A sanitaryware audit checks three things: that the plant really makes what it sells, that its process can make your models to your standard, and that it controls quality from casting to packing. Walk the whole line, from slip preparation to the loading bay.
The general method for any factory audit is in our guide on what a factory audit should contain. This article covers what is specific to sanitaryware.
Is it really a factory?
Some sellers in Morbi and Thangadh are traders who buy from several plants. Check that the company name on the documents matches the plant, and that the production you see includes your models. Our guide on telling a trader from a manufacturer lists the signs.
Casting and moulds
- Check whether the plant uses bench casting in plaster moulds, pressure casting in resin moulds, or both.
- Ask how many moulds it has for each of your models, and how often moulds are replaced.
- Look at casting thickness and how pieces are handled when wet.
- See whether moulds for your models are in use, or only shown for the visit.
Drying, glazing and firing
- Look at the drying area and how pieces are supported to avoid warpage.
- Check whether glazing is done by robot or by hand, and how glaze thickness is controlled.
- See the kiln type, such as tunnel or shuttle, and ask for firing records.
- Ask what share of pieces is refired and how refired pieces are marked.
Testing
A serious sanitaryware plant has a flush test rig and runs routine water absorption tests. Ask to see a flush test on one of your models, and ask for the test log. Check that third-party test reports name your models and the standard your market uses. Our guide on how sanitaryware is tested lists the main tests.
Grading and packing
- See how fired pieces are inspected and graded, and where rejects and seconds go.
- Check that seconds are kept apart from export stock.
- Look at carton quality, inserts and how fittings are packed.
- Ask how the plant traces a piece back to its casting date and kiln run.
Capacity and workload
Ask how many pieces the plant fires per day, and how much of that capacity is already booked. A plant that is full may push your order back or hand part of it to another factory. Compare the number of moulds, casting benches and kiln cars you see with the output it claims.
Also look at working conditions and housekeeping. A clean, organised casting shop and a tidy glaze line usually go with better control of defects. Many export buyers also need basic labour and safety checks for their own customers.
Documents to collect
- GST registration and Importer Exporter Code in the plant's name.
- Quality certificates, such as ISO 9001, and product test reports for your models.
- A list of export markets and sample shipping documents, with buyer names removed.
- The parts list and suppliers for fittings on each model.
Next step
We audit sanitaryware factories in Morbi and Thangadh against your models and market, and report what we find. To arrange one, book a free sourcing review.