The use of Statistical Process Control Technique in the Ceramic Tile Manufacturing: a Case Study

Ali Mostafaeipour

Industrial Engineering Department, Yazd University, Yazd, Iran

Ahmad Sedaghat

Mechanical Engineering Department, Isfahan University of Technology, Isfahan 84156-83111, Iran

Ali Hazrati

Industrial Engineering Department, Yazd University, Yazd, Iran

Mohammadali Vahdatzad

Industrial Engineering Department, Yazd University, Yazd, Iran

QC 37

ABSTRACT

Statistical Process Control (SPC) is an effective powerful methodology for analyzing, monitoring, managing, and improving process performance.

The purpose of this study is to introduce Statistical Process Control technique in Yazd ceramic tile manufacturing plant in Iran for reducing unwanted ceramic tile defects and wastages.

Defects were categorized on their frequencies by examining defective tiles produced in the manufacturing plant. The most important defect was a variety of cracks in different tiles.

By implementing control diagrams R, X and six-pack for a sensitive parameter, a significant result was observed. Also, system troubleshooting was performed by examining the process and its related machines.

After identifying and resolving the given defect and reevaluating the process by the mentioned diagrams, the quality of observed ceramic tiles were improved significantly.

Hence, this study presents a complete process to help manufacturer identify defects for process improvement with immediate benefits for the current development cycle in the plant.

General Terms

Improvement of process performance

Keywords

Statistical Process Control; ceramic tile; manufacturing; Pareto chart; Yazd.