As we all know, tooling and cutting tools are essential tools for production and processing. The manufacturing volume, usage, consumption and other expenses occupy a certain share of total production cost. Minimizing the manufacturing volume and purchasing volume of tooling tools is to reduce production. One of the basic work of cost. In 2009, Dawn, from the perspective of reducing production costs, combined with the number of tooling dispatches and tool purchases in the previous two years, determined the annual number of tooling dispatchers and tool purchase amount control indicators, and incorporated them into the company's comprehensive balance score. Among the card assessment indicators.
In order to successfully realize the cost control indicators, Dawn will distribute the tooling indicators through the company, the branch, and the construction department, and set up a tooling dispatching review team composed of technical, production, and management personnel. Work is strictly reviewed. The tooling management department fully controls the indicators of each branch and promptly reminds the units whose quarterly indicators reach the critical point. At the same time, the company thoroughly inspected the status of tooling in-process and revoked useless and ineffective dispatch. The company has accurately grasped the status of tooling in the product, avoiding the blind and repeated dispatching phenomenon in the past, and providing an accurate basis for the tooling dispatch system.
In order to make full use of the company's inventory and use blunt tool resources to reduce procurement costs, Dawn has strengthened the external tool return grinding supplier strength, and issued annual regrind to the company's machine processing plant and research tooling factory with tool return grinding equipment. Plan indicators. In 2009 alone, the company returned more than 20,000 purchased tools, based on the current purchase price, saving about 10 million yuan in procurement funds.
The machine processing plant belonging to Dawn, as the unit with the largest tool consumption and tool purchase capital, adopts a series of effective measures, such as issuing the grinding index to the operator of the knife sharpener, which makes the sharpening machine play a big advantage. For some of the high-cost coated imported alloy tools, recoating to extend the service life of the tool; localized testing of some imported alloy tools, research and development instead of imported tools; cleaning of the backlog of the tool and the body of the tool, Re-use by transformation; after sorting and selecting the used blades, arrange roughing and reuse. The actual purchase amount in 2009 is only equivalent to 51% of the total purchases in 2008.
The value of fixed assets occupied by existing equipment at dawn is huge. How to improve equipment utilization, give full play to equipment efficiency, and truly protect production has been upgraded to the company's strategic height. In 2009, under the guidance of the work theme of AVIC Dawn's “Highly Concerned Valueâ€, equipment utilization rate was included in the company-level comprehensive balanced scorecard as an indicator, which received high attention from the whole company.
The Dawn Operation Support Center formulated and issued the “Usage Statistics Method†to unify and standardize the statistical methods of each unit. At the same time, in order to provide accurate data and improvement basis for each unit and various functional departments, the impact is also provided in the method. The type analysis of the rate factors makes each unit pay more attention to the reasons affecting the utilization rate in addition to the statistical utilization value. Every month, Dawn will publicize the equipment utilization situation and influencing factors of each unit through the intranet. This practice not only attracts the attention and attention of leaders at all levels, but also the relevant departments actively remove the obstacles affecting equipment utilization for the grassroots units. The equipment use unit also actively takes measures based on the comparison values ​​on the same platform to improve equipment utilization efficiency through improvement. In 2009, the company strengthened the equipment maintenance work as an important part of the TPM promotion, and checked the equipment one by one according to the maintenance standard. Under the improvement of the maintenance acceptance rate by 10 percentage points, the equipment failure rate was significantly reduced.
In addition, Dawn also revamped “silent†equipment through technological transformation. A large-scale equipment is basically idle, with a utilization rate of 23% in 2008. In 2009, the company successfully implemented the transformation of the equipment, and the utilization rate reached about 80%. A CNC grinding machine has not been officially put into use since the purchase. In order to give full play to the performance of the equipment, through the implementation of repairs and partial modifications, the equipment that has been idle for many years has been put into normal use, which not only solves the company's numerical control equipment capability. Insufficient problems, but also greatly improved the utilization level of the device.
Promoting the application of combination tooling is an effective way to reduce the tooling dispatch. Through the formulation of the "Combination Fixture Management Method", Dawn Rational's combined fixture dispatching process and usage management encourages the tooling design department to use the combined tooling as much as possible in the tooling design process. As a research and tooling factory of the combined fixture manufacturing unit, it strengthened the organization of the combined fixture station, formulated relevant performance appraisal methods, and promoted and applied the combination fixture through a series of methods, such as sending letters to the tooling demand unit and making the “combination fixtureâ€. Application Tutorial, send expert on-site training, select experienced fitters to the production site to help debug.
This series of practices not only enables the combination fixture to be applied to production as soon as possible, but also enhances the confidence of the application of the combined fixtures in each production line. For the old, eliminated and multi-year inventory of tooling, the Dawn Operation Support Center and the Scientific Research Tooling Factory carried out the re-use of used tooling in line with the principle of repairing old and used waste. Through the transformation, renovation, disassembly of tooling components, etc., the old tooling has been used in different applications, which directly reduces the production cost of the tooling and shortens the tooling production cycle. According to incomplete statistics, as of October 2009, the company has completed more than 900 dismantling of used tools, and reused more than 300 tooling, saving nearly one million yuan.
At the beginning of 2009, based on the investigation and analysis of the demand for purchased tools of each branch, Dawn decomposed the tool purchase amount control index into each production plant, and the factory manager signed the responsibility statement for the control index. In May 2009, the company revised and issued the “Administrative Measures for the Examination and Approval of Purchased Toolsâ€. The new tool procurement process simplifies some unnecessary links. The tool approval department is responsible for the occurrence of tool capital expenses, and the management duties are more clear. For the more than 20,000 pieces of purchased knives accumulated over 5 years from various production units, the company adopted the practice of publicizing on the intranet. Through publicity, the demand unit gets the information and allocates it according to the demand, which reduces the backlog and revitalizes the funds. Through inventory, publicity and other work, in 2009 the company has allocated more than 8,000 pieces of tools and revitalized more than 5.2 million yuan.
In view of the fact that the equipment technology upgrade is fast, the equipment maintenance technicians are short, and the equipment maintenance personnel are required to update the knowledge quickly, Dawn actively carries out trainings on various levels of equipment maintenance personnel, and organizes the coverage equipment only in 2009. There were 24 training sessions, such as CNC repair and maintenance, and mechanical repair fitters. The number of trainees was 576, and the total number of hours was 894 hours. At the same time, give full play to the backbone function of mechanical repair system technical experts and skill experts, the company organized experts to conduct technical lectures for more than 200 hours, organized on-site technical consulting services more than 130 times, organized experts to write technical series "800 cases of equipment maintenance and troubleshooting" 》, the tacit knowledge mastered by the experts is made explicit, shared by the company's equipment maintenance personnel, and accumulated as a technical wealth that can be passed down.
As a large-scale aero engine research and production unit, Dawn has set up an energy and power management office in the operation support center for the current situation of energy consumption of aviation enterprises, and is responsible for the management of energy consumption. At the same time, energy conservation and consumption reduction work will be carried out in the aspects of improving energy efficiency, optimizing process flow, improving energy utilization efficiency, reducing oil consumption, implementing water-saving technology transformation and improving water utilization rate.
The central air-conditioning system used at dawn involves more than 10 workshops, with a total of nearly 40 sets. The annual central air-conditioning power consumption is nearly 6 million kilowatts per hour, accounting for about 8% of the company's total electricity consumption. Since 2006, Dawn set about the transformation of the central air-conditioning frequency conversion power-saving device, and achieved good results. In 2009, only through the transformation of central air-conditioning, it saved nearly 300,000 kilowatt-hours per year. According to the layout of the water supply pipe network, 28 new water supply control wells were built according to the layout of the water supply pipe network, which required the water supply pipe network to be partitioned and controlled. By doing a repair and stopping, it completely changed the waste of “local water stoppage and water withdrawal from the whole networkâ€.
A high-energy-consuming vacuum furnace equipment, by identifying the responsible person for recording and scientific analysis, to find out the law of energy consumption, under the premise of ensuring the production schedule, adopting the same process to combine the furnaces to improve the efficiency of the vacuum furnace. , thereby reducing power consumption and improving energy efficiency. This one piece of equipment saved nearly 700,000 kilowatts per hour from January to November 2009, saving 590,000 yuan; at the same time saving argon worth about 210,000 yuan, shortening the production cycle by 5,234 hours, effective Avoid the energy consumption of the “big horse trolleyâ€.
At the moment, Dawn sprints the goal of tens of billions to the most critical moment, and there are scenes of great enthusiasm everywhere. How to provide strong operational guarantee for the company's lean production has become the primary task facing the AVIC Dawn Operation Support Team. While they are deeply responsible and have a mission, they will also develop and innovate, take corporate culture as the guide, adhere to the principle of continuous improvement, and strive to create a "politically qualified, excellent style, excellent business, quality service, and protection." A powerful team, bravely assisting AVIC in the dawn of a new round of soaring.
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