Establishing a new sanitaryware plant is a complex undertaking, and robust Planning Documentation is foundational to ensuring both financial viability and operational efficiency. This documentation must provide a comprehensive roadmap, covering every element from raw material selection to the final calculation of Production Cost.
A thorough document should be organized into the following four strategic phases, designed to support streamlined Production and minimize the occurrence of Defects.
I. Manufacturing Process and Core Material Formulation
This section serves as the technical bedrock for product quality and process stability by standardizing all input elements.
Raw Material Specifications:
Body Raw Materials: Detailed list of all Raw Materials for the Slip (e.g., Kaolin, Ball Clay), complete with clear Technical Specifications to guide supplier selection.
Glaze Raw Materials: Specifications for all materials required for the Glaze Slurry(e.g., frits, colorants).
Mold Raw Materials: Explicit requirements for Plaster and other materials necessary for the fabrication of Plaster Molds and tooling.
Core Formulation: Documentation of the initial Slip and Glaze Formulation for initial Production Cost analysis and quality assurance.
Quality Control (QC) Laboratory Setup: Listing of all Laboratory Equipment required for testing the quality of incoming Raw Materials, assessing Slip Rheological properties, and verifying final product performance (e.g., Water Absorption, MOR) post-Firing.
II. Capacity Planning and Major Equipment Configuration
This phase translates the Target Production Capacity into precise machinery requirements for every critical factory department.
Capacity Back Calculation: Back Calculation of the required Processing Capacity for all departments (Slip preparation, Casting, Glazing, Firing) based on the target daily output and required Cycle Time.
Slurry Preparation Machinery: A complete list of all equipment for Slip and Glaze Slurry preparation (e.g., Ball Mills, agitators), sized based on capacity, with a plan for Redundancy to mitigate Equipment Breakdown.
Forming and Glazing Equipment:
Casting Unit: Specification of the types of Casting Machines (e.g., High-Pressure) and Casting Tools required.
Glazing Unit: Details of necessary Spray Guns, tanks, and other tools for the Glazing application.
Drying and Firing Infrastructure: Determining the appropriate Dryer type and the Specification of the Kiln (e.g., Tunnel Kiln or Shuttle Kiln), aligned with the calculated capacity.
Utility and Maintenance Machinery: Specification of utility equipment essential for operation, such as the Compressor, generator, and other Maintenance Machinery.
III. Operational Budget and Financial Forecast
This critical section converts the technical plan into a financial feasibility analysis, leading directly to the projected Production Cost per Kilogram.
Equipment Investment Cost: Aggregating the total Investment Cost for all machinery and equipment purchases.
Manpower Resource Budget: Detailed listing of Manpower requirements for each department and the associated Salary Estimate, forming the basis of the Labor Cost calculation.
Inventory and Logistics Budget:
Raw Material Inventory: Estimation of the initial Raw Material stock required to maintain continuous Production.
Equipment Weight and Shipping Cost: Recording the total weight of all equipment to accurately estimate Shipping Cost.
Utility Consumption Estimates:
Fuel Consumption: Estimation of Gas Consumption required for the Kiln Firing process.
Water Requirements: Calculation of the total water volume needed for the entire Production process.
Cost Accounting Model: Establishing a detailed Calculation Model for the Production Cost per Kilogram, integrating all input data for the final Financial Assessment.
IV. Factory Layout and Project Execution Plan
This final section addresses the physical structure of the facility and the timeline for project delivery.
Space and Layout Requirements:
Space Requirement: Detailed minimum floor area required for all departments (Casting Shop, Drying, Glazing, etc.), and the total factory footprint.
Factory Layout: Schematic drawings including department placement, floor elevation, and required height clearances.
Warehouse Planning: Defining the necessary Warehouse Space for Raw Materials, Green Body, finished goods, and packaging.
Project Erection Plan: A detailed, Stage-wise timeline for the factory Erection, covering procurement, installation, and commissioning phases.
Packaging Material Specification:Defining the Specification of the Packaging Materials required for the final product dispatch.