Root Cause Analysis and Production Process Control of Brick Product Quality Problems

Root Cause Analysis and Production Process Control of Brick Product Quality Problems

Problems such as cracking, chipping, and insufficient strength in finished bricks are often not caused by a single factor. Learning to trace back from the finished product to the production process to identify the root cause and establishing effective control points is key to stable quality.

Rapid Root Cause Analysis of Common Quality Problems

When problems are found in bricks, the following clues can be used for investigation:

Insufficient Brick Strength, Brittleness

Primary suspicion: raw materials and proportions: Check whether raw materials such as sand and fly ash are clean, and whether the soil content or impurities exceed the standard. Verify whether the proportion of cementing materials such as cement is accurate and whether there is dampness or clumping.

Secondly, check the molding pressure: Does the brick making machine's pressure reach the set value? Is the mold worn, leading to insufficient compaction?

Finally, confirm the curing process: Is the curing time sufficient? Do the temperature and humidity of the curing environment meet the requirements (especially whether early watering and moisturizing are adequate)?

Brick Cracking (Cracks or Fractures)

Rapid drying is the main reason: After the brick blanks are formed, are they exposed to direct sunlight or placed in a windy area, causing the surface moisture to evaporate too quickly, resulting in uneven shrinkage and cracking?

Check the demolding process: Is the operation too rough during demolding? Are the robotic arm or pallet stable, causing internal damage to the brick blanks?

Check the raw materials: Are there too many or too large particles in the raw materials, forming stress points internally?

Inaccurate Brick Dimensions, Chipping and Corner Damage

Core check: the mold: Is the mold severely worn, leading to larger dimensions or corner defects? Is the inner wall of the mold clean? Is there any material sticking to the mold, causing damage to the brick blanks?

Check the material feeding process: Is the raw material evenly and sufficiently filled into the mold? Are there any "material shortage" areas?

Confirm the operating procedure: During demolding and initial handling (when the brick blanks have the lowest strength), are there any collisions due to improper operation?

Key Control Points in the Production Process

To systematically reduce problems, several "checkpoints" must be maintained in the production process:

Raw Material Entry Checkpoint: Establish simple acceptance standards, and conduct visual inspection and simple tests (such as feel and impurity observation) on each batch of incoming raw materials such as sand and gravel to ensure stable raw materials.

Batching and Mixing Checkpoint: This is the "heart" of quality. The raw materials must be weighed and mixed strictly according to the verified proportions, ensuring sufficient mixing time to allow the raw materials and water to mix evenly. Any change in the proportions or moisture content will inevitably lead to quality fluctuations.

Molding pressure control: Regularly inspect and record the main pressure value of the brick-making machine to ensure stable pressure. Insufficient pressure results in weak bricks, while excessive pressure can cause hidden cracks.

Curing environment control: Move the newly formed, most fragile brick blanks to a curing area protected from sunlight and wind, and regularly sprinkle water to maintain moisture according to procedures. This is a crucial step in ensuring strength development and preventing cracking.

Mold and equipment condition control: Manage the molds as critical wear parts, regularly checking their wear and cleanliness. At the same time, keep the conveyor pallets flat and ensure the handling equipment operates smoothly.

In summary, the core approach to solving brick quality problems is to immediately identify the corresponding production stage when a defect is observed in the finished product. By controlling the four core aspects of "raw materials, proportions, molding, and curing," and maintaining daily records, quality problems can be transformed from "post-production remediation" to "pre-production prevention," enabling the continuous and stable production of high-quality bricks.