FRONTIER CERAMICS

LTD

FRONTIER CERAMICS LTD.

FCL Plant
• The Plant is in operation for at least last decade and a half, so there are
systems and trained manpower who is running the production: Yet, the plant
is not operating at desired “bottom line”
• To bridge the Gap between the existing operations/systems and the desired
“bottom line” following should be revisited;
• Organization Structure

• Production and support Processes

• Procedures & Systems

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FRONTIER CERAMICS LTD.
Processes
For a continuous process plant, as per industry norm, following functions must
be addressed (Other support functions like Personnel & IR, Admin, IT etc. has not been addressed now) ;

• Technical

• Manufacturing / Production

• Supply Chain

• Engineering & Projects

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FRONTIER CERAMICS LTD.
Processes Interlinking

T e c h n i c a l
SUPPLY CHAIN MANUFACTURING TECHNICAL PLANT DEVELOPMENT
Quality Control
management
system
Inward Outward Production Lab & Tests Engineering Projects
(based on Intl
Standards,
ISO 13006)
Sub processes Sub processes Sub processes Sub processes
T e c h n i c a l

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FRONTIER CERAMICS LTD.
 Focused Processes
Supply Chain
• All activities associated with the flow and transformation of goods from raw
materials to end users.
• Network of facilities include:
• Material flow from suppliers and their “upstream” suppliers at all levels,

• Transformation of materials into semi-finished and finished products (internal

Production processes)

• Distribution of products to customers and their “downstream” customers at all

levels.

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FRONTIER CERAMICS LTD.
 Supply Chain

UPSTREAM INTERNAL DOWNSTREAM

Distribution
Centers

Retailers
Assembly/ Manufacturing
2nd Tier Supplier 1st Tier Supplier
and Packaging

Customers

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FRONTIER CERAMICS LTD.
 Focused Processes
Three Flows in Supply Chain
• There are three kinds of flows in a supply chain:
• material, information, capital.
• Upstream
• Material: Raw material Clay minerals, etc……
• Information: Suppliers, logistics, etc…….
• Finance: Payments
• Downstream
• Material: Finished product, various sizes
• Information: Agents, logistics, delivery. Etc…..
• Finance: Invoices, Pricing, Credit Terms, cash flow, aging, etc……

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FRONTIER CERAMICS LTD.
 Focused Processes
Production
• Process P&ID
Diagrams to be
developed (where not
available) with control
point values.
Sample P&ID

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FRONTIER CERAMICS LTD.
 Focused Processes
Technical; Process Quality Control
• Raw Material
• Raw material handling and Mixing
• Recipe preparation
• Feed material preparation
• Tile Manufacturing
• Based on ISO 13006 (or any other standard based on same)

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FRONTIER CERAMICS LTD.
Technical; Process Quality Control; Tile Manufacturing
Based on ISO 13006 (or any other based on same)

Test Standard Description

EN ISO 10545-1 Part 1: Sampling and basis for acceptance

EN ISO 10545-2 Part 2: Determination of dimensions and surface quality

EN ISO 10545-3 Part 3: Determination of water absorption, apparent porosity, apparent relative density and bulk density

EN ISO 10545-4 Part 4: Determination of modulus of rupture and breaking strength

EN ISO 10545-5 Part 5: Determination of impact resistance by measurement of coefficient of restitution

EN ISO 10545-6 Part 6: Determination of resistance to deep abrasion for unglazed tiles

EN ISO 10545-7 Part 7: Determination of resistance to surface abrasion for glazed tiles

EN ISO 10545-8 Part 8: Determination of linear thermal expansion

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FRONTIER CERAMICS LTD.
 Technical; Process Quality Control; Tile Manufacturing
Based on ISO 13006 (or any other based on same)

Test Standard Description

EN ISO 10545-9 Part 9: Determination of resistance to thermal shock

EN ISO 10545-10 Part 10: Determination of moisture expansion

EN ISO 10545-11 Part 11: Determination of crazing resistance for glazed tiles

EN ISO 10545-12 Part 12: Determination of frost resistance

EN ISO 10545-13 Part 13: Determination of chemical resistance

EN ISO 10545-14 Part 14: Determination of resistance to stains

EN ISO 10545-15 Part 15: Determination of lead and cadmium given off by glazed tiles

EN ISO 10545-16 Part 16: Determination of small colour differences

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FRONTIER CERAMICS LTD.
Roadmap

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FRONTIER CERAMICS LTD.
T HANK YOU

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FRONTIER CERAMICS LTD.