Republic of the Philippines

DON HONORIO VENTURA STATE UNIVERSITY

College of Engineering and Architecture
Villa de Bacolor, Pampanga
Department of Industrial Engineering

Activity 1:
Quality
Assessment
and
Analysis

An Industrial Engineering On-the-Job/Student Internship Program

Submitted by:
Sarnicula, Sol-amor R.

Submitted to:
Engr. Roma De Jesus
OJT/SIP Adviser
 PROPOSED CORRECTIVE ACTION PLAN

1.1 Bisque Firing

• The bisque firing process needs to be done under a very controlled heat, as the clay is
put in a kiln and heated slowly and then also cooled slowly. This enables the pottery to
become porous and able to handle water-based paints without it cracking or failing.
• The size, height, weight, and width of the clay transformation should be equal and
accurate measurements to prevent oversize and undersize defects.
• The shape issue body in the bisque firing should be gentle and controllable to achieve the
right hole, and prevent some issues on other corner like (shoulders, lower body, etc.)
• For grinding and epoxy, when grinding ceramics, it must be taken into account that the
real depth of cut is larger than the assumed value, because the movement of grains
causes additional splintering, leading to a larger depth of cut. In order to optimize the
process, aiming for the control of thermal conditions, an increasing focus on proper tool
selection emerges, for each material to be ground.
• About the design of the ceramic, these principles include balance, emphasis, movement,
pattern, rhythm, repetition, variety, and unity. The dry pressing method is one of the most
commonly used ceramic forming methods and has many advantages such as simple
processing, simple operation, short cycle, high efficiency, and easy realization of
automated production. In addition, the ceramic produced by the method has the
characteristics of high density, accurate size, small shrinkage, high mechanical strength,
and good electrical properties.

1.2 Gloss Firing

• To avoid sharp glaze with light and dark shade (color variation) of the glossing process,
by mixing your glazes, applying the glaze to bisque-ware, letting it dry, then finally loading
it into the kiln for the glaze firing. The kiln is slowly brought up to the appropriate
temperature for the silica in the glaze to melt, then slowly cooled again.
• To avoid excess glaze by applying it lightly to not cause glaze to run off the pot, not to
weld lids to pots and pots to kiln shelves, and can’t result in blistering. To avoid blistering
and blebs, it would be well to replace them with other fluxing agents, or fritted materials.
• For grinding of the gloss firing, the hardness should be dominant and professional shaping
to achieve the correct design.
• Crazing is the most common glaze defect, and normally the easiest to correct. In both
crazing and shivering the eradication of problems relies on matching the thermal
expansion characteristics of both body and glaze. In practice, the most effective ways to
correct crazing are:
1. increase the silica, in body or glaze
2. decrease the feldspar, in body or glaze
3. decrease any other material containing sodium or potassium
4. increase the boron 5. increase the alumina, i.e., the clay content

1.3 Base Painting

• To correct the no water seal defects, it needs to be seal acrylic paint to a ceramic surface;
you need to heat cure the paint. Instead of letting it air dry, you want to bake the painted
piece, then seal the paint with a water-based polyurethane varnish, clear acrylic coat, or
modge podge. A kiln is the best option to make food-safe dishware.
• To correct the base paint through smudges and dirt, if the surface of the ceramic is glossy,
lightly sand the area with steel wool or very fine sandpaper. Then, apply 2 coats of primer
to the ceramic. Once the primer is dry, apply 2 coats of latex, epoxy, or acrylic paint to the
ceramic, sanding lightly over the dry paint in between coats.
• To correct the obvious patching in the base painting, wipe down the wall and apply a coat
of primer to the patched area and about a foot into the painted wall using a medium nap
roller. Once the primer has dried thoroughly, apply two coats of finished paint from the
same paint can used to paint the wall originally.

1.4 Hand Painting

• The corrective way of hand panting obvious retouch and in metal, when the ceramic
coating gets old or really worn, it gets easier to remove it from the surface using the mixture
of clay and iron dust remover. You can also use grinder polisher to buff and wax the
surface to completely remove the coating.
• The color variation in hand painting is need to transparent and adjustable when it needs
to be retouch. Matching colors, texture and sheen on a restored object has the longest
learning curve of repair and restoration process. The color and sheen match has to be
 perfect if it is expected to be seamless and invisible. To achieve good results, one must
take into account the fact that the color could change as it dries and could change again
once cold glaze is applied. The changes are sometimes making the color darker,
sometimes lighter and sometimes the hue is modified.
• To retouch and sanding in rough surface use small brush to paint in the areas that are
chipped. This paint is sort of a medium consistency, not as thick as an acrylic paint but
certainly not a super water/runny paint either. It covers better than you might think, but for
the white mugs had to use couple coats then let it the paints fully dry.
• To rework or level of the hand painting of the ceramics, the unstable or stability in most
instances, shivering can be corrected by additions of feldspar, frit or other high-expansion
materials to the glaze. If the problem persists, the solution is to adjust the clay body recipe
or change to another clay body altogether.

1.5 Packaging

• In packaging, the wrong placement of felt dot can be considered as defects since it needed
to change the position, the best choice is a box just big enough to fit the pot after it has
been wrapped in bio-peanuts. Use Bio-peanuts, these are void fill packaging made from
corn starch. They are totally bio-degradable and disintegrate if they come in contact with
water. Also use brown recycled paper to fill around the internal box and sometimes use
air pockets (can reused from parcels).
• The alternative packaging is to achieve the safety and security and avoid major
cracked/damage of the ceramics, identify fragile areas such as handles, spouts, lips, or
hand-built additions that require extra padding. Fold two 12-inch sections of bubble wrap
and use stretch wrap or blue painter’s tape to secure them over or around fragile sections.
• The biggest tip for the vast majority of the parcels uses two boxes. The pot will be snuggly
tucked up inside the first box. There should be ‘air’ in-between your first box and the
exterior box. This is the only way to ensure that if your package does get kicked around
the exterior box will take the impact and the pot will remain safe. The internal box should
be ‘levitating’ inside the exterior box - kept in place with void filling packaging. Always
give the parcel a good shake - if the inner box rattles around that is a recipe for disaster-
there should be no movement of the pot or the inner box. Always use a double-walled
cardboard for overseas or large shipments; single wall boxes are just not strong enough.
1.6 Final QC

As set out in the introduction, quality assurance of the supplied raw material requires a clear
agreement between supplier and producer, in which both define the methods or control
procedures to be used in verifying conformity to specified product (clay) requirements.
Documented procedures are required for such an agreement, which clearly set out the steps and
methodology to be followed.

• Basic control. The tests involved in this control are characterized by their speed (maximum
time 6 hours) and simplicity, and serve to initially verify raw materials conformity.
• Supplementary control. Generally, the tests involved in this more thorough type of control
are to be run on samples that do not pass the foregoing control, in order to verify non-
conformity. The tests may be more complicated and last considerably longer (over 24
hours).
• The clay supplier brings together clays from different mining operations and subjects
these to grinding and homogenization. Homogenization is carried out by stockpiling.
• The clay mining company verifies the quality of the raw materials to be supplied to the
producer, by running a basic control. These tests are conducted before or during
stockpiling.
• If the raw material meets the agreed requirements, the sampled lot can be mixed with
other lots to form the pile that will subsequently be supplied to the customer. Otherwise, a
supplementary control is required.
• If on running a supplementary control the sample is shown to comply, the sampled lot can
be added to the stockpile; otherwise, the material can only be added if mixing with other
lots reduces existing deviations. In an extreme case, the material shall be rejected
• Upon reception, the user shall run basic acceptance control. The tests to be performed
are identical to those carried out by the supplier.
• If the raw material meets the agreed requirements, homogenization takes place by the
usual stockpiling system, followed by incorporation into the production process; otherwise,
a supplementary control is to be run.
• Finally, if the lot sampled meets supplementary control requirements, it can be
incorporated into the production process after homogenizing; otherwise, the composition
formula needs to be modified or in an extreme case, the material shall be rejected.
 PROPOSED PREVENTIVE ACTION PLAN
Occupational health and safety impacts during the construction and decommissioning of
ceramic tile and sanitary ware manufacturing facilities are common to those of most industrial
facilities, and their prevention and control are discussed in the Ceramic Manufacture 1980’s
Production Process Guidelines. Occupational health and safety issues associated with the
operations phase of ceramic tile and sanitary ware manufacturing primarily include the following:

• Respiratory hazards
• Exposure to heat
• Exposure to noise / vibration
• Physical hazards
• Electrical hazards

1.1 Bisque Firing

• Make sure your pot is not watery or wet. Prior to bisque firing your clay, you won’t be
able to get rid of the chemically bonded water. This will only happen during bisque firing.
But it’s important that to get rid of as much of the mechanical water as you can.
• Don’t put greenware directly on the floor of your kiln. Instead, put a kiln shelf at the
bottom of the kiln, and place the shelf on very short props. This will allow air and heat to
circulate under the bottom shelf. And it will protect the delicate bricks on the floor from
your pottery.
• It’s okay for pieces of greenware to touch one another in a bisque fire. In fact, you
can stack greenware in a bisque fire. This is a good way of fitting more pottery into your
kiln as your bisque fire. If you do stack greenware, remember to put the heavier items on
the bottom.
• A good way of doing this is nesting smaller items inside larger ones. Make sure that
the weight of the smaller items is sitting on the base of the lower item. This avoids undue
pressure being applied to the rim of the item below.
• Some potters allow greenware pottery to touch the walls of the kiln. Personally, I
would avoid doing this, as I like to protect the walls as much as I can. It’s important
however to avoid pottery resting on or touching the elements. This can damage the
elements, and then your kiln won’t fire properly.
1.2 Gloss Firing

• Use lead-free glazes. If the glaze does not state "lead-free" or "leadless" on the label, assume
it contains lead until proven otherwise.
• Lead glazes should only be used on non-food ware items. Design lead-glazed pieces so
that they won't be used for food or drink. Lead-glazed pottery should be labeled as lead-
containing.
• If possible, don't use colorants that are known human carcinogens and avoid probable
human carcinogens. There is no known safe level of exposure to carcinogens.
• Consider wearing a respiratory when weighing and mixing powdered. Wet glazes are
not an inhalation hazard. Good housekeeping procedures and cleanup of spills reduce the
risk of inhalation or ingestion of toxic dusts.
• Wet mop spilled powders and gloves should be worn while handling wet or dry glazes.
• Good dilution ventilation or local exhaust ventilation should be available when applying
solvent-containing glazes.
• Basic personal hygiene rules should be followed including restricting eating, drinking, or
smoking in the studio, and wearing personal protective equipment such as gloves, and
separate work clothes or coveralls.
• Wash hands after work. Leftover glazes and glaze scrapings can be homogenized,
combined, tested, and used as a glaze.

1.3 Base Painting

• You should use several coats. You can also buy water-based polyurethane from a
hardware store, but make sure to get something that says it dries clear and non-yellowing.
This technique has been known to work quite well for sealing unglazed ceramics that have
been painted with acrylics; however, it is not guaranteed to last a lifetime.
• Acrylic paints are the best paints to use for painting pottery. Because the paint is oil-
based, it is incredibly flexible and may be utilized to paint almost whatever you can think
of. Many dry to a matte finish, while others dry to a glossy sheen or a satin finish. They
are highly tough and will not crack, chip, or fade. Aside from these ideal features, there
are a few more to be aware of.
• When painting ceramics using acrylic paint, seek paint that comes in a variety of
hues. You may use any color straight from the bottle, or one can mix hues to make new
 ones. When it relates to specialized paint for pottery, you could find a hue that is distinctive
to you and develops your own unique “signature” shade.

1.4 Hand Painting

• Practice your design on a ceramic tile before you start painting the plates. Use water
and dish washing liquid to wash finished plates but don’t use a scourer and don’t put them
in the dishwasher as this will take off the paint. Don’t allow your paintbrush to dry while
you are still using it; once the paint dries on it, you will not be able to get it off.
• Wipe the plate with a clean dry cloth to ensure there is no dirt or grease on the surface.
• Draw the outline of your pattern onto the ceramic using a pencil. Use tracing paper
if you do not want to draw freehand. Use stencils if you wish.
• Hold the outliner tube as if it was a pen and squeeze. Cover the pencil outline with the
outliner. Allow to dry for an hour.
• Squeeze a little ceramic paint onto a palette or similar surface and dip in your
paintbrush. Apply the paint onto the plate as desired.

1.5 Packaging

• The most defects in packaging results were in defects than the reject. Using right and
proper materials in packing the ceramic can appreciate of the customer product security.
Sorting and packaging may still be a manual operation, as in the case of some types of
clay bricks, roof tiles, and shaped refractory products.
• To prevent the damage of the packaging, demand rigorous inspection and sorting
followed by sophisticated protective packaging. By that the defects in sort of packaging
are lessen than before.
• Do not use bubble wrap or Styrofoam. The ceramic product will break inside the box
before the consumer can appreciate it. As a plastic product, it is not biodegradable, which
impacts the environment. It is not typically a branded material, which misses a chance to
personalize the shipping experience. Cutting and taping bubble wrap can be a time-
intensive process.
1.6 Final QC

• Resistance of ceramic tiles to chemical substances. Resistance of Ceramic Tile to

Chemical Substances Test is used for testing ceramic tiles that are to be used as food
preparation counters, bathrooms, flooring in residential and commercial buildings, where
tiles may become exposed to food, and chemicals. A solution of hydrochloric acid and
potassium hydroxide are the common testing liquids used for testing. Color difference
tests are used to determine which tile surfaces are affected by acids and alkalies.
• Breaking strength of ceramic tile. Breaking Strength of Ceramic Tile Test establishes
whether or not a ceramic tile, glazed ceramic wall tile, ceramic mosaic tile, quarry tile, or
paver tile meets the strength requirements as noted in the ceramic tile specifications. The
tile strength is measured by the force in pounds to cause the tile to break. The breaking
strength of ceramic tile test is measured by using a pressure gauge that reads force in
pounds.
• Relative resistance to deep abrasive wear of an unglazed ceramic tile. Relative
Resistance to Deep Abrasive Wear of an Unglazed Ceramic Tile measures the resistance
to deep abrasive wear of an unglazed ceramic tile specifically used for floor installations.
A rotating disk is used to perform the test by creating deep abrasive wear into the tile. This
method is used to measure the durability of an unglazed tile.
 Figure 1. Pareto Chart of Ceramic Manufacture Defect
RESULTS
Cumulative Cumulative
Types of Defects Total Defects Total Percentage
Frequency Percentage
First Firing 6147 6147 63% 63%
Gloss Firing 2460 8607 25% 89%
Base Painting 163 8770 2% 91%
Hand Painting 574 9344 6% 96%
Packaging 23 9367 0% 97%
Final QC 323 9690 3% 100%

The Pareto analysis states that 80% of a Ceramic Manufacture defect are achieved from
20% of the work—or conversely, 80% of problems can be traced to 20% of the causes. With
Pareto analysis, each problem or benefit is given a numerical score based on the level of impact
on the company; the higher the score, the greater its impact.

In these results, the largest source of defects is from Bisque Firing and Gloss Firing. The
chart shows 6,147 defects about bisque fiiring, which account for 63% of all the defects.
From a business strategy perspective, those two problems should be addressed first to
achieve maximum impact. Judging by the comments, we can assume that fixing the process
better would be the best course of action.
 Figure 1.1 Pareto Chart of Ceramic Manufacture Reject
RESULTS
Cumulative Cumulative
Types of Defects Total Reject Total Percentage
Frequency Percentage
First Firing 157 157 53% 53%
Gloss Firing 82 239 28% 80%
Base Painting 0 239 0% 80%
Hand Painting 8 247 3% 83%
Packaging 50 297 17% 100%
Final QC 0 297 0% 100%

The Pareto analysis states that 80% of a Ceramic Manufacture reject are achieved from
20% of the work—or conversely, 80% of problems can be traced to 20% of the causes. With
Pareto analysis, each problem or benefit is given a numerical score based on the level of impact
on the company; the higher the score, the greater its impact.

In these results, the largest source of reject is from First Firing and Gloss Firing. The chart
shows 157 rejects about first fiiring, which account for 53% of all the defects.
Figure 2. Histogram of Distribution Quantity Affected (DEFECT)

FREQUENCY VARIABLES

57 0-9

57 10-19

38 20-29

15 30-39

0 40-49

6 50-59

0 60-69

0 70-79

5 80-89

3 90-99

2 100-109

0 110-119

1 120-129

1 130-139

2 140-149

1 150-159

4 160-169

1 170-179
 0 180-189

0 190-199

1 200-209

1 210-219

1 220-229

1 230-239

1 240-249

0 250-259

0 260-269

2 270-279

2 280-289

1 290-299

0 300-309

1 310-319

0 320-329

0 330-339

0 340-349

1 350-359

0 360-369

0 370-379

1 380-389

Based on the pareto results, the highest frequency using a histogram graph is from either
First Firing and Gloss Firing defects. The bar line represents on how many the two occurred in
the defects which is 57. The third in line is the Base Painting.
From a business strategy perspective, those two problems should be addressed first to
achieve maximum impact. Judging by the comments, we can assume that fixing the process
better would be the best course of action.
 Figure 2.1 Histogram of Distribution Quantity Affected (REJECT)

FREQUENCY VARIABLES

140 0-9

3 10-19

1 20-29

0 30-39

1 40-49

0 50-59

1 60-69

0 70-79

1 80-89

Based on the pareto results, the highest frequency using a histogram graph is from either
First Firing and Gloss Firing reject. The bar line represents on how many the two occurred in the
defects which is 140. The third in line is the Base Painting.
From a business strategy perspective, those two problems should be addressed first to
achieve maximum impact. Judging by the comments, we can assume that fixing the process
better would be the best course of action.
 CERAMIC MANUFACTURE DEFECT CHECK SHEET
Dates (June 1-29, 2022)
Section Defect Types/Event Occurrence Total
Sun. Mon. Tues. Wed. Thurs. Fri. Sat.

First Firing Damaged body 0 0

First Firing Damaged body 0 0

Gloss
Firing Undersize on height (1.4cm) 0 0

First Firing Oversize height (1cm) 62 62

First Firing Oversize height (1cm-1.5cm) 44 44

First Firing Oblong 5 5

First Firing Oversize (1cm) 1 1

First Firing Undersize (1cm) 8 8

First Firing Paling butas 36 36

Hand
Painting Obvious retouch 6 6

First Firing Oversize height (1.5cm) 1 1

First Firing Undersize height (1cm) 3 3

Oversize height (1.5cm), shape
issue lower body, shape issue
First Firing shoulder 16 16

Final QC Damage 0 0

First Firing Oversize height (1cm) 85 85

Gloss
Firing Sharp Glaze 98 98
Gloss
Firing Sharp Glaze 42 42
Gloss
Firing Light shade with sharp glaze 21 21
Gloss
Firing Dark shade 26 26
Gloss
Firing Sharp glaze 41 41

First Firing Crack ang dugtungan 13 13

First Firing Halata yung dugtungan 64 64

First Firing Cracked body 15 15

First Firing Oversize height (2cm) 20 20

Gloss
Firing Sharp glaze 24 24
Gloss
Firing Light shade with sharp glaze 31 31
Gloss
Firing Sharp glaze and light shade 11 11
Gloss
Firing Excess glaze 386 386
Gloss
Firing Sharp glaze 43 43
Gloss
Firing Dark shade 45 45
Gloss
Firing Bubbles 102 102
Gloss
Firing Excess glaze 273 273
Gloss
Firing Incorrect design 14 14
Gloss
Firing Sharp glaze 30 30
Gloss
Firing Dark shade 58 58
Gloss
Firing Crack 4 4
Gloss
Firing Light shade with sharp glaze 43 43
Gloss
Firing Sharp glaze 9 9
Gloss
Firing Sharp glaze and light shade 27 27
Gloss
Firing Bottom crack 14 14
Gloss
Firing Chip off 11 11
Shape issue body, oversize
height (2cm), oversize body
First Firing (1.2cm) 18 18

First Firing Shape issue 10 10

First Firing Shape issue 10 10

First Firing Shape issue 10 10

First Firing Shape issue 10 10

First Firing Shape issue 10 10

First Firing Shape issue 10 10

First Firing Shape issue 10 10

Gloss
Firing Peel off glaze 0 0
Gloss
Firing Chip off 5 5
Gloss
Firing Crack 2 2
Gloss
Firing Dents body, off shape 0 0
Gloss
Firing Chip off 1 1
Gloss
Firing Dents off shape 0 0
Gloss
Firing Sharp glaze and light shade 70 70
Gloss
Firing Light shade 26 26
Gloss Bottom crack, light shade and
Firing sharp glaze 20 20
Gloss
Firing Bottom crack and light shade 9 9
Gloss
Firing Dark shade 8 8
Gloss
Firing Dents, off shape 0 0
Gloss
Firing Bottom crack 31 31
Gloss
Firing Sharp glaze and light shade 8 8
Gloss
Firing Dents off shape 14 14

First Firing Dents body 20 20

First Firing Cracked 1 1

First Firing Chipped off 5 5

First Firing Chipped off 2 2

First Firing Dents body 9 9

First Firing Off shape 5 5

Final QC Poor metal attachment 1 1

Packaging Wrong placement of felt dot 3 3

Shape issue, lower body, excess
First Firing clay 24 24
Excess clay, undetailed design,
First Firing shape issue 20 20

First Firing Excess clay, undetailed design 19 19

First Firing Cracked 1 1

First Firing Excess clay 23 23

Oversize height and body
(1.5cm), shape issue shoulder,
First Firing excess clay 5 5

First Firing Cracked, excess clay 1 1

Shape issue, design issue, lower
First Firing body 18 18

First Firing Cracked excess clay 7 7

Shape issue, design issue, lower
First Firing body 16 16
Hand
Painting Obvious patching 161 161
Gloss
Firing Light shade (Color variation) 17 17

First Firing Dents body 17 17

First Firing Crack Minor 10 10

Hindi rounded sa bottom at
First Firing mouth, design issue 71 71
Hindi rounded sa bottom at
First Firing mouth, design issue 97 97

First Firing Chipped off 236 236

First Firing Wave mouth 60 60

First Firing Black spot 28 28

First Firing Oblong 18 18

First Firing Crack 4 4

First Firing Damage 14 14

Gloss
Firing Bubbles 0 0
Gloss
Firing Major crack 0 0
Gloss
Firing Chip off 13 13
Gloss
Firing Chip off 19 19
Gloss
Firing Chip off 7 7
Gloss
Firing Crack 15 15
Gloss
Firing Chip off 17 17
Gloss
Firing Crack 8 8

First Firing Shape issue 279 279

First Firing Shape issue with Chipped off 137 137

First Firing Wave mouth 359 359

First Firing Shape issue 314 314

First Firing Chipped issue 15 15

First Firing Wave mouth 271 271

First Firing Oversize body (2cm) 25 25

Gloss Shape not conforms to the
Firing sample 0 0
Gloss Shape not conforms to the
Firing sample 0 0

First Firing Wrong hole, sharp bottom/ mouth 140 140

Gloss
Firing Deep design 26 26
Gloss
Firing Deep design 20 20
Gloss
Firing Unstable stability 17 17

First Firing Shape issue 286 286

First Firing Chipped off 15 15

Hand
Painting 2 Obvious retouch 42 42
Hand
Painting 2 Color variation 38 38
Oversize bottom (1.5cm),
oversize height (1cm), oversize
body (0.8cm), oversize bottom
First Firing (1cm) 240 240
Hand
Painting Dark color effect 27 27
Hand
Painting Obvious retouch 14 14
Hand
Painting Rough surface 12 12
Hand
Painting Obvious retouch metal 70 70
Hand
Painting Obvious retouch metal 52 52

First Firing Major cracked, oversize (2cm) 7 7

First Firing Chipped off, Oversize (2cm) 59 59

First Firing Makapal ang labi, Oversize (2cm) 57 57

First Firing Chipped off 153 153

First Firing Cracked 1 1

Damaged stem, crack body,
First Firing bottom crack 292 292

First Firing Makapal ang labi 54 54

First Firing Chipped off design 36 36

Hand
Painting 2 Unstable stability 43 43
Hand
Painting 2 Unstable stability 13 13
Hand
Painting 2 Unstable stability 10 10
Gloss
Firing Crack 18 18
Gloss
Firing Chip off 5 5
Gloss
Firing Reddish 5 5
Gloss
Firing Unstable stability 12 12
Gloss
Firing Oversize on height (1cm) 20 20
Gloss
Firing Oversize on body (1cm) 24 24
Gloss
Firing Oversize on body (1.5cm) 24 24
Gloss
Firing Oversize on body (1cm) 0
Gloss Dark shade and thin glaze
Firing application 19 19
Gloss
Firing Color not conforms to the sample 75 75

Base Paint No water seals 25 25

Base Paint Smudges and dirt 29 29

Base Paint Obvious patching 16 16

Incomplete water seal, hair brush
inside, excess water seal on
Base Paint mouth 80 80

Final QC Stability/ Unstable 176 176

Final QC Chipped off 23 23

Final QC Incomplete inside paint 14 14

Final QC Chipped off 26 26

Final QC Stability/ Unstable 83 83

Design not conform to the
sample/ mataba ang labi, oversize
body (0.5cm), oversize height
First Firing (0.5cm) 11 11
Oversize body (1.2cm), oversize
height (1.5cm), handle issue,
First Firing neck issue, overweigh t 1 kilo 12 12
Design not conform to the
sample, shape not conform to the
First Firing sample 11 11

First Firing Overweight (3/4kgs) 11 11

First Firing Neck issue 228 228

Gloss
Firing Wave mouth, maliit butas 200 200

First Firing Rough inside body, shape issue 11 11

First Firing Wave mouth 8 8

First Firing Yellowish 59 59

Oversize body (1.5cm), hindi flat
First Firing mouth 15 15
Oversize body (1.5cm), hindi flat
First Firing mouth 6 6
Damaged design, oversize height
First Firing (1cm) 160 160

First Firing Off shape 25 25

First Firing Dents body 18 18

First Firing Off shape 26 26

First Firing Dents body 20 20

First Firing Malalim ang design 26 26

Oversize body (1.5cm), Oversize
First Firing height (1.5cm) 30 30
Oversize bottom (1com), Oversize
First Firing height (1cm) 93 93

First Firing Hindi flat sa top 32 32

First Firing Shape issue inside 36 36

First Firing Paling 10 10

Malalim ang textured, wave
First Firing mouth 21 21
Malaliman g textured, wave
First Firing mouth 14 14

First Firing Oversize height (1.5cm) 47 47

First Firing Oversize height (1.5cm) 149 149

First Firing Makapal ang labi 31 31

Oversize height (2cm), Chipped
First Firing off, damage design 127 127
Shape inside not conform to the
First Firing sample 35 35

Base Paint Light shade (Color variation) 13 13

Gloss
Firing Bubbles 15 15
Gloss
Firing Crack on top 10 10

First Firing Unstable 100 100

First Firing Unstable 28 28

Hand Paint Dark Shade (Color variation) 86 86

Gloss
Firing Chipped off on body 33 33
Gloss
Firing Major crack 5 5
Gloss Peel off Glaze
Firing 2 2

First Firing Oversize height (1.5cm) 161 161

First Firing Makapal ang labi 19 19

First Firing Dents 26 26

First Firing Black spot 22 22

First Firing Off shape 8 8

First Firing Incomplete handle 4 4

First Firing Damaged/ Major cracked 0 0

Packaging Damaged/ Major cracked 0 0

Slanted/ Wobbly 0 0
Gloss
Firing Oversized on height 0 0
Gloss
Firing Dark shade and sharp glaze 165 165
Gloss
Firing Oversize height (1.5cm) 28 28
First Firing Chipped off design 288 288

Damaged (Major cracked) 0 0

Packaging Sharp Glaze 20 20

Gloss
Firing Sharp Glaze 20 20
Gloss
Firing Bubbles 14 14
Gloss
Firing Wobbly/ slanted 18 18
Gloss
Firing Oversized on height (1cm) 21 21
Gloss
Firing Wave mouth (Wobbly) 21 21

First Firing Oversize body (1cm) 6 6

First Firing Wave mouth (Wobbly) 8 8

First Firing Wave mouth (Wobbly) 14 14

First Firing Wave mouth 12 12

First Firing Wave mouth 30 30

First Firing Unstable wobbly (Paling) 60 60

First Firing Unstable wobbly (Paling) 20 20

First Firing Wobbly (Paling) 35 35

First Firing Rough body 80 80

First Firing Unstable wobbly (Paling) 22 22

Total 366 2265 2131 1563 0 1706 1659 9690

CERAMIC MANUFACTURE REJECT CHECK SHEET

Dates (June 1-29, 2022)
Section Defect Types/Event Occurrence Total
Sun. Mon. Tues. Wed. Thurs. Fri. Sat.

First Firing Damaged body 60 60

First Firing Damaged body 80 80

Gloss
Firing Undersize on height (1.4cm) 15 15

First Firing Oversize height (1cm) 0 0

First Firing Oversize height (1cm-1.5cm) 0 0

First Firing Oblong 0 0

First Firing Oversize (1cm) 0

First Firing Undersize (1cm) 0

First Firing Paling butas 0 0

Hand
Painting Obvious retouch 0 0

First Firing Oversize height (1.5cm) 0 0

First Firing Undersize height (1cm) 0

Oversize height (1.5cm), shape
issue lower body, shape issue
First Firing shoulder 0 0
Final QC Damage 0 0

First Firing Oversize height (1cm) 0 0

Gloss
Firing Sharp Glaze 0 0
Gloss
Firing Sharp Glaze 0 0
Gloss
Firing Light shade with sharp glaze 0
Gloss
Firing Dark shade 0 0
Gloss
Firing Sharp glaze 0

First Firing Crack ang dugtungan 0 0

First Firing Halata yung dugtungan 0

First Firing Cracked body 0 0

First Firing Oversize height (2cm) 0

Gloss
Firing Sharp glaze 0 0
Gloss
Firing Light shade with sharp glaze 0
Gloss
Firing Sharp glaze and light shade 0
Gloss
Firing Excess glaze 0 0
Gloss
Firing Sharp glaze 0 0
Gloss
Firing Dark shade 0
Gloss
Firing Bubbles 0 0
Gloss
Firing Excess glaze 0 0
Gloss
Firing Incorrect design 0
Gloss
Firing Sharp glaze 0 0
Gloss
Firing Dark shade 0
Gloss
Firing Crack 0
Gloss
Firing Light shade with sharp glaze 0 0
Gloss
Firing Sharp glaze 0
Gloss
Firing Sharp glaze and light shade 0
Gloss
Firing Bottom crack 0
Gloss
Firing Chip off 0
Shape issue body, oversize
height (2cm), oversize body
First Firing (1.2cm) 0 0

First Firing Shape issue 0 0

First Firing Shape issue 0 0

First Firing Shape issue 0 0

First Firing Shape issue 0 0

First Firing Shape issue 0 0

First Firing Shape issue 0 0

First Firing Shape issue 0 0

Gloss
Firing Peel off glaze 0 0
Gloss
Firing Chip off 0
Gloss
Firing Crack 0
Gloss
Firing Dents body, off shape 3 3
Gloss
Firing Chip off 0 0
Gloss
Firing Dents off shape 2 2
Gloss
Firing Sharp glaze and light shade 0 0
Gloss
Firing Light shade 0
Gloss Bottom crack, light shade and
Firing sharp glaze 0
Gloss
Firing Bottom crack and light shade 0
Gloss
Firing Dark shade 0
Gloss
Firing Dents, off shape 3 3
Gloss
Firing Bottom crack 0 0
Gloss
Firing Sharp glaze and light shade 0
Gloss
Firing Dents off shape 0

First Firing Dents body 0 0

First Firing Cracked 0 0

First Firing Chipped off 5 5

First Firing Chipped off 0 0

First Firing Dents body 0

First Firing Off shape 0

Final QC Poor metal attachment 0 0

Packaging Wrong placement of felt dot 0 0

Shape issue, lower body, excess
First Firing clay 0 0
Excess clay, undetailed design,
First Firing shape issue 0 0

First Firing Excess clay, undetailed design 0 0

First Firing Cracked 0 0

First Firing Excess clay 0

Oversize height and body
(1.5cm), shape issue shoulder,
First Firing excess clay 0 0

First Firing Cracked, excess clay 0 0

Shape issue, design issue, lower
First Firing body 0

First Firing Cracked excess clay 0 0

Shape issue, design issue, lower
First Firing body 0
Hand
Painting Obvious patching 0 0
Gloss
Firing Light shade (Color variation) 0 0

First Firing Dents body 0 0

First Firing Crack Minor 0 0

Hindi rounded sa bottom at
First Firing mouth, design issue 0 0
Hindi rounded sa bottom at
First Firing mouth, design issue 0 0

First Firing Chipped off 0 0

First Firing Wave mouth 0

First Firing Black spot 0

First Firing Oblong 0

First Firing Crack 0

First Firing Damage 0

Gloss
Firing Bubbles 10 10
Gloss
Firing Major crack 2 2
Gloss
Firing Chip off 0 0
Gloss
Firing Chip off 0 0
Gloss
Firing Chip off 0 0
Gloss
Firing Crack 0
Gloss
Firing Chip off 0 0
Gloss
Firing Crack 0

First Firing Shape issue 0 0

First Firing Shape issue with Chipped off 0 0

First Firing Wave mouth 0 0

First Firing Shape issue 0 0

First Firing Chipped issue 0

First Firing Wave mouth 0

First Firing Oversize body (2cm) 0

Gloss Shape not conforms to the
Firing sample 13 13
Gloss Shape not conforms to the
Firing sample 6 6

First Firing Wrong hole, sharp bottom/ mouth 0 0

Gloss
Firing Deep design 0 0
Gloss
Firing Deep design 0 0
Gloss
Firing Unstable stability 0 0

First Firing Shape issue 0 0

First Firing Chipped off 0 0

Hand
Painting 2 Obvious retouch 0 0
Hand
Painting 2 Color variation 0 0
Oversize bottom (1.5cm),
oversize height (1cm), oversize
body (0.8cm), oversize bottom
First Firing (1cm) 0
Hand
Painting Dark color effect 0 0
Hand
Painting Obvious retouch 0
Hand
Painting Rough surface 0
Hand
Painting Obvious retouch metal 0 0
Hand
Painting Obvious retouch metal 8 8

First Firing Major cracked, oversize (2cm) 0 0

First Firing Chipped off, Oversize (2cm) 0

Makapal ang labi, Oversize
First Firing (2cm) 0

First Firing Chipped off 0 0

First Firing Cracked 0 0

Damaged stem, crack body,
First Firing bottom crack 0 0

First Firing Makapal ang labi 0 0

First Firing Chipped off design 0 0

Hand
Painting 2 Unstable stability 0 0
Hand
Painting 2 Unstable stability 0 0
Hand
Painting 2 Unstable stability 0 0
Gloss
Firing Crack 0 0
Gloss
Firing Chip off 0 0
Gloss
Firing Reddish 0 0
Gloss
Firing Unstable stability 0 0
Gloss
Firing Oversize on height (1cm) 0 0
Gloss
Firing Oversize on body (1cm) 0 0
Gloss
Firing Oversize on body (1.5cm) 0 0
Gloss
Firing Oversize on body (1cm) 21 21
Gloss Dark shade and thin glaze
Firing application 0 0
Gloss
Firing Color not conforms to the sample 0 0

Base Paint No water seals 0 0

Base Paint Smudges and dirt 0

Base Paint Obvious patching 0

Incomplete water seal, hair brush
inside, excess water seal on
Base Paint mouth 0 0

Final QC Stability/ Unstable 0 0

Final QC Chipped off 0

Final QC Incomplete inside paint 0 0

Final QC Chipped off 0

Final QC Stability/ Unstable 0

Design not conform to the
sample/ mataba ang labi,
oversize body (0.5cm), oversize
First Firing height (0.5cm) 0 0
Oversize body (1.2cm), oversize
height (1.5cm), handle issue,
First Firing neck issue, overweigh t 1 kilo 0 0
Design not conform to the
sample, shape not conform to the
First Firing sample 0 0

First Firing Overweight (3/4kgs) 0 0

First Firing Neck issue 0 0

Gloss
Firing Wave mouth, maliit butas 0 0

First Firing Rough inside body, shape issue 0 0

First Firing Wave mouth 0 0

First Firing Yellowish 0 0

Oversize body (1.5cm), hindi flat
First Firing mouth 0 0
Oversize body (1.5cm), hindi flat
First Firing mouth 0 0
Damaged design, oversize height
First Firing (1cm) 0 0

First Firing Off shape 0 0

First Firing Dents body 0

First Firing Off shape 0 0

First Firing Dents body 0

First Firing Malalim ang design 0 0

Oversize body (1.5cm), Oversize
First Firing height (1.5cm) 0 0
Oversize bottom (1com),
First Firing Oversize height (1cm) 0 0

First Firing Hindi flat sa top 0 0

First Firing Shape issue inside 0 0

First Firing Paling 0 0

Malalim ang textured, wave
First Firing mouth 0 0
Malaliman g textured, wave
First Firing mouth 0 0

First Firing Oversize height (1.5cm) 0 0

First Firing Oversize height (1.5cm) 0 0

First Firing Makapal ang labi 0

Oversize height (2cm), Chipped
First Firing off, damage design 0
Shape inside not conform to the
First Firing sample 0 0

Base Paint Light shade (Color variation) 0 0

Gloss
Firing Bubbles 0 0
Gloss
Firing Crack on top 0 0

First Firing Unstable 0 0

First Firing Unstable 0 0

Hand Paint Dark Shade (Color variation) 0 0

Gloss
Firing Chipped off on body 0 0
Gloss
Firing Major crack 0
Gloss Peel off Glaze
Firing 0

First Firing Oversize height (1.5cm) 0 0

First Firing Makapal ang labi 0

First Firing Dents 0 0

First Firing Black spot 0

First Firing Off shape 0

First Firing Incomplete handle 0

First Firing Damaged/ Major cracked 2 2

Packaging Damaged/ Major cracked 1 1

Packaging Slanted/ Wobbly 49 49

Gloss
Firing Oversized on height 7 7
Gloss
Firing Dark shade and sharp glaze 0 0
Gloss
Firing Oversize height (1.5cm) 0 0

First Firing Chipped off design 0 0

First Firing Damaged (Major cracked) 2 2

Packaging Sharp Glaze 0 0

Gloss
Firing Sharp Glaze 0 0
Gloss
Firing Bubbles 0 0
Gloss
Firing Wobbly/ slanted 0 0
Gloss
Firing Oversized on height (1cm) 0
Gloss
Firing Wave mouth (Wobbly) 0 0

First Firing Oversize body (1cm) 0 0

First Firing Wave mouth (Wobbly) 8 8

First Firing Wave mouth (Wobbly) 0 0

First Firing Wave mouth 0 0

First Firing Wave mouth 0 0

First Firing Unstable wobbly (Paling) 0 0

First Firing Unstable wobbly (Paling) 0 0

First Firing Wobbly (Paling) 0 0

First Firing Rough body 0 0

First Firing Unstable wobbly (Paling) 0

Total 3 61 36 155 0 21 21 297

 NARRATIVE REPORT

Quality control or inspection is one of the recurring topics among Industrial community.
“Quality control” is a common phrase in the engineering world, but the public may not know exactly
what it means. Quality control (QC) not only ensures that quality products make it to the market,
it also protects consumers. As Carmagen Engineering, Inc. puts it, “[quality control] is a periodic
sampling of a contractor’s or vendor’s engineering performance during the course of a job.”
Quality control begins shortly after a contract is accepted, and it often continues even past the
product’s rollout. Emulation of human decision in classification is what inspection is all about.

Our OJT/SIP Coordinators gave us an IE-OJT activity that focus on “Quality Assessment
and Analysis.” A ceramic manufacturer in Pampanga has twelve (12) processes used in
operation. The company has started since 1980’s despite of that it still experiencing quality
issues/problems. In this activity, I needed to proposed an action plan that will assess for quality
inspection of a ceramic manufacture. The action plan is intended to reduce the defects and reject
due to a quality control tools. As a future Industrial Engineering, I provided my three (3) chosen
graphs/charts that will greatly help the company to assure the quality control which is first, the
Pareto Chart, Histogram, and Check Sheet. I am tasked to do a proposed corrective and
preventive action plan that can help the company minimize or eliminate quality problems.

I formulate and generate my ideas by benchmarking in the internet that helps me to do

the right and accurate analyzation. A day with Tuesday, I familiarizing the Lesson by watching
YouTube or reading learning materials that related to the QC’s. The attached data I need in
assessing and analysis of quality issues that was experiencing is available. By testing my skills
and knowledge about the said tasks, I challenge myself to do a trial-and-error to execute the
needed skills to my quality assessment. The following day, I started to visualize what am I really
doing and learn to understand the activity by identifying the work and task to be assessed and
start properly the assessment. At first glance of this activity, I felt drained and unmotivated by
looking the bombarded information that am I looking because of the numerical data.

To gain some important information that will help me to move forward to the activity and
do more of its content, my classmate and I talked about what can be ideas or concept that will
probably lessen the time that consuming by doing the hard activity. Since I'm an IE student, it’s a
habit or natural to eliminate or lessen the process that can slow the activity. After that I finally
filling the gap of my input graphs since I made a long way of process making it. I also asked my
relationship partner on what can he say about this activity. When I am unfamiliar to do a certain
task, I rushed to him right away since I know what he is capable of thinking especially in
brainstorming an excellent idea.

On the last 2 days of activity, at last I almost completed my three (3) graphs by being
patience and understanding it result my dedication an excellent performance by testing my skills
to the activity. As usual as a student, the double checking of the numerical data information is
always with me. Since I'm proposing a solution to the company that will probably benefit the both
of us. By the said information, I finalizing the observed data and starting to analyzing the results.
While transferring the complete data, there is suddenly a file corrupted warning on my done
graphs analysis. I was confused and frustrated a lot since it happened on the middle of the night
that I will sleep right away when I am done. The disadvantage of the poor online connection and
poor performance computer had me lost trusting myself to do it again. While doing it, I’m happy
while talking in my group chat that I'm almost done nevertheless it’s gone that smile on my face.
I tried to back up my file yet there is no chance to retrieved it since I ask my partner that he
suggested I should scratch from the start. And yet, I pushed myself to do it again while I wishing
to achieve my desired output.

July 22, 2022 (Friday) was the last day of guide schedule of the activity. The heavens
heard my feelings because I exceed my corrupted output and it was a great outcome. By finalizing
the written report of the quality assessment, I finally saw the whole picture of the problems of the
company by completing the analysis using the effective and efficient quality control tools. By that
I started summarizing my findings to the quality results and analyzing the needed solution. I listed
the enumerate the needed proposal corrective action plan by understanding the results of the
Pareto Chart. The highest total defects were in the Bisque Firing which is total of 6147 defects. I
focused on first the BF by offering a detailed quality solutions since it was one of the important
processes on the production of ceramic manufacture.

At the following process, I provided a corrective plan based on the defects description
since most of it is under the types of defects. While the preventive action plan is more detailed by
bolding the process that needed to prevent or avoid. I added the Occupational Health and Safety
since it impacts during the construction and decommissioning of ceramic tile and sanitary ware
manufacturing facilities are common to those of most industrial facilities, and their prevention and
control are discussed in the Ceramic Manufacture 1980’s Production Process Guidelines.
Occupational health and safety issues associated with the operations phase of ceramic tile and
sanitary ware manufacturing primarily include the following: Respiratory hazards, Exposure to
heat, Exposure to noise / vibration, Physical hazards, Electrical hazards.

As future Industrial Engineer, it plays an important role in the quality management

transformation. The course work of the IE teaches me in several engineering techniques that are
essential in implementing the quality management philosophy. One such technique is statistical
process control. In most cases, it is the IE who is responsible for developing, maintaining and
interpreting the control charts. I must be able to identify special causes of variation in a process
and remove them. It is my job to maintain control of a process.

The quality control is important in ceramic productions since it helps to minimize the issues
and can easily identified and corrected the big picture. Therefore, quality control with regard to
the composition of the ceramic material is a challenge for each manufacturer. It is necessary to
prepare ceramic materials quickly and reproducibly in order to carry out representative and
reliable quality checks. This narrative report has sought to provide an overview of the current
situation and the future prospects for instrumentation and control in the ceramic tile manufacturing
process. Therefore, I should like to thank all the staff that have participated directly or indirectly in
this work, as well as the companies and public bodies whose economic support has made it
possible for mere ideas to become useful products for the ceramic tile manufacturers.