulverization with 250 ton hydraulic force per unit area. Then the pulverization gets the needed form. Then it is delivered to the conveyor belt. The mill has one 3-layer drier ( B ) . Dryer is used to dry extra wet from the surface of the natural tiles.
Startup clip for this drier is 20 proceedingss. The capacity of this drier is 645 square pess. After drying the natural tiles are delivered to the conveyor belt and it reaches to the dust storm. The dust storm ( C ) is used to clean the upper surface country of the tiles. Blower is used to take light dust from the surface. Glaze spray ( D ) is used to glaze the surface of tiles. This mill has two roller printing machines ( E ) . These are optional and it is used if there is any excess printing needed. Before firing anti adhesive coating ( F ) is pasted under the tiles. This coating is used so that tiles do non lodge in the kiln ( oven ) . Alumina is used as an anti adhesive stuff. Accumulator ( G ) militias the tiles for firing. Capacity of this collector is 360 square pess. In stage ( H ) the tile goes through a low-temperature fire called bisque firing before firing. Glaze drier removes excess glaze of natural tiles before firing. After glazing, the tile must be heated intensely to beef up it and give it the coveted porousness ( I ) . This is a firing machine specially designed to fire the natural tiles.
The organic structure and glaze are so fired together in a procedure called GLOST fire. Both firing procedures take topographic point in a tunnel or uninterrupted kiln, which consists of a chamber through which the ware is easy moved on a conveyer on furnace lining BATTS-shelves built of stuffs that are immune to high temperatures-or in containers called SAGGERS. Output of this kiln is 16 square pess per minute. This is the procedure where the soft natural tiles are transformed into difficult tiles through different bed of firing. Cooler fan ( J ) is used to chill the discharged tiles. After chilling the manual review takes topographic point where the quality accountant inspects each and every tiles and expression for textures jobs, deformation, topographic point, border interruption and colour utilizing their ain judgement ( K ) . And they categorize the tiles in the undermentioned manner:
Rate A: Nothing defects.
Class Bacillus: one or two defects.
Grade C: More than two defects.
Once the tiles are inspected so they are kept in a topographic point for uninterrupted 8 hours chilling at room temperature ( L ) .Then the cooled tiles are taken for squaring and scaling Water is sprayed to the surface of the tiles before cutting the borders ( M ) . This is done so that the tiles do non interrupt while the cutting procedure occurs. There are 2 cutting machines. This machines cut the tiles to give it a needed size, called the squaring and scaling stage ( N ) . Water Dryer ( O ) is used to dry the H2O that was sprayed earlier. Heater ( P ) heats the tiles and prohibitionists it for packing. In Final physical review ( Q ) procedure finished tiles are inspected to look for any border interruption. Finally in packaging stage ( R ) tiles are so manually packed. Each battalion contains 10 tiles. Then the battalions are taken to the stock list.
Most modern tile makers now use statistical procedure control ( SPC ) for each measure of the fabrication procedure. Many besides work closely with their natural stuff providers to guarantee that specifications are met before the stuff is used. Statistical procedure control consists of charts that are used to supervise assorted treating parametric quantities, such as atom size, milling clip, drying temperature and clip, compression force per unit area, dimensions after pressing, denseness, firing temperature and clip, and the similar. These charts identify jobs with equipment, out of spec conditions, and aid to better outputs before the concluding merchandise is finished. The concluding merchandise must run into certain specifications sing physical and chemical belongingss. These belongingss are determined by standard trials established by the Bangladesh Standard Testing Institution ( BSTI ) . Properties measured include mechanical strength, scratch opposition, chemical opposition, H2O soaking up, dimensional stableness, hoar opposition, and additive coefficient of thermic enlargement.
Fu-Wang ceramics ( wall tiles ) and the Hua-Thai ( floor tiles ) Ceramics, our survey companies are registered with ISO 9002. In our mill visit we barely find choice control measures taken except some manual review. No Statistical record has been maintained other so the entire batch end product and the no of Grade A, Grade B and bit tiles no. Quality control inspectors look for the possible defects like texture, deformation, topographic point, colour, two-dimensionality, etc. We have provided 36 informations seta about the figure of Grade A, Grade B and bit tiles from one line of Hua-thai ceramics. Based on the information we have done our Analysis. Rest of the lines of the company did n’t supply us any information so we do n’t cognize whether they have maintained any sort of record or non.
Quality control Data of Hua-Thai Floor Tiles:
We have considered the Grade A as chief merchandise and the Grade B every bit good every bit bit as our faulty merchandise and have done the analysis based on that. Were Grade A represents no defects, Grade B represents 1-2 defects, Scrap represents more so 2 defects in the tiles end product. The batch size is 2180 SFT of homogeneous floor tiles.
Sample Size n=2180 SFT
Relationship diagram between different Grades of end product:
The undermentioned diagrams are shown between different types of end product
Rate A V Bit
Rate A and Scrap has a negative relationship. As Grade A addition the scrap lessening. It is besides seeable in the additive line drawn.
Problem work outing session 2
Question 1: Using quality control informations, concept and define relationship among class A V class B. Remark on your findings.
Question 2: Using quality control informations, concept and define relationship among class A V class B and bit. Remark on your findings.
Question 3: Explain your findings and urge agencies to hasten efficiency by commanding the Grades.