Since the beginning of this year, Zhuzhou Cemented Carbide Group Co., Ltd. (hereinafter referred to as "ZhuHang") has vigorously carried out the work of reducing costs and losses, improving quality and increasing efficiency, and has achieved remarkable results.
The Hard Drill Alloys Division of Zhuhai uses the PDCA ten-step method to increase the turnover speed of products and finished products, reduce non-productive expenses, and reduce various costs. At the same time, the division internally decomposes cost indicators, assigns responsibilities to departments or individuals, regularly holds cost analysis meetings, enhances cost control awareness, establishes a benign model of "improvement and continuous improvement", continues to tap potential, and comprehensively seeks to reduce costs and increase efficiency path. The cost of molds accounts for more than 50% of the cost of auxiliary materials in the drill alloy business unit, and the cost of molds plays a key role in controlling the cost of auxiliary materials.
In order to further reduce the cost of molds, the Hard-Drill Bit Alloys Division of Zhuhai also reorganized the "Newly Opened Mold Review Management Measures", requiring sales staff to increase communication and communication with customers, and reduce unnecessary mold production and new models. Development. For customers who really need to open new molds, apply for procedures related to new molds (or punches). The product line manager is responsible for the approval of the necessity of new molds, further standardizes the process and develops corresponding assessment methods.
At the same time, on the one hand, the production plant of the hard drill alloy division of the company has carried out a comprehensive cleaning of the molds in use, and classified the molds that can be repaired and reused to reduce the cost of reconfiguration. On the other hand, according to the contract, the standard number of punches in the past was changed to be configured as needed, which reduced waste. At the same time, the division has also increased its research on mold materials, and explored replacement of materials for some vulnerable molds to improve toughness and reduce losses.
In order to further reduce the consumption of auxiliary materials, the Hard-Drill Alloy Division of Zhuhai re-uses some of the used boats and unifies the packaging labels for domestic and foreign sales, etc., to reduce costs and increase efficiency in all aspects. This year's auxiliary materials have dropped by 16% year-on-year, of which the cost of molds has dropped by 12% compared with the same period last year, and the cost reduction and loss reduction work has achieved results.
The Hard Drill Alloys Division of Zhuhai has also vigorously carried out lean production, achieving the goal of improving quality and efficiency through measures such as reducing the return rate, improving product size control accuracy, and timely solving sudden product quality problems. Returned material is the most important factor affecting the input and output rate. By improving the formability of the mixture and adjusting the pressing parameters of the manipulator, the returned material rate has dropped by 10% compared with the same period last year. In response to the quality problems that were likely to occur in the production process of related products in the past, the business department took corresponding measures to deal with it. The product quality was better controlled and the product input-output rate increased year-on-year.
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