The Ceramics Industry's Quality Challenge
In ceramics manufacturing, you fire a batch of tiles or sanitaryware into the kiln, and what comes out isn't always what went in. Some tiles come out as premium Grade A, others as Grade B, and some as seconds or rejects. Your production plan may target 10,000 square meters of premium tiles, but the kiln gives you a mix of grades.
This creates a unique business challenge: you're essentially producing multiple products (different grades) from a single production process. Your Grade A tiles sell at premium prices, Grade B at a discount, and seconds go to a clearance outlet. Without tracking this grade split per batch, you can't optimize your kiln parameters to maximize premium output.
ReoBiz tracks production from raw material mixing to kiln firing to grade sorting. You see the grade split per kiln load, identify which clay body formulations produce the best results, and monitor breakage rates to catch kiln issues early.
Grade Split Unpredictability
A kiln load that should produce 80% Grade A might yield only 60% due to temperature variations, clay inconsistencies, or glaze issues. Without batch-level grade tracking, you can't diagnose the root cause.
Breakage & Reject Rates
Ceramics are fragile at every stage - production, storage, and transport. Breakage rates of 3-5% are normal, but without tracking where breakage occurs, you can't reduce it. Kiln breakage, handling breakage, and transport breakage need separate monitoring.
Complex Inventory by Size, Color, Grade
Tiles are stocked by size (300x300, 600x600), pattern, color shade, and grade. A customer needs 200 sqm of a specific tile in the same shade batch. Without precise inventory by these attributes, shade mismatches cause returns.
Kiln Energy Optimization
Kilns consume enormous amounts of energy (gas or electricity). Running them at less than full capacity wastes fuel. Without load planning and energy monitoring, you're burning money on every under-loaded firing.