Craftsmanship, casting shaft heart -- Remember Song Zhongliang, the struggle star of Drive Shaft Company
In the key stage of high-quality development of the drive shaft company, the roaring workshop is the main battlefield, and the front-line industrial workers are the main force in the front. In the atmosphere of the company's 100-day labor competition carried out in full swing, Song Zhongliang, the usually silent, but unusually sensitive to the sound of equipment operation of the first-line team leader, with his wisdom and sweat, in the ordinary position set off a silent revolution on efficiency, quality and heritage.
The “liberation” of a screw”
After the full implementation of double-shift system, new bottlenecks have appeared at the same time as the production capacity is increased: the impact of equipment changeover and debugging time on the production capacity occupies a relatively high percentage. The traditional workpiece positioning needs to lock the workpiece completely, every time the production change, the workers have to spend a lot of time with the screw “struggle”. Every minute of equipment downtime is a loss of efficiency and cost. Song Zhongliang saw in the eyes, anxious in the heart. He day and night “look and smell”, finally burst out of the “workpiece rotary stop screws pre-tightening technology” inspiration - by part of the screws into a pre-tightened state, not only to maintain stable positioning, but also To realize the fast clamping and releasing of the workpiece. He used his spare time to debug repeatedly, measured the torque, adjusted the angle, and tested the critical value of the preloading force.
When the new tooling test is successful, the effect is amazing: the workpiece changeover time is greatly reduced, and the equipment downtime has been reduced by 30%. the “liberation” of a screw has opened up the production line's “two veins”. This is not only a technical victory, but also a successful breakthrough of traditional thinking.
Building a Lean Manufacturing Moat
Solve the “point” problem, Song Zhongliang will look to the “line” - he is determined to create a highly efficient, clean “material highway He is determined to build an efficient and clean ”material highway“, reduce the time for operators to go back and forth and find materials, and compete for more time, leaving more time for product processing. He put forward the ”middle axis of the large box turnover mode“, the scattered, frequent box change operations into a regular quantitative integration of centralized distribution, ”less food, more meals“ instead of ”sporadic foraging". This change had an immediate effect: the frequency of box changing was reduced by 60%, and the efficiency of internal logistics was improved by 35%.
He implemented the “special crate” system, customized special equipment for different processes and cleanliness requirements of the parts, and set up strict cleaning and management standards, the product pass rate increased by 18%. the workshop has become clean and orderly, and the logistics route is clear and efficient.
Casting for the future
Double-shift system brings a leap in production capacity, but also brings the challenge of talent shortage. The traditional “master with apprentice” model is difficult to cope with the scale of demand for new employees, and the training speed can not keep up with the rhythm of production, so the quality and safety risks are hidden.
Song Zhongliang took the initiative to take up the important responsibility of talent training, and constructed a set of systematic “1+N” teaching system. The system is based on the specialties of skilled workers and the acceptance ability of new employees to scientifically “match the class”, to realize the efficient transfer of experience. He implements the “action decomposition teaching method”, which breaks down the operation into standardized modules that can be replicated and assessed, so that newcomers can quickly get started. And then through the “theory - practice - quality control” three-stage ladder assessment and certification, to ensure that every newcomer on the job independently is both a skilled worker and a quality inspector. Under this system, it takes only 5 days for a new employee to work independently, creating an “acceleration” of the workshop's talent training.
Song Zhongliang has no earth-shattering feat, but he always thinks instead of complaining, challenges inertia with innovation, and guards the future of the company's development with inheritance. He puts the goal of “improving quality and efficiency” into the details of the tightness of a screw, the design of a crate, and the growth of a new employee. He is the struggler that the company needs - to study technology pragmatically, always keep an eye on the overall situation of production; plowing the first-line operating positions, service company development. In him, we see the valuable innovative power and rock-solid craftsmanship of grass-roots employees in the process of promoting lean production and enhancing core competitiveness of the Drive Shaft Company. Site improvement is a continuous process, Song Zhongliang and workshop partners, is still moving steadily towards a higher goal.
Graphic: Wang Lianying