Chongqing ERA continued to promote excellence improvement projects around the YES excellence system, and pursued continuous improvement based on the principle of "cost reduction and efficiency increase, safety and quality first".
The improvement team is the workshops of the Production Department and the Warehousing Department. From January to July 2022, there are 324 improvement cases, involving seven types of safety, cost, site and efficiency. At the same time, the improvement effect is graded, including 33 Class A cases, 23 Class B cases, 220 Class C cases and 48 Class D cases. The annual amount of improvement effect is about 750000 yuan
1.PE corrugated pipe automatic framing project
Promotion background:
Focusing on production automation and tight personnel balance, improve the working efficiency of front-line employees, achieve the standard man machine ratioФ Optimization of corrugated pipe production process below 400.
Promotion achievements:
The efficiency is increased by 100%, and the human-machine ratio is increased from 1:1 to 1:2; The labor cost saved by 8 sets of equipment is 540000 yuan.
2.Improvement of Mechanical and Manual Fixture Proportioning
Promotion background:
The manipulator is used singly, the product proportion is insufficient, and the utilization rate is not high.
Promotion achievements:
The utilization rate of equipment is improved, and the proportion of equipment and products reaches 1:6.
3.PE bellows flaring material saving project
Promotion background:
Reduce the crushing ratio of corrugated pipe and improve the first pass rate without affecting the process design of product equipment
Promotion achievements:
The cumulative joint weight of single product decreased by 1.84%. For each ton of finished products produced, 15.5 yuan of processing cost will be saved.
4.PE-RT coil packaging structure optimization project
Promotion background:
On the premise of meeting the customer's product appearance needs, we will make structural adjustments to the packaging materials, optimize the staff's operating procedures, and achieve a win-win situation of cost saving and efficiency improvement.
Promotion achievements:
The PE woven film is widened, the wrapping material PE-RT winding film is canceled, and the cost per ton of packaging material is reduced by 22 yuan/ton.
5.Improvement of automatic rubber cutting of pipe products
Promotion background:
Low degree of automation, low operation efficiency and high cost.
Promotion achievements:
The labor intensity of employees was reduced. After 71 sets of equipment were fully opened, 42 people were saved, and the monthly cost was 2.52 million yuan.
6.Improvement project of hollow wall winding pipe flaring
Promotion background:
The appearance of the injection flaring joint of the hollow wall winding pipe is abnormal, and the service performance is unqualified.
Promotion achievements:
The one-time qualification rate of flaring injection molding of hollow wall winding pipe is 100%
7.Isolation of defective electrical bushing with abnormal vacuum
Promotion background:
The abnormal vacuum alarm (perforation, reducer) during the electrical casing process shall be eliminated.
Promotion achievements:
Reduce the risk of outflow of defective products, improve quality control, and reduce manual detection of incomplete defects.
8.Meter weight control digital project
Promotion background:
The meter weight recording process is complex, and the weighing data is distorted, which makes it impossible to monitor the saving rate of meter weight in real time.
Promotion achievements:
Automatic collection of weighing data, real-time monitoring of rice weight saving dynamics; Digital management workshop mode import.