Reform Creates Profits

Continuous casting and rolling production line is a key project introduced by Zhengzhou Longxing Concrete Pipe and Stake Accessory Company in 2012. Through half a year’s effort, the company successfully started the pilot production in June, 2012. On the whole, the rolling mill’s pilot production went on smoothly. Related technicians found some bugs during the pilot production. Here we share our “roll reform” experience.

Hong Maojing, the technician who is in charge of production adjustment of the roll mill, has abundant roll mill adjusting experience. During the pilot production, he found the roll that the company uses can only produce three types of the products. Moreover, when changing the type, workers have to dismantle all six rolls and fix a new set of rolls. The installing and commissioning of the roll will take two days. According to the monthly production, we need to change the roll at least three to five times. Accordingly, there will be 1/3 days of the month wasted on changing the roll.

Why does it take 2 days to change the roll every time? Can we shrink the changing period by technic reform? Can we produce all types of products by using only one set of roll? A series of questions came up in Mr. Hong’s mind. Combined with the past experience and the characteristics of the products, he bravely imagined that  if we modify the roll bridge and process the two grooves with the same size into different ones of depth and width so as to make the size of the groove can cover all types of products. Hence we do not need to dismantle the roll when we change the types of product. Under this circumstances, What we need to do is to adjust the gap and guide fitting respectively. He reported his idea to the production manager and got strong support.

After reform, the present roll can meet up with all production need . Instead of taking 2 days previously, it now only takes 3 to 4 hours to adjust the roll. Through this reform, the company’s roll mill line greatly saved time cost and the work efficiency was improved by 200%. In order to encourage worker’s innovation, the company praised Hong Maojing in written form and awarded him 500 RMB in cash.

Reforms exist in everywhere as long as you observe and think carefully. We hope all the others can learn from Hong Maojing to actively summarize experience and try to find the existed problems. When creating the profits for the company, you yourself can also enjoy the happiness that the achievements brought.