Planning (PCP) and buying
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1. Receive orders and plan production |
The PCP sector receives the customer's order and plans the month's production. |
2. Calculate the amount of raw materials required |
The PCP sector, based on monthly production and customer orders, calculates the raw materials to be purchased. |
3. Request raw materials in the Purchasing system |
The order for raw materials is made by the PCP through the company's system for the purchasing sector. |
4. Present and analyze supplier prices |
The purchasing department receives the order from the PCP and sends it to the supplier for pricing. |
5. Formalize the purchase order |
Formalize the purchase order, with quotations and approvals, and send it to the supplier. |
Producing
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6. Receive orders |
Inspect the raw material received. |
7. Check invoice and material |
The person responsible for each sector checks the invoice and the material received. |
8. Store material |
After verification, the raw material is stored. |
9. Load the tractor with material |
The first step in production is to load the tractor (loader) with the basic raw material, which is dough. |
10. Weigh material |
The tractor loaded with the MP takes it from storage to the scale machine, where the MP is weighed. |
11. Grind material |
After weighing, the MP is transported to the mill, where the mass is ground, generating the so-called ceramic slip. |
12. Dry ceramics using the Atomizer |
The ceramic slip is taken to the atomizer, which, through drying, generates atomized powder. |
13. Pressing Atomized Powder |
The atomized powder is taken to pressing, forming the "bisque", the pressing forms the ceramic. |
14. Dry ceramics |
For the ceramic to gain more resistance, it is taken by conveyor belts to the second dryer. |
15. Glaze ceramics |
After leaving the dryer, the ceramic is glazed, gaining a smooth, crystalline coating and engobe is applied, which is a layer of clay that allows the color to change. |
16. Print on ceramics |
The ceramics enter the HD machine and digital printing on the piece is carried out, this activity is the only one that differentiates the products of this export. |
17. Burn bisque |
After digital printing, the ceramic is taken to the industrial oven, in which the "Bisque firing" generates the last step to form the piece. |
18. Classify ceramics |
The ceramics are taken to the surface, monitoring and classifying the products. |
19. Print the barcode |
When leaving the surface, the barcode is printed on the side of the part, this is an exclusive requirement for the export process to the USA. |
20. Calibrate ceramics |
Each ceramic is measured and separated according to the measurements. |
Packing
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21. Group the pieces |
After calibration, the packaging machines group 14 ceramics into a single box. |
22. Packing boxes on the palletizer |
The pallet machine receives the boxes from the packaging machine and packs them automatically. |
23. Control Quality |
The quality inspector visually analyzes the quality of ceramics, packaging, and pallets. |
24. Store Product |
Once the pallet is properly loaded, it is taken to storage using forklifts. |
Shipping
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25. Plan Storage |
This activity precedes the previous one, the warehouseman and the forklift operator, depending on the day's production, plan how and where the pallets will be stored. |
26. Issue documents |
The shipper is responsible for preparing the proforma, separating each proforma by shipment, and making it using different colored papers. |
27. Sort pallets |
Depending on the day's load, the pallet load is separated for wrapping. |
28. Wrap pallets |
Each pallet is taken to a wrapping machine, where the operator wraps the pallet with insulation paper to protect the load. |
29. Load truck |
With the pallet wrapped, the forklift operator takes the load to the truck, and the truck is loaded. |
30. Check the loaded batch and issue the invoice |
With the truck properly loaded, the logistics assistant carries out the first check of invoices, packing lists, and proformas. |