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Production

There are some points which are as follows:

  • The Group has best available production facility to produce 2500 pcs per day.
  • The Production and operations are virtually self regulatory and not dependent on any one single person.
  • There is minimum employee turnover and absenteeism, giving stability to production.
  • The quality awareness culture is cascaded top down and hence every person is formally or informally involved in improving and maintaining highest quality levels
  • Employee involvement in improvements has been going on since the day the company started way back in 1976. Thus, the improvements are never a surprise at the SPW group.
  • Wastage is minimized at every stage of production to maintain low costs.

Raw Material

Best Quality Washed Clay is procured. The clay is cleaned of unwanted agents (ferrous as well as non-ferrous) by the supplier, so it can directly be used for production. This kind of clay improves the quality of slip. QC checks all the inward material before issuing for production.

Ball Mill

Pebbles used are quiet hard and do not wear for a long time. The batches of pebbles are of uniform size. Thus, the grinding is uniform.

Casting

There are 7 batteries employed for fast moving products. Other casting is done manually. The Green stage and Dry stage check is done to assure the quality of the cast before sending it to glazing. There is no use of glazing rejected material. The rejected material is recycled.

Glazing

Glazing is done in highly controlled environment by well trained glazers. The result of the glazes are checked by firing before the glazing mixes are used for mass production. The glazing is highly consistent and lot to lot differences are almost nil.

Firing

Tunnel kilns are used for firing of the material. Liquid Fuels are used for firing and the parameters of firing are controlled. This improves the quality of Glaze and the strength of the piece itself.

Sorting & Packing

There is hundred percent checking of the fired goods. The pieces not meeting the minimum requirement are rejected there itself. Other goods are sorted into First Choice and ROK depending on the pinheads.

Storage and Packing - The Sorted articles are stored inside the plant storeroom. On receipt of dispatch note, the goods are packed. There are two type of packing, Grass Packing and Box Packing. They are provided as per the customer demand. Some of the consignments are shrink wrapped and palletized. Shrink-wrapping eliminates the material movement relative to each other. This reduces transportation breakage to a great extent.

Loading - Loading is done with Fork Lift, if Palletized, else, it is manual. Palletized material is loaded extremely fast. The material is also placed in a very organized manner. It facilitates downloading as well.

Technology

Features:

  • High capacity Tunnel was first introduced by the group in the town and the group remained leader in use of the technology fro about two years
  • The group also implemented Battery Casting.
  • The group adopted box packing by studying the needs of the market and the existing packing material of non-Indian companies. There were no Indian Companies that had efficient box packing systems.
  • Palletizing too was done scientifically be the group.
  • Maintaining Laboratory that supports production.
  • Design Department with experienced designers and Computers to design products as per market requirements.
  • Containerization was done by use of Fork Lift.

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