Sanitary ware production control software
Sepia software is a production tracking system for sanitary ware industrials. The fully integrated technology allows for the complete monitoring and tracking of the production using barcodes. Clients have found that significant loss reduction can be achieved by installation of Sepia system. This system allowing new clients to begin their production tracking at a basic level, which can be added to as more data is required. In its simplest form, barcodes are applied and scanned after casting and the pieces are then scanned again on final inspection. Defects identified can be attributed to the individual item and referenced with the casting process. A touch screen is commonly used at this point and the position of the defect can also be assigned to each piece.
It is important to gather as much information about the production process in order to identify the causes of the faults.
At the casting stage all the moulds are identified with their own barcode which is scanned together with the barcode applied to the piece.
Operators will have their own unique ID or barcode which will be entered into the system at the start of the day.
For additional production information, scanning systems can be incorporated at each stage of the process such as drying,
spray glazing, firing (kiln & position) and reprocessing.
The tracking system can be further extended into packaging, labelling, warehousing and dispatch.
Sanitary ceramic production control software is a smart, industry-leading system that fully automates the
production process of products like toilets, washbasins, tiles, and shower trays.
first barcode-based production automation system, it uses fire-resistant barcodes and
professional barcode scanners to track and record data at every stage—from casting to packaging.
With over 20 monitoring stations, full customization, and integration with financial and CRM systems,
this software boosts production efficiency by up to 30%,
reduces waste and losses by up to 10%, and aligns product quality with global standards like ISO 13006 and ISIRI 25.
How Does the Software Work with Barcode Scanners?
The software integrates barcode scanners and fire-resistant barcodes to deliver a seamless, error-free tracking system:
Fire-Resistant Barcode Application:
Ceramic barcodes, made with fire-resistant inks (based on ceramic pigments), are applied during the casting stage.
These barcodes maintain quality in high-temperature kilns .
Scanning at Each Stage:
Barcode scanners at various stations (casting, glazing, firing, quality control, and packaging)
capture product details like identification codes, production time, and status.
Data Storage and Analysis: The software stores scanned data and generates real-time reports on efficiency, waste, and inventory.
Management Dashboard Integration: Managers can monitor production line status online via the software’s dashboard and make quick decisions.
This system eliminates human errors and ensures complete transparency in the production process.
Software Data Registration Stations
The production control software records data through various stations, divided into two categories:
Production Stations:
Include master mold-making, mold-making, casting, drying,
glazing, finishing, kiln loading, waste, grading, quality
control, and weighing.
These stations cover core production processes,
recording data on raw materials, molds, and product quality.
Post-Kiln Stations:
Include refiring, decoration, warehouse entry,
packaged products, and material consumption formulas.
These stations track final stages like decoration, packaging,
and inventory management.
Each station uses fire-resistant barcode scanning to transmit accurate data to the software, enabling real-time monitoring and error reduction.
Key Features of the Software
This software elevates sanitary ceramic production with advanced features:
First Barcode Automation System: Pioneers automated tracking with fire-resistant barcodes.
Easy Use Without Advanced Knowledge: Simple interface for operators with minimal computer skills.
User-Friendly Environment: Visual menus for quick training and high productivity.
Full Customization: Tailored to each factory’s needs (stations, reports, and processes).
One-Year Warranty: Ensures flawless performance with a full warranty.
Custom Reports: Ability to add new reports during after-sales service.
Online Data Display: Online dashboard for real-time production data access.
Online and Offline Logging: Stores data in both modes for uninterrupted operation.
Managerial Charts: Displays data as charts for analysis and decision-making.
Delivered Barcode Tracking: Tracks dedicated barcodes for each department (e.g., glazing or warehousing).
Role Management: Adds or removes organizational roles for flexibility.
Data Export: Outputs to Excel or formats compatible with financial and CRM systems.
Benefits of the Software for Production
This software offers the following competitive benefits for sanitary ceramic factories:
Waste Reduction (5-10%):
Precise tracking of defective units reduces waste during stages like glazing or firing.
Improved Worker Precision:
Encourages delivery of high-quality products with accurate grading, enhancing product value.
Casting Loss Reduction (5-10%):
Tracks molds and products from casting to kiln, minimizing losses.
Accurate Incentive Payments:
Calculates worker bonuses based on actual intact product output.
Defective Mold Detection:
Waste reports identify faulty molds quickly.
Prevention of Manual Misreporting:
Eliminates inaccurate manual reports via barcode tracking.
Customer Issue Tracking:
Integrates with CRM for complaint tracking and improved service.
Overall Efficiency Boost:
Cuts production time by up to 30% with automated monitoring at production and post-kiln stations.
Eco-Friendly:
Reduces raw material and energy consumption with optimized processes.
Transparency and Quick Decision-Making:
Real-time data access for better production line management.
Applications in the Sanitary Ceramic Industry
The software is applicable at every stage of sanitary ceramic production and designed for various factories:
Casting and Mold-Making:
Records raw material and mold data via barcode scanning at master mold-making and casting stations.
Quality Control and Grading:
Detects defects and grades products at quality control and weighing stations.
Export:
Provides standardized reports for international clients, such as European and Middle Eastern markets.
Inventory and Packaging Management:
Tracks inventory and packaged products at warehouse entry and packaging stations.
Glazing and Firing:
Monitors glaze quality and kiln temperature with fire-resistant barcodes at glazing and kiln-loading stations.
Large and Small Factories:
Suitable for brands like Chini Kurd, Golsar, Morvarid, and smaller workshops.
Complementary Technologies of the Software
The software enhances efficiency with the following technologies:
Internet : Connects barcode scanners to a network for online monitoring and automatic alerts.
Artificial Intelligence (AI): Analyzes data to predict defects and optimize processes.
Mobile App: Provides managers with report and dashboard access via smartphones.
ERP and CRM Integration: Coordinates with financial and customer management systems for improved service.
These technologies transform the software into a complete solution for production automation.
Frequently Asked Questions
What barcodes does the software work with?
Ceramic fire-resistant barcodes that withstand high temperatures, ideal for sanitary ceramic production.
Is reporting possible with the system?
Yes, real-time and detailed reports on efficiency, waste, and inventory are provided as charts and files.
Can it connect to financial systems?
Yes, integrates with financial and CRM systems via Excel or any required file format.
How many operators are needed?
For casting, one per 10-15 lines; glazing, one per 1-5 cabins; kiln loading, one; grading, one device per sorter.
How does it reduce waste?
Precise tracking of missing units reduces inaccurate reporting by staff.
How is data recorded?
Online and offline via barcode scanners; after initial entry, all steps are automated via barcode scanning.
What tools are needed for setup?
A server and barcode scanners are sufficient for implementation.
What happens if a barcode is damaged?
A new barcode is issued and replaces the previous one in the system.
Is it suitable for small factories?
Yes, the software is customizable for both large and small factories, offering high flexibility.
Why Choose Our Software?
Our software is the top choice for sanitary ceramic factories because:
Leading Technology:
First barcode automation system with fire-resistant barcodes.
Full Customization:
Tailored to each factory’s processes.
24/7 Support:
Professional team for training and ongoing troubleshooting.
Fast ROI:
Reduces waste and boosts efficiency within 6 months.
Transform your sanitary ceramic production with our smart software!
Contact us on WhatsApp For a free consultation, software demo, or purchase.
applications
This software used in the sanitary ware factories to production process monitoring.
description
This software work whit heatproof barcode label. you can used it whit English and persian language.