Introduction: The Strategic Value of Yield Metrics
For Sanitaryware manufacturers, yield metrics are far more than mere statistics; they function as Key Performance Indicators (KPIs) that reflect the health of the entire Manufacturing Process. By accurately tracking these 7 core Yields, companies can pinpoint efficiency bottlenecks, elevate Quality Control, and ultimately ensure the sustainability and profitability of their Production Process.
In practical calculation, it is often assumed that Work In Progress (WIP) inventory levels remain constant to simplify the analysis of process efficiency. However, experienced operational teams must recognize that WIP levels can fluctuate due to changes in production planning, demand variability, and various operational factors.
Phase I: Casting and Drying Yields (Green Body Quality)
Metrics in this phase measure Green Body quality and Forming Process efficiency from Slip input up to pre-Glazing.
1. Casting Yield
Definition & Function: This serves as the benchmark for measuring the quality and efficiency of the Slip Casting Forming Process and the Casting Department. It focuses on evaluating the stability of the Molds and the Slip Formulation during High-Pressure Casting or Battery Casting.
Calculation Formula:
Casting pass rate = (Number of qualified parts sent to the dryer / Total number of castings) * 100
2. Green Body Yield
Definition & Function: Green Body Yield is the Quality Inspection of the Green Body conducted after the Drying stage and before Glazing. It primarily reflects the condition of the Dryer, control over the Green Body Handling process, and the accuracy of the Fettling operation.
Calculation Formula:
Green blank yield = (Number of qualified pieces sent to the glazing process / Total number of pieces received from the casting department) * 100
Phase II: Glazing Yield (Glazing Quality)
This metric specifically targets the efficiency of the Glazing stage and Glaze quality control.
3. Glazing Green Yield
Definition & Function: Glazing Green Yield measures the efficiency of the Spray Glazing or Dipping operation and the adherence stability of the Glaze Formulation on the Green Body. It is assessed post-Glazing and pre-Kiln loading, aiming to eliminate Defects like Pinhole, Cracking, or uneven Glaze Thickness.
Calculation Formula:
Glazed green body yield = (Number of qualified pieces sent to the kiln / Total number of pieces that have completed glazing) * 100
Phase III: Firing Yields (Firing Performance)
This is the most critical stage, assessing the impact of Kiln operations on Body Vitrification and Glaze quality.
4. First Fire Yield
Definition & Function: Measures the passing rate of the First Fire stage (e.g., Bisque Firing). It reflects the effects of the Firing Curve, Kiln Furniture setup, and the Oxidizing Atmosphere or Reducing Atmosphere on the Green Body.
5. Second Fire Yield
Definition & Function: Measures the passing rate of the Second Fire stage (e.g., Glaze Firing). It focuses on controlling Glaze Defects such as Crazing and Blister.
6. Overall Firing Yield
Definition & Function: Overall Firing Yield is a composite metric for the comprehensive efficiency of all Kiln operations. By comparing the number of final passed Fired products against the total Kiln load, it evaluates the cumulative impact of the Firing process on product Warpage and overall Color Variation (Shading).
Calculation Formula:
Overall firing yield = (Number of passable pieces after all firing stages / Total number of pieces loaded into the kiln) * 100
Phase IV: Ultimate Manufacturing Effectiveness
7. Global Yield
Definition & Function: Global Yield is the ultimate comprehensive metric for assessing the Overall Efficiency and Cost-Effectiveness of the entire Sanitaryware Manufacturing Process. It reflects the cumulative impact of all stages, from Slip input to final Packaging and placement in the warehouse.
Calculation Formula:
Overall yield = (Total number of passable pieces sent to the warehouse / Total number of pieces at the start of the casting process) * 100
Conclusion: Driving Continuous Improvement Through Data
In summary, metrics like Casting Yield, Green Body Yield, Glazing Green Yield, Firing Yields, and Global Yield collectively provide a comprehensive overview of Manufacturing Efficiency at every stage. Sanitaryware manufacturers must ensure the sustainability and overall profitability of their operations by continuously monitoring these metrics and performing targeted Troubleshooting to address identified deviations.