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  • Working together reduces rejection rates

    Introduction

    Slovakia-based bathroom products manufacturer, Festap, was experiencing rejection rates of up to 15% on its bath tub production line. By providing superior steels with outstanding deep drawing properties, better suited to the enamelling process, Tata Steel reduced this to just 0.1%.

    Detailed Information

    Summary

    Summary

    • A specialised approach, a specific solution

      Tata Steel’s expertise in a wide range of sectors led to exactly the right solution, generating working capital savings, higher yield and greater efficiencies for the customer.

    • We put our ideas to the test

      Festap conducted extensive trialling to determine the most appropriate material, comparing Tata Steel product performance against other suppliers’ steels.

    • Working together, we found a solution

      Close cooperation with the customer gave Tata Steel a deeper understanding of the processes involved and where the problem lay.

    • Festap wanted to avoid serious production defects

      The company faced unacceptably high rejection rates for the steel bath tubs it produced.

    Tata Steel is the best supplier we’ve worked with and is now our partner of choice. We could not afford to pay less for the quality.

    Martin Moravcik, General Director, Festap


    Introduction
    Based in Slovakia, Festap is a leading European manufacturer of bath tubs and shower trays to the European and Russian market. Currently, the company produces approximately 180,000 units per annum, with bath tubs accounting for 90% of its output.

     

    Challenge

    Despite having perfected a unique process to achieve a high quality enamel coating, Festap was encountering major problems in the manufacturing process. Up to 15% of the company’s bath tubs were having serious defects from pressing, yet the precise cause was unknown.

     

    Solution

    Tata Steel identified that the problem lay with the steel being used. After extensive trials, the team was able to supply Festap with materials that were much more suited to its manufacturing processes. These were Ymvit® 04 Plus (European standard DC04EK), and Ymvit® Extra 06 (European standard DC06ED).

    Challenge

    Challenge

    Unique process requires unique solution

    Festap prides itself on being at the cutting edge of technology, and has developed a unique process to achieve a high quality enamel coating. However, in 2014 the company was experiencing a serious issue.

     

    Between 10% and 15% of its enamelled steel bath tubs were splitting during the manufacturing process. This meant that for every 100t of bath tubs to be sold, Festap needed to produce 130t-140t to account for rejections. Unsurprisingly for a company so focused on quality, this was an unacceptably high level of failures.

     

    Making the grade

    Festap was using enamelling grade steel, but for applications such as the production of bath tubs, the steel also has to have excellent deep drawing properties and be able to withstand nine different processes during production:

     

    1. Steel is pressed in three stages - deep drawing the tub; cutting and bending the edges; cutting the hole
    2. Cleaning (alkylic degreasing, 90°C)
    3. Rinsing
    4. Pickling (4% H2SO4, 70°C)
    5. Rinsing warm and cold
    6. Ground coat one step electrostatic powder spraying (thickness 30-50mu)
    7. Frit four steps electrostatic powder spraying (thickness 200mu)
    8. Firing - the steel is heated to 840°C; a process is based on 2C1F
    9. Final inspection before packaging.

     

    Working closely with Festap to analyse the problem thoroughly, Tata Steel was quickly able to gain an understanding of the company’s specific needs and the difficulties it was facing.

     

    To determine the right solution for this project, Tata Steel took advantage of its wide ranging expertise in all sectors where advanced steels are essential to complement Festap’s reputation for technology and innovation.

    Solution

    Solution

    Delivering the right solution

    Thanks to close collaboration with the technical team at Festap and in-depth assessment of all the different requirements involved at each stage of production, Tata Steel was able to determine the most suitable steels for the enamelling process.

     

    One very important requirement was for the steel surface to be less reactive, to prevent the material from oxidising when the frit is applied. A ‘frit’ is a ceramic composition fused in a special oven and quenched to form a glass, which is then granulated. Frits play a key role in enamelling, and for good adhesion it is essential that the frit is correctly matched to the steel.

     

    Trials of recommended materials begain in September 2014. The process was supervised by Tata Steel’s engineering experts, who were able to provide Festap with knowledge and advice based on over 20 years’ experience.

     

    The two Tata Steel products trialled were Ymvit® 04 Plus (European standard DC04EK) and Ymvit®Extra 06 (European standard DC06ED). These products have a titanium alloy which gives the material deep drawing properties – a critical requirement for bath tub manufacture.

     

    These were trialled against a number of materials from other European steel producers, and emerged as stronger and superior. After pressing with the Tata Steel products, Festap found that the rejection rate had dropped dramatically – to less than 0.1%.

     

    This was a very significant reduction of the 10%-15% rejection rate that Festap had been experiencing previously – and was hailed as a highly successful outcome.

     

    A winning formula

    By switching to the Ymvit®product, Festap’s manufacturing process now achieves a much higher yield, bringing the company far greater efficiencies and savings on working capital. 

     

    The Ymvit®steel is manufactured at Tata Steel’s cold rolling mill in Ijmuiden and supplied in coil form to Festap’s plant in Fiľakovo, Slovakia. The dimensions supplied are 1200 x 1400mm, in a thickness of 2.0mm and 1.4-1.5mm for very deep drawing.

     

    Tata Steel now supplies 100% of the steel used by Festap for bath tubs, with current delivery volumes of 400-500 tonnes per month.

    Gallery

    Gallery

    Summary

    • A specialised approach, a specific solution

      Tata Steel’s expertise in a wide range of sectors led to exactly the right solution, generating working capital savings, higher yield and greater efficiencies for the customer.

    • We put our ideas to the test

      Festap conducted extensive trialling to determine the most appropriate material, comparing Tata Steel product performance against other suppliers’ steels.

    • Working together, we found a solution

      Close cooperation with the customer gave Tata Steel a deeper understanding of the processes involved and where the problem lay.

    • Festap wanted to avoid serious production defects

      The company faced unacceptably high rejection rates for the steel bath tubs it produced.

    Tata Steel is the best supplier we’ve worked with and is now our partner of choice. We could not afford to pay less for the quality.

    Martin Moravcik, General Director, Festap


    Introduction
    Based in Slovakia, Festap is a leading European manufacturer of bath tubs and shower trays to the European and Russian market. Currently, the company produces approximately 180,000 units per annum, with bath tubs accounting for 90% of its output.

     

    Challenge

    Despite having perfected a unique process to achieve a high quality enamel coating, Festap was encountering major problems in the manufacturing process. Up to 15% of the company’s bath tubs were having serious defects from pressing, yet the precise cause was unknown.

     

    Solution

    Tata Steel identified that the problem lay with the steel being used. After extensive trials, the team was able to supply Festap with materials that were much more suited to its manufacturing processes. These were Ymvit® 04 Plus (European standard DC04EK), and Ymvit® Extra 06 (European standard DC06ED).

    Challenge

    Unique process requires unique solution

    Festap prides itself on being at the cutting edge of technology, and has developed a unique process to achieve a high quality enamel coating. However, in 2014 the company was experiencing a serious issue.

     

    Between 10% and 15% of its enamelled steel bath tubs were splitting during the manufacturing process. This meant that for every 100t of bath tubs to be sold, Festap needed to produce 130t-140t to account for rejections. Unsurprisingly for a company so focused on quality, this was an unacceptably high level of failures.

     

    Making the grade

    Festap was using enamelling grade steel, but for applications such as the production of bath tubs, the steel also has to have excellent deep drawing properties and be able to withstand nine different processes during production:

     

    1. Steel is pressed in three stages - deep drawing the tub; cutting and bending the edges; cutting the hole
    2. Cleaning (alkylic degreasing, 90°C)
    3. Rinsing
    4. Pickling (4% H2SO4, 70°C)
    5. Rinsing warm and cold
    6. Ground coat one step electrostatic powder spraying (thickness 30-50mu)
    7. Frit four steps electrostatic powder spraying (thickness 200mu)
    8. Firing - the steel is heated to 840°C; a process is based on 2C1F
    9. Final inspection before packaging.

     

    Working closely with Festap to analyse the problem thoroughly, Tata Steel was quickly able to gain an understanding of the company’s specific needs and the difficulties it was facing.

     

    To determine the right solution for this project, Tata Steel took advantage of its wide ranging expertise in all sectors where advanced steels are essential to complement Festap’s reputation for technology and innovation.

    Solution

    Delivering the right solution

    Thanks to close collaboration with the technical team at Festap and in-depth assessment of all the different requirements involved at each stage of production, Tata Steel was able to determine the most suitable steels for the enamelling process.

     

    One very important requirement was for the steel surface to be less reactive, to prevent the material from oxidising when the frit is applied. A ‘frit’ is a ceramic composition fused in a special oven and quenched to form a glass, which is then granulated. Frits play a key role in enamelling, and for good adhesion it is essential that the frit is correctly matched to the steel.

     

    Trials of recommended materials begain in September 2014. The process was supervised by Tata Steel’s engineering experts, who were able to provide Festap with knowledge and advice based on over 20 years’ experience.

     

    The two Tata Steel products trialled were Ymvit® 04 Plus (European standard DC04EK) and Ymvit®Extra 06 (European standard DC06ED). These products have a titanium alloy which gives the material deep drawing properties – a critical requirement for bath tub manufacture.

     

    These were trialled against a number of materials from other European steel producers, and emerged as stronger and superior. After pressing with the Tata Steel products, Festap found that the rejection rate had dropped dramatically – to less than 0.1%.

     

    This was a very significant reduction of the 10%-15% rejection rate that Festap had been experiencing previously – and was hailed as a highly successful outcome.

     

    A winning formula

    By switching to the Ymvit®product, Festap’s manufacturing process now achieves a much higher yield, bringing the company far greater efficiencies and savings on working capital. 

     

    The Ymvit®steel is manufactured at Tata Steel’s cold rolling mill in Ijmuiden and supplied in coil form to Festap’s plant in Fiľakovo, Slovakia. The dimensions supplied are 1200 x 1400mm, in a thickness of 2.0mm and 1.4-1.5mm for very deep drawing.

     

    Tata Steel now supplies 100% of the steel used by Festap for bath tubs, with current delivery volumes of 400-500 tonnes per month.

    Gallery

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