Final Inspection Process in Sanitaryware Manufacturing

Final Inspection Process in Sanitaryware Manufacturing

Final inspection is the last step in the sanitaryware production process. Fired wares are transferred to the final inspection or quality department for assessment. Inspection can be conducted in either a batch or continuous manner, with the goal of completing the inspection for the total number of fired products produced per day.

Final Inspection purpose is to visually inspect each ware, check dimensions and structural integrity, record data, and send products for additional processing if needed.

In sanitaryware manufacturing, all fired products are 100% inspected to ensure they meet standards for functionality, aesthetics, and safety before reaching the customer. A thorough inspection process helps maintain high quality, reduces returns, and enhances customer satisfaction.

Visual Inspection

Visual inspection is the first and most basic step. It involves checking the product surface for visible defects like cracks, pinholes, chips, glaze imperfections, or kiln-related issues.

Dimensional & Functional Inspection

Items like basins, toilets, and sinks are checked for dimensional specifications, especially fixing and installation holes, to ensure proper installation and functionality. Dimensional accuracy checks confirm that each product falls within the required tolerance levels, making them suitable for plumbing connections.

Structural Integrity

During visual inspection, a gentle knock with a rubber or wooden hammer is used to relieve any stress in the ware. This knock test can reveal hidden cracks in the body, with the sound of the knock helping assess the structural integrity. This step prevents products with hairline cracks from reaching customers.

Classification

Based on the inspection, the pieces are classified into different grades, rework, or rejected categories. The standards of classification vary for each company based on their customer base.

Data Recording

Recording final inspection data is essential. This includes details like:

• Model name

• Count of good pieces

• Refire pieces

• Defective pieces

• Defect types

• Caster

• Inspector

• Sprayer

• Kiln car number

• Data from each process step

This data is crucial for troubleshooting defects and improving production yield.

Send for Processing

Based on type or model, pieces are sent for additional processes such as:

• Cold repair

• Buffing

• Cutting

• Putty application