I put forward a plan to reduce costs and improve efficiency. Reducing costs has always been the content that enterprises attach great importance to in management, but it is very difficult to reduce costs and needs many experiments. Let me give you a brief introduction of my cost reduction and efficiency improvement plan.
I provide 1 to reduce costs and improve efficiency.
Lu Hua, Huanghua Factory of Beijing Lingyun Dongyuan Company: In the process of reducing costs, improving quality and increasing efficiency, we should go deep into the front line, start from bit by bit, and explore and innovate in practice. As far as Lingyun Huanghua Factory is concerned, considering that the rolled outer plate products are positioned from the bottom of the outer plate in the production process, the head of the outer plate products can be shortened by 10 mm. After testing10 kinds of rolled products, the product structure and product quality will not be affected.
Zhang Shuo, Quality Department of Chongqing Factory of Lingyun Dongyuan Company, Beijing: By minimizing the lap gap in product assembly, refining the actual gap value of external parts welding, carrying out tolerance management, and intensively controlling the welding process, the repair welding rate of products is comprehensively reduced and the quality loss is reduced.
Wei Xu, Logistics Department of Huanghua Factory of Beijing Lingyun Dongyuan Company: In the process of reducing costs, improving quality and increasing efficiency, we pay attention to reality. Based on the fact that the current output is lower than expected, after consultation with the logistics company, the fixed warehousing service fee is changed to daily settlement under the condition that the normal working days are not met every month, which can effectively reduce the warehousing cost.
Li Weiqiang, Production Department of Chongqing Factory of Beijing Lingyun Dongyuan Company: Installing on-line current monitor in key welding processes and strengthening the control of welding quality through visual management can effectively improve the stability of welding quality and reduce the cost of rework.
Zhou Tong, Production Manager of Operation Management Department of Beijing Shidong Lingyun Company: In the process of reducing cost, improving quality and increasing efficiency, we pay attention to innovation and development, improve the process level, and independently design semi-automatic gluing equipment and automatic punching machine equipment according to product structure and process requirements, so as to reduce labor costs and improve production efficiency. Improve the process equipment, face the present situation of increasingly diversified products, and improve the scraper at the lower end of the laminator, which can be tried out for various models. Optimize production layout, eliminate waste, improve reasonable station occupation and improve production line efficiency.
An Shi, the production chief of the operation management department of Beijing Shidong Lingyun Company, and Wang Jindong, the production chief of Shunyi Branch: In the process of reducing costs, improving quality and increasing efficiency, we insisted on developing high-performance and high value-added products, and achieved a breakthrough in PP+TPV extrusion process. Learn from the existing production line mode in Korea, introduce its mature PP+TPV new material and inner velveteen production technology, and better realize product lightweight. Compared with PVC I/S products, the weight is reduced by 34% under the same length. The successful introduction of new materials and new processes not only meets the needs of customers, but also reduces the manufacturing cost. At the same time, the reduction of manufacturing cost provides advantages for the subsequent bidding of new models.
Ding Xinghao, head of development department of Beijing Shidong Lingyun Company: During the implementation of cost reduction, quality improvement and efficiency improvement, it was found through discussion and experiment that only changing one cavity in the old mold can meet the requirements of new product mold development. The renovation cost of the old mold is estimated to be about 30,000 yuan, which directly reduces the cost by about 654.38+10,000 yuan.
Zhang Wen, Quality Department of Lingyun Co., Ltd.: QC project can solve the long-standing problem of tool waste rebound of a certain model threshold, greatly improve the appearance quality of products, and reduce the internal waste loss and external repair cost.
Quality Department of Lingyun Co., Ltd.: By adjusting the action sequence of the equipment, the bad problem of one-time non-standard punching and five-sequence side punching of Mercedes-Benz unit was eliminated, the loss of waste products was reduced and the punching accuracy of the equipment was improved.
In order to reduce costs and increase efficiency, in the face of the severe market situation, all employees of No.2 blast furnace in No.2 Iron Works have made long-term preparations to deal with difficulties. # Blast Furnace requires each team leader and party member to take the lead in making the promise of "frugality, starting with me" and actively respond to the call of "frugality, energy saving and consumption reduction" advocated by the company and the ironworks. Adhere to economy, oppose waste, start from me, start from bit by bit, and start from what you can.
1 Blast Furnace starts with optimizing process, optimizing operation, strengthening equipment maintenance, eliminating leakage, repairing old materials and utilizing waste, reducing machine material consumption and ensuring safe production, giving full play to the advantages of full participation, and promoting the realization of cost reduction and efficiency increase with practical actions.
Carry out scientific and technological innovation and improve production and cost indicators.
According to the characteristics of ironmaking process, the "three optimization" measures are implemented: optimizing the burden structure, optimizing the operating system and optimizing the equipment operation.
Optimize the burden structure
Under the condition of not affecting the smooth operation, output and quality of blast furnace, the proportion of raw ore is increased and the proportion of pellets is gradually reduced to achieve the purpose of reducing costs. According to the follow-up analysis of the production practice of increasing the proportion of raw ore in blast furnace from May to August in 2009, it is considered that the proportion of raw ore should be controlled at 10%-20%, the proportion of pellets should be controlled at 0-5%, and the cost per ton of iron should be reduced by 20-30 yuan. The annual cost of a single blast furnace is reduced by 5 million to100000, and the cost reduction effect is remarkable.
Optimize the operating system
The smooth running stability of blast furnace is an important factor to reduce cost and increase efficiency. Explore the appropriate charging system at the upper part and air supply system at the lower part of 1 blast furnace, so as to make the upper and lower parts adjust each other, improve the utilization rate of gas, keep sufficient physical heat of slag and iron, keep stable central airflow and marginal airflow, and make the blast furnace run smoothly, thus laying a foundation for reducing silicon content in pig iron, increasing coal ratio and reducing coke ratio. According to the characteristics of 1 blast furnace, it is considered that 10t- 12t large ore batch is suitable for 1 blast furnace, which is of great significance for reducing cost and increasing efficiency.
Optimize equipment operation
Reducing the failure rate of blast furnace equipment is an important aspect of reducing costs. It is considered that the key to ensure the normal operation of blast furnace equipment is to do a good job in the auxiliary workshop of machine maintenance.
Adhere to the key energy-saving measures of "one implementation, one improvement and one reduction", that is, adhere to the implementation of low-silicon iron smelting, improve the coal ratio and reduce the coke ratio.
Reduce silicon content in pig iron, increase coal ratio and reduce coke ratio.
The energy consumption of ironmaking process accounts for 60-70% of the whole steel process, and the process cost also accounts for 50-55% of the whole steel system cost. Whether the iron and steel enterprises are profitable and competitive depends on the cost of ironmaking, and improving the coal injection ratio and reducing the coke ratio are the most important things to reduce the cost of ironmaking. This year, the average coke ratio of 1 BF hovered around 420kg/t, and the average silicon content of pig iron was around 0.60%. Although this index is directly related to unreasonable furnace type, unsatisfactory coke quality and low grade, it is not the only reason. Therefore, in order to make a breakthrough in 1 blast furnace, besides continuously reducing coke ratio and silicon content in pig iron, stable control and avoiding repetition are of great significance to reducing production consumption.
Desulfurization. Due to the unstable composition and quality of raw fuel, controlling the sulfur content of pig iron in small blast furnace has driven the cost up to a certain extent, so it is suggested to scientifically grasp the balance between quality requirements and cost control.
Pay close attention to basic management to ensure safe production of blast furnace
Take 8S as the management center of gravity and work hard.
Whether the management of an enterprise is mature or not will directly affect the production cost. It is a very real idea to ask the management for benefits. In the face of increasingly severe external competition, only by strengthening management can we reduce costs. Judging from the feedback effect of many large excellent enterprises (Haier is the best example), 8S is the most effective and direct method to reduce management costs. 8S is very simple, which is easy for team leaders and workers to master. The core issue is cleanliness, cleanliness, cleanliness. Some people say it is simple, but it is not. It will be harder to stick to it for a long time. The 8S management has really been achieved and done well, which is a great progress in basic management.
Establish a long-term management mechanism to reduce costs and increase efficiency.
According to the management level, the cost reduction and efficiency improvement indicators are decomposed into workshop level, team level and operation level, with clear rewards and punishments.
Establish a long-term and effective safety training mechanism.
Organize training courses regularly to improve the quality, safety and operation level of employees, improve the overall quality of the workforce, and form a good atmosphere for learning technology and drilling business. Let every employee start from consciousness and change "want me to be safe" into "I want to be safe".
Establish a reasonable labor competition management mechanism.
Carry out labor competition, set reasonable quality and output targets, and decompose them into teams and individuals, link benefits with work, and stimulate employees' sense of honor and urgency. However, a lot of statistical analysis is needed to establish a more feasible evaluation benchmark. It is suggested that the operating indexes such as furnace temperature, sulfur content, batch number, output, coke ratio and quality should be decomposed into classes, and classes should compete with each other, so as to strengthen the unified operation of three classes and strictly control the furnace temperature and slag alkalinity to ensure stable and high production of blast furnace. In the operation outside the furnace, the operation indexes such as accurate tapping, iron quantity difference, qualified rate of taphole angle and equipment maintenance are the main competition contents, and the dynamic management of production equipment is strengthened by adopting team ratio, post ratio and individual ratio to reduce all kinds of accidents and create favorable conditions for the operation inside the furnace.
Small technological transformation can also solve big problems.
Full action, small transformation, big harvest. Combine management innovation with technological innovation, actively carry out the activity of "changing small leather into small leather" and carry out local equipment transformation or process optimization.