Technological innovation reduces costs and improves quality and efficiency to promote development

Technological innovation reduces costs and improves quality and efficiency to promote development

-the new material workshop technological innovation sees practical results

The world's macro economy is changing rapidly, especially the continuation of the financial crisis in recent years has brought new shocks to the global economy. The global economy has already weakened, and signs of a second dip are obvious. Therefore, various industries including our company have encountered great pressure and difficulties. The worse the market is, the more fierce and cruel industry and industry competition is. How to maintain strength, reduce negative impacts, and find a place in the cracks is a problem that we urgently need to deal with and solve now.

The overall market situation is sluggish, and the national economic control policies are unclear. It is not advisable to sit still or invest blindly. Only starting from the reform of production technology and management, reducing costs, improving product quality, and protecting the interests of employees, in order to find new growth points to deal with difficulties, and seek progress while maintaining stability. Technological reform and innovation, as the eternal subject of all enterprises, is the key to development, a breakthrough, and also one of the biggest difficulties. The new material workshop started some explorations and found a way to take technological transformation and promote development.

The company has been in development for more than 40 years. No matter the overall scale, employee treatment, management and technical level, there have been earth-shaking changes. This fully reflects the hard work, forge ahead, and never let up spirit of the generations of employees. The new material workshop is a relatively young production unit of the company with relatively advanced hardware facilities. It was officially put into production in May 2002. In order to speed up the reform of the technology industry and the improvement of product structure to adapt to the development and changes of the industry, the company's senior management through preliminary inspections, fundraising, and reasonable planning and implementation, efficiently and quickly built the initial new material workshop. As a result of seizing market opportunities, it achieved profitability in the first year, highlighting the far-reaching foresight and extraordinary courage and wisdom of the company's senior management.

After 10 years of continuous expansion and transformation, 566 looms have been formed in the new material workshop, with an annual production capacity of nearly 30 million meters of glass fiber cloth, and the output value has exceeded that of the weaving workshop. The supporting processes such as warping, drawing-in and cloth inspection are complete, and the development form is good. The new material workshop has been expanded step by step, matured and improved, which has played a strong role in promoting the healthy, stable and rapid development of the company. As a pillar-type production unit, how to play a greater role to increase efficiency and reduce burdens for the company and continue to promote technological reform and innovation is necessary and necessary. According to the investigation, the two major technological transformation projects and several small projects that have been completed and are being implemented in the new material workshop so far this year have been effective in production and operation, and have been recognized by the company’s leaders and widely praised by the employees.

One is the technological transformation project of the rapier loom weft shear system. Since the original system consists of 38 parts, the structure is too complicated, and there are many units in series, any failure of any unit will cause the entire system to lose function, poor reliability, low use value, and high maintenance costs. In the case of very tight staff in the workshop, how to improve the reliability of the system and ensure the efficient operation of the equipment has become an urgent issue facing the workshop leaders. Under the condition of fully considering the comprehensive factors such as efficiency, cost, environment and labor intensity, a preliminary plan for technological transformation of the system was determined. In December of last year, the workshop designed and manually processed two sets of new weft shear systems for experiments, simplified the original system unit composition to four, and then processed 40 sets out for further testing. After two months of trial operation, the new system worked stably, and the failure rate, failure rate, mean time between failures and reliability were greatly improved. The machine operation and product quality information feedback was good, and the workshop formally reported to the company’s technical department for technical reform declaration , Ready to enter the practical stage. Once the approval is over, the processing and production of accessories will begin immediately in March, and the original rapier loom mixing box, scissors box and other weft shear systems will be dismantled from April to June, and new art blade cutting devices will be installed and commissioned. The time is tight and the workload is large. In addition to the spare time for the installation of large-scale machine repairs and maintenance workers in the workshop, they also use Saturday and Sunday to work overtime to keep up with the progress. Due to the common problems in the quality of the processed parts, the accessories must be processed again during the installation process to ensure that they are foolproof in use, and the difficulty and intensity of the work continue to increase. With the sincere cooperation and united efforts of workshop leaders and relevant technical personnel, all 436 weft shear systems were replaced on schedule in June. According to current estimates, the system is expected to save material costs per quarter (80 yuan per pair of weft shears and 220 yuan per pair of scissor box combination) from the cost control alone of the system, and more than 20,000 yuan per weft, and the weft can be reduced by 3.5 cm per weft. It can reduce the waste of weft by 72 tons per year, worth about 640,000 yuan. The current weft cutting system adopts an art blade cutting device, which is simple in structure and small in area. It not only greatly reduces the labor intensity of mechanics and car operators, improves labor productivity, but also effectively reduces safety risks. After several months of observation, the new weft shearing device is operating stably and reliably, and the product quality has been further improved. Now it has been put into production normally, and the expected results have been achieved.

The second is a safe and energy-saving control system for rapier looms. Zhao Dejiang, an electrical equipment officer in the new material workshop, served as the main person in charge for the implementation of this work. According to the technical reform budget and actual effect evaluation, 500 sets of safety and energy-saving devices have been processed and manufactured. It is understood that the device is a technical result of independent intellectual property rights designed by the workshop electrician after a long period of research and self-design. The project officially mass-produced printed circuit boards in March this year, and completed the assembly, welding and installation of electronic components. More than 300 units have been installed so far, and it is expected that all looms will be fully covered in October. Due to the particularity of its operation, the project can only be installed by three professional electricians in the workshop, and the task load is quite large. From the project book, we see that the main function of the safety and energy-saving device is to automatically control the operation of the equipment. When the weft break or warp break waiting for the loom exceeds the set time, the motor automatically stops running, and other operation buttons are automatically blocked. Only when the button is re-inched can it be turned on normally, which avoids personal injury caused by employees during production. The security risk is greatly reduced. Due to the timing control of the motor, the production energy consumption is reduced at the same time. It is estimated that a single machine can save 0.7 kWh per day on average, and the annual energy saving cost is nearly 100,000 yuan. The technical and economic indicators are satisfactory. The emergence of the safety and energy-saving control system has played a positive role in improving the safety performance of the loom equipment in the workshop, eliminating safety hazards, and reducing the occurrence of safety accidents, achieving the control goals of safety, efficiency and energy saving.

The new material workshop always adheres to the high-efficiency energy-saving, service production as the center, and the leaders take the lead in grasping and grasping for a long time. Reforms and innovations are not big or small. We have implemented improvements to the weft feeder supports and selvedges, and various technical reforms continue to advance. Many seemingly simple small changes can often play a big role in the actual production process.

In an extraordinary period when the situation on all parties is severe, strengthening confidence and maintaining stability is the current top priority. The market is the rice bowl of operation, and the operation is the rice bowl of the enterprise. There is less and less food. To be full, it is necessary to reduce the necessary waste and improve the quality of the meal. A conclusion can be drawn from the new material workshop through the relevant technological transformation work, that the path of technological transformation is completely correct and effective. Through the implementation of technological transformation to reduce costs and increase benefits, it ensures that employees' incomes are basically stable, their thinking is basically stable, and production is basically stable, while ensuring that the workshop is responsible to society, the company and employees. In a long difficult period, each workshop and each department must combine their own nature and actual conditions, learn from, learn, reform and innovate, find breakthroughs, rise to the difficulties, stabilize the workforce, and tide over the difficulties together.