TROUBLE SHOOTING CHART - BODY DEFECTS

S.NO TYPE OF DEFECT CAUSES REMEDY

1 Pin Hole 1. Leakage in slip supplying pump which may allow 1. Ensure all pumps supplying slip are functioning correctly. Also
air inside the pipeline. circulation of slip before casting starts.
2. Slip specifications & ageing time. 2. Specs should be maintained & should be aged for 96 hrs.
3. Sieves for fresh, scrap & return slip are not cleaned 3. Cleaning of those should be regular & cross checked.
properly.
4. Fast filling of the mould. 4. Monitoring the filling time of the mould.
5. Sticking of small sponge fragments in the body. 5. Good quality sponge should be used.
6. Filling time of the Ark. 6. Checking of the Ark which is giving more pin hole.
7. Presence of other particles in slip while filling. 7. Nylon mesh to be used at the mouth of slip pipe.
8. Presence of unwanted elements in return slip. 8. Proper sieving of return slip.
9. Design of stirrer. 9. Changing the design of the stirrer.
10. Excess mica in clay. 10. Constituents of the clays should be checked.
11. Mould condition. 11. The life / wet&dry condition & dust accumulation of the moulds
12. Blunging time should be checked.
13. High concentration of soluble salt. 12. Sufficient blunging time should be given.
14. Chocking of supply slip line. 13. Low cocn. Of soluble salt should be maintained.
14. Regular cleaning of supply slip line is required.
2 Bad Finish 1. Quality of moulds 1. Mould parts should fit properly. Surface of moulds, quality of POP
2. Improper sponging. & mixing should be good.
3. Improper mould filling. 2. Proper sponging in Casting/Glazing areas.
4. Finishing water (muddy). 3. Casters should be guided on the proper way of filling.
5. Thick glaze. 4. Finishing water should be changed frequently in Casting/Glazing.
5. Glaze coat should not be thick.
3 Clay Dirt 1. Falling of punched clay on the surface. 1. Removal of punched clays from the greenware.
2. Type of punch 2. Punch design should be improved to follow the above.
3. Blowing & sponging not proper. 3. Proper blowing & sponging before spraying.
4. Stocking of extra glazed pieces for long. 4. Extra glazed pieces should be covered.
5. Finishing water. 5. Changing of water frequently in Casting/Glazing.
6. Scrapping of excess glaze with blade. 6. Wet sponging should be done instead of scrapping.
4 Pores 1. Improper mould fitting. 1. Proper mould fitting.
2. Quality of moulds 2. Good quality of moulds should be used (no pit).
3. Dry finishing. 3. Wet finishing should be done instead of dry finishing.
5 Foreign Body 1. Mould filling without mesh. 1. Use of nylon mesh during filling.
2. Loose particles from atmospheric air & roof. 2. Cover the pieces after releasing /repairing the roof.
3. Rusted pipe line. 3. Rusted pipe line should be removed.
6 Sagging 1. Wet condition of the moulds. 1. Casting should be avoided on wet moulds.
 2. Design of moulds. 2. Correction of mould design.
3. Kiln car top level. 3. Kiln car top should be flat.
4. Green strenght of the body. 4. Body comp. Should be proper.
5. Early release of cast pieces. 5. Avoid early releasing of pieces.
6. Drying system not good. 6. Better drying system should be provided.
7 Bubble 1. Quality of raw materials. 1.Proper testing of raw materials needed.
2. Kiln temperature. 2. Avoid temp. fluctuation.
8 Bursting 1. Wet pieces are sprayed & loaded. 1. Avoid wet pieces carry over/spraying & loading.
2. Generation of air pocket during filling. 2. Carefull mould filling.
9 Shattering

10 Seam Mark 1. Mould joint impressions are not removed while 1. It should be finished at the Casting & Glazing area.
finishing.
11 Spangling

12 Green Spot

13 Not Well Attended

14 Cracks

a. Rim crack 1. Early releasing 1. Avoid early releasing.

2. Jerk on greenware trolley 2. Good condition of flooring & trolleys.
3. Bad handling of pieces. 3. Handling the pieces with care.
4. Wet condition of the mould. 4. Proper mould drying.
5. Glazed pieces kept in trolleys for long time. 5. Stocking of glazed wares should be avoided.
6. Properties of slip. 6. Maintaining specs properly.
b. Panel crack 1. Less thickness of the cast pieces. 1. Thickness should be proper.
2. Pcs kept on floor. 2. Avoid keeping in the floor.
3. Air entrapped during slip run-off. 3. Run-off should be done carefully.
4. Design of the mould. 4. Correction in the moulds.
5. Improper drying of the greenwares & moulds. 5. Proper drying.
6. Improper loading. 6. Loading should be done carefully.
c. Punch crack 1. Bad condition of the punch. 1. Correction in the punch.
2. Punched while the piece is either very soft or hard. 2. It should be avoided.
d. Bowl crack 1. Early releasing. 1. Avoid early releasing.
2. Mishandling during loading. 2. Take care at the time of loading.
e. Outlet crack 1. Early releasing of the plug or punch cutting 1. Release only after proper drying, taking consideration of weather
2. Mishandling during spraying &loading. slip & mould condition.
2. People should be trained properly
f. Bracket crack 1. Mould design. 1. Punch mark should be on proper place.
2. Punched while the piece is either too soft or hard. 2. It should be avoided.
g. Inlet crack 1. Early or improper release of the plug. 1. Plug should be removed only when the piece is properly dried & it

h. Mould crack 1. Faulty design of the mould.
2. Early release of the cast pieces.
3. Sticking with the kiln car.
i. Fire crack 1. Too dry mould.
2. Early release of the cast pieces.
should be done carefully.
1. Correction in the design of mould.
2. Avoid early releasing.
3. Application of setter wash properly.
1. Proper application of slurry water.
2. Avoid early releasing.
 TROUBLE SHOOTING CHART - GLAZE DEFECTS

S.NO TYPE OF DEFECT CAUSES

1 Thin Glaze 1. Lack of sprayer skill.

2. Improper maintenance of glaze specs.
3. Compressed air pressure fluctuations.

2 Crawling 1. Poor sponging of wares.

2. Glaze quality & parameters
3. Over spraying.

3 Glaze Removal 1. Removal of excess glaze by blade.

2. Loading of wares without gap.

4 Groove Crawling 1. Dust or talc accumulation on the groove area.

5 Colour Mix 1. Handling of two colours by same person.

2. Using same setter for more than one colour
6 Bad Logo 1. Improper application of logo.
2. Moisture on the stickers.
3. Quality of stickers.
7 Glaze Waviness 1. Pressure variation at the time of spray.
2. Uneven coating over the wares.
8 Glaze Pin Hole 1. Too violent/fast spraying.
2. Too long an interval between successive coats
3. Excessive fine grinding of the glaze.
9 Without Logo 1. Non application & improper checking of glazed
wares.
10 Glaze Specks 1. Iron content in glaze.

11 Glaze Sundry

12 White Spot 1. Inadequate dispersion of the opacifier.

13 Matt Glaze 1. If the glaze layer is too thin to cover the normal
surface of the body.
2. Temperature & firing time too low for the glaze
 to mature.
14 Badge Mark 1.Due to improper stamping badge mark appears
at the glazed protion.
 REMEDY

1. Patternwise, locationwise, colourwise analysis to be made. Feedback &

training to be given.
2. Glaze parameters to be maintained as per weather & colour.
3. Air pressure to be maintained more than 5 kg/cm 2. Accordingly arrangements
to be made, so fluctuations also avoided.
1. Wares to be cleaned properly & water to be changed in a frequent interval.
Glaze to be applied in grooved areas (EWCs & AIPs).
2. Good quality CMC (binders) to be used & parameters to be maintained as per
requirement.
3. More glaze thickness also causes crawling, which is to be avoided.
1. Glazing setting to be cleaned often. Wet sponging to be done to finish the
wares.
2. Wares loaded without gap to be avoided.
1. Water to be poured & groove area to be cleaned. If required glaze can also
be applied by brush in that area.
1. Hands to be cleaned before changing over to another colour.
2. Setter to be cleaned before changing the colour.
1. Stickers to be wet properly before application.
2. Stickers to be dried before taking for application.
3. Quality of stickers should be good.
1. Pressure regulators to be adjusted at Gun & Pot.
2. Locationwise, patternwise feedback & training to be given to the frontliners.
1. Spraying should be done in normal speed.
2. Interval between two coats should not be long.
3. Fine grinding to be avoided.
1. Wares to be checked at stamping, loading & pushing area.

1. Glaze to be sieved through magnets.

2. All air lines to be cleaned periodically.
3. Filters to be provided on air line.

1. Glaze to be milled properly.

1. Parameters of the glaze to be maintained properly.

2. Adequate maturing time & temperature to be given to the wares.

1. Stamping should be proper.