Cost management for sanitaryware manufacturing facilities
The sanitaryware manufacturing industry is seeing tremendous growth, leading to increased rivalry. In order to succeed in this ever-changing climate, businesses must manufacture items at a lower cost than their rivals. It is essential to achieve a competitive advantage by providing wholesalers with cost-effective items that generate significant revenues. In order to accomplish this, it is necessary to identify and tackle the issues that have the potential to decrease production costs in the sanitaryware industry.
Differences in production costs per ton between countries are influenced by factors such as fuel costs, availability of raw materials, and labor charges. In light of the dynamic nature of the corporate environment, it is imperative to consistently strive for cost reduction. Let's examine particular aspects that require focus to improve productivity and decrease expenses in the production of sanitaryware.
Reducing the number of rejected items:
The primary emphasis is placed on minimizing failures at each level of the process. Losses in sanitaryware production are classified as "green rejects" before kiln firing and "fired rejects" after kiln firing. Minimizing rejects during the fire process is essential due to their lack of reusability and the significant expenses associated with their disposal. It is advisable to promptly deal with green rejects, as they can be recycled with minimum loss, unlike burnt rejects. It is advisable to employ a specialist in sanitaryware to efficiently rectify any procedural deficiencies.
Maximizing the efficiency of equipment and workforce:
Optimal utilization of machinery and human resources can result in decreased production costs per unit. For example, by optimizing technology and workflow, the Saudi ceramics facility was able to achieve a 15% improvement in productivity by maximizing the use of high-pressure casting machines. Efficiently optimizing kilns, dryers, robots, and casting equipment is crucial for achieving cost-effective production.
Weight reduction:
Decreasing the weight of a product has a direct impact on reducing production costs by lowering the amount of raw materials used, reducing fuel consumption, and decreasing transportation charges. Significant weight reductions can be achieved by making modifications to designs in order to remove extraneous bulk and optimize mold thickness. Even though small cost reductions are achieved by altering the size of the mold, any optimization is valuable in cost management techniques.
Improvements to the process:
The implementation of process enhancements, such as minimizing energy usage while maintaining high quality standards and optimizing kiln loading to preserve fuel, has a substantial effect on production expenses. By transitioning from bench casting to battery casting and avoiding deviations from conventional procedures, operations can be streamlined and expenses can be reduced.
Expanding production volume leads to a decrease in per-unit costs since fixed costs are distributed among a larger number of units. Fixed expenses such as security, administrative personnel, and utilities stay consistent, resulting in cost-effectiveness with increased output levels. This idea is applicable to all activities, as the goal of optimizing efficiency helps to reduce per-unit production costs.
Reducing Rework:
Rework increases costs as a result of extra labor and material use. Implementing preventive steps to minimize errors following the casting and firing process is of utmost importance. By improving employee skills and implementing stringent quality control methods, rework costs can be further reduced and overall product quality can be enhanced.
Investing in automation leads to a decrease in labor expenses and enhances production efficiency, especially in regions with high costs. By incorporating advanced technologies such as low-pressure and high-pressure casting tools, monorail systems for transporting wares, robotic glazing systems, and automated batching programs, the manufacturing processes for sanitaryware can be optimized.
