Trouble Shooting Chart(1)

  • May 2020
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TROUBLE SHOOTING CHART - BODY DEFECTS S.NO 1

TYPE OF DEFECT Pin Hole

CAUSES 1. Leakage in slip supplying pump which may allow air inside the pipeline. 2. Slip specifications & ageing time. 3. Sieves for fresh, scrap & return slip are not cleaned properly. 4. Fast filling of the mould. 5. Sticking of small sponge fragments in the body. 6. Filling time of the Ark. 7. Presence of other particles in slip while filling. 8. Presence of unwanted elements in return slip. 9. Design of stirrer. 10. Excess mica in clay. 11. Mould condition. 12. Blunging time 13. High concentration of soluble salt. 14. Chocking of supply slip line.

2

Bad Finish

1. Quality of moulds 2. Improper sponging. 3. Improper mould filling. 4. Finishing water (muddy). 5. Thick glaze.

3

Clay Dirt

4

Pores

5

Foreign Body

6

Sagging

1. Falling of punched clay on the surface. 2. Type of punch 3. Blowing & sponging not proper. 4. Stocking of extra glazed pieces for long. 5. Finishing water. 6. Scrapping of excess glaze with blade. 1. Improper mould fitting. 2. Quality of moulds 3. Dry finishing. 1. Mould filling without mesh. 2. Loose particles from atmospheric air & roof. 3. Rusted pipe line. 1. Wet condition of the moulds.

REMEDY 1. Ensure all pumps supplying slip are functioning correctly. Also circulation of slip before casting starts. 2. Specs should be maintained & should be aged for 96 hrs. 3. Cleaning of those should be regular & cross checked. 4. Monitoring the filling time of the mould. 5. Good quality sponge should be used. 6. Checking of the Ark which is giving more pin hole. 7. Nylon mesh to be used at the mouth of slip pipe. 8. Proper sieving of return slip. 9. Changing the design of the stirrer. 10. Constituents of the clays should be checked. 11. The life / wet&dry condition & dust accumulation of the moulds should be checked. 12. Sufficient blunging time should be given. 13. Low cocn. Of soluble salt should be maintained. 14. Regular cleaning of supply slip line is required. 1. Mould parts should fit properly. Surface of moulds, quality of POP & mixing should be good. 2. Proper sponging in Casting/Glazing areas. 3. Casters should be guided on the proper way of filling. 4. Finishing water should be changed frequently in Casting/Glazing. 5. Glaze coat should not be thick. 1. Removal of punched clays from the greenware. 2. Punch design should be improved to follow the above. 3. Proper blowing & sponging before spraying. 4. Extra glazed pieces should be covered. 5. Changing of water frequently in Casting/Glazing. 6. Wet sponging should be done instead of scrapping. 1. Proper mould fitting. 2. Good quality of moulds should be used (no pit). 3. Wet finishing should be done instead of dry finishing. 1. Use of nylon mesh during filling. 2. Cover the pieces after releasing /repairing the roof. 3. Rusted pipe line should be removed. 1. Casting should be avoided on wet moulds.

7

Bubble

8

Bursting

9

Shattering

10 Seam Mark

2. Design of moulds. 3. Kiln car top level. 4. Green strenght of the body. 5. Early release of cast pieces. 6. Drying system not good. 1. Quality of raw materials. 2. Kiln temperature. 1. Wet pieces are sprayed & loaded. 2. Generation of air pocket during filling.

2. Correction of mould design. 3. Kiln car top should be flat. 4. Body comp. Should be proper. 5. Avoid early releasing of pieces. 6. Better drying system should be provided. 1.Proper testing of raw materials needed. 2. Avoid temp. fluctuation. 1. Avoid wet pieces carry over/spraying & loading. 2. Carefull mould filling.

1. Mould joint impressions are not removed while finishing.

1. It should be finished at the Casting & Glazing area.

1. Early releasing 2. Jerk on greenware trolley 3. Bad handling of pieces. 4. Wet condition of the mould. 5. Glazed pieces kept in trolleys for long time. 6. Properties of slip. 1. Less thickness of the cast pieces. 2. Pcs kept on floor. 3. Air entrapped during slip run-off. 4. Design of the mould. 5. Improper drying of the greenwares & moulds. 6. Improper loading. 1. Bad condition of the punch. 2. Punched while the piece is either very soft or hard. 1. Early releasing. 2. Mishandling during loading. 1. Early releasing of the plug or punch cutting 2. Mishandling during spraying &loading.

1. Avoid early releasing. 2. Good condition of flooring & trolleys. 3. Handling the pieces with care. 4. Proper mould drying. 5. Stocking of glazed wares should be avoided. 6. Maintaining specs properly. 1. Thickness should be proper. 2. Avoid keeping in the floor. 3. Run-off should be done carefully. 4. Correction in the moulds. 5. Proper drying. 6. Loading should be done carefully. 1. Correction in the punch. 2. It should be avoided. 1. Avoid early releasing. 2. Take care at the time of loading. 1. Release only after proper drying, taking consideration of weather slip & mould condition. 2. People should be trained properly 1. Punch mark should be on proper place. 2. It should be avoided. 1. Plug should be removed only when the piece is properly dried & it

11 Spangling 12 Green Spot 13 Not Well Attended 14 Cracks a. Rim crack

b. Panel crack

c. Punch crack d. Bowl crack e. Outlet crack

f. Bracket crack g. Inlet crack

1. Mould design. 2. Punched while the piece is either too soft or hard. 1. Early or improper release of the plug.

h. Mould crack

i. Fire crack

1. Faulty design of the mould. 2. Early release of the cast pieces. 3. Sticking with the kiln car. 1. Too dry mould. 2. Early release of the cast pieces.

should be done carefully. 1. Correction in the design of mould. 2. Avoid early releasing. 3. Application of setter wash properly. 1. Proper application of slurry water. 2. Avoid early releasing.

TROUBLE SHOOTING CHART - GLAZE DEFECTS S.NO

TYPE OF DEFECT

CAUSES

1

Thin Glaze

1. Lack of sprayer skill. 2. Improper maintenance of glaze specs. 3. Compressed air pressure fluctuations.

2

Crawling

1. Poor sponging of wares. 2. Glaze quality & parameters 3. Over spraying.

3

Glaze Removal

1. Removal of excess glaze by blade. 2. Loading of wares without gap.

4

Groove Crawling

1. Dust or talc accumulation on the groove area.

5

Colour Mix

6

Bad Logo

7

Glaze Waviness

8

Glaze Pin Hole

9

Without Logo

1. Handling of two colours by same person. 2. Using same setter for more than one colour 1. Improper application of logo. 2. Moisture on the stickers. 3. Quality of stickers. 1. Pressure variation at the time of spray. 2. Uneven coating over the wares. 1. Too violent/fast spraying. 2. Too long an interval between successive coats 3. Excessive fine grinding of the glaze. 1. Non application & improper checking of glazed wares. 1. Iron content in glaze.

10 Glaze Specks

11 Glaze Sundry 12 White Spot 13 Matt Glaze

1. Inadequate dispersion of the opacifier. 1. If the glaze layer is too thin to cover the normal surface of the body. 2. Temperature & firing time too low for the glaze

14 Badge Mark

to mature. 1.Due to improper stamping badge mark appears at the glazed protion.

REMEDY 1. Patternwise, locationwise, colourwise analysis to be made. Feedback & training to be given. 2. Glaze parameters to be maintained as per weather & colour. 3. Air pressure to be maintained more than 5 kg/cm 2. Accordingly arrangements to be made, so fluctuations also avoided. 1. Wares to be cleaned properly & water to be changed in a frequent interval. Glaze to be applied in grooved areas (EWCs & AIPs). 2. Good quality CMC (binders) to be used & parameters to be maintained as per requirement. 3. More glaze thickness also causes crawling, which is to be avoided. 1. Glazing setting to be cleaned often. Wet sponging to be done to finish the wares. 2. Wares loaded without gap to be avoided. 1. Water to be poured & groove area to be cleaned. If required glaze can also be applied by brush in that area. 1. Hands to be cleaned before changing over to another colour. 2. Setter to be cleaned before changing the colour. 1. Stickers to be wet properly before application. 2. Stickers to be dried before taking for application. 3. Quality of stickers should be good. 1. Pressure regulators to be adjusted at Gun & Pot. 2. Locationwise, patternwise feedback & training to be given to the frontliners. 1. Spraying should be done in normal speed. 2. Interval between two coats should not be long. 3. Fine grinding to be avoided. 1. Wares to be checked at stamping, loading & pushing area. 1. Glaze to be sieved through magnets. 2. All air lines to be cleaned periodically. 3. Filters to be provided on air line.

1. Glaze to be milled properly. 1. Parameters of the glaze to be maintained properly. 2. Adequate maturing time & temperature to be given to the wares.

1. Stamping should be proper.

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