Spinning Enterprises: Equipment Stability Is The Key To Foundation Maintenance Management.

Spinning production is a labor-intensive industry. Although the performance of domestic equipment is far less than that of the past, the old equipment emphasizes careful maintenance.

In recent years, technological progress has greatly liberated labor force, which is the inevitable trend of China's textile modernization to integrate with the world, but it does not mean that every factory can reduce people at will.

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There are two kinds of phenomena: one is based on cost pressure, the other is reduction by percentage per year, and technological pformation fails to keep pace with it.

The other is that they often fail to recruit people. The spinning workshop is short of cars, especially during holidays, hot seasons or increasing the working hours of the operators, increasing from 8 hours to 12 hours, or increasing wages as chips, expanding blindly, and the maximum wage exceeds 9000 yuan / month.

Equipment or that equipment, but maintenance workers have been reduced, and some 6 people are responsible for 36 vehicles. Sometimes only 4 or 5 people are left. The wages of workers have increased, but the quality of equipment maintenance has not been improved. The failure rate and the breakage rate have increased, which can only be sacrificed at the expense of product quality.

Even when some enterprises are short of people, they can replace workers with management.

This vicious shortage will not only cause confusion in management, but also aggravate the loss of personnel.

Of course, many enterprises choose intelligent equipment with reliable performance, high automation and self diagnosis and self monitoring function instead of manual labor, and the result shows that although high quality and high added value products can be produced though few labor is employed.

Equipment stability is the foundation

Spinning production is a labor-intensive industry. In the early 80s of last century, there were 200~300 workers in ten thousand spindles. Although the performance of domestic equipment was far less than that in the past, the old equipment emphasized meticulous maintenance, emphasized the state of equipment, and ensured the operation quality of equipment through multi employment and decomposition management.

In recent years, technological progress has greatly liberated labor force, blowing carding, automatic winding, automatic changing cylinder.

The popularization and use of such new equipment has obviously decreased, and the intensive use of large quantity, large drafting, large drums, large volumes, unwrapped whole barrel changing, roving and other technologies has been promoted with the introduction of the spinning collective doffing long vehicle.

This is an inevitable trend for China's textile modernization to integrate with the world, but it does not mean that every factory can reduce people at will.

It is understood that quite a number of small and medium sized spinning enterprises in China are using the A equipment in the 80s and 90s of last century (which accounts for more than 50%). These A devices belong to low grade equipment, with low production efficiency, high failure rate and frequent maintenance.

After that, FA series products have adopted the initial mechatronics technology, such as frequency converter, display screen, industrial control computer, and so on.

There are also a large number of non-standard FA series or even no model equipment on the market. The equipment started to fail for six months to a year. After 2~3 years, the failure began to increase gradually.

Finally, the high-performance spinning equipment has been introduced in recent years. The new blowing carding unit, the collective automatic doffing spinning machine, the coarse and thin connection, the automatic winding machine, the automatic pport device and so on are widely used in reliable performance equipment, with high automation and convenient maintenance.

Many enterprises are willing to spend huge sums of money on importing equipment. The main reason is that its failure rate is low. Even after 3~5 years of use, it will not increase too much workload as long as it is maintained according to the manufacturer's instructions.

Operation optimize heavy details

In addition to equipment factors, we must comprehensively manage the resources of enterprises, deal with the contradiction between saving labor and stabilizing employees, and adopt flexible incentives to maximize efficiency so as to ensure the optimization of output and quality.

The details of labor management should be strengthened, and the operation items can be separated, for example, the separation of trucks and roving, and the use of concentrated yarn replacement.

The separation of spinning truck and part of cleaning can increase the level and reduce the intensity of work.

Combined with the above measures, the workload of the middle and above varieties can reach 30~40 units / people, and it can also be combined. The use of the collector spinning truck can ensure that the vehicle is blocked and doffed on one post under the premise of breaking rate and head retention rate. Under the condition of keeping the size of the stand, the doffing will be cancelled, the operator's traveling speed will be increased, and the "brake pedal pulley block" can be used to block the car, speed up the tour speed, improve the efficiency and quality of the joint, especially for the enlargement of the ring and rotor spinning long cars.

Maintenance management is critical.

The equipment maintenance methods of spinning enterprises can be roughly divided into two categories, one is the traditional equipment maintenance mode.

The maintenance worker inspected the equipment for routine inspection, regular inspection, precise inspection or re inspection.

To do a more detailed job is to adhere to the principle of "contracting out to the team, charter flights to people, and ensuring that equipment is good at all times of the day". The "five guarantees and one hang" responsibility system is the responsibility of "Five Guarantees", namely, the output of the package, the quality of the package, the package in good condition, the consumption of the package and the safety of the package.

Shandong Liaocheng Guan Xing textile group still adheres to the overhaul system of traditional equipment, so that periodic maintenance and state maintenance can coexist and complement each other.

Every year, the equipment operation operation ratio is rewarded, the innovative talents are rewarded, the preventive maintenance is carried out, the night shift fault is prevented, and the quality of the products is ensured by improving the professional and technical personnel level. The effect is very good.

The other is lean state maintenance mode.

The management of textile equipment should be done for certain reasons, and the international advanced management mode should be used, such as "TPM total production maintenance", and lean equipment management should be carried out.

The so-called lean equipment management is to use lean thinking and lean methods to pursue the highest level of failure free production safety, and form a device management mode combining failure maintenance, regular maintenance, condition based maintenance and active maintenance.

This maintenance mode is a new mode of equipment maintenance already developed by developed countries in Europe and the United States. It is based on the device itself with on-line detection device, man-machine conversation, digital display failure, remote monitoring and configuration, and the equipment parts are safe, reliable and durable. It can be used to integrate the maintenance mode with the fault free state.

By reforming the traditional flat cars, overhaul and reduce the cost of maintenance and maintenance.

The core of fault free maintenance is pre detection and post control, which is a maintenance management mode which combines planned condition maintenance with random state maintenance.

It not only solves the waste of resources in the past, but also achieves the goal of reducing burdens and increasing efficiency. Many large spinning enterprises in China have gained successful experience in lean state maintenance.

The above two maintenance modes will have good results, no matter which one is adopted.

Employment is based on "things" to determine people, is to meet the quality of products as the premise, if the first use of personnel indicators down, it is bound to make the original should not do the project, and ultimately may be because the product is not recognized by customers affect the survival of enterprises.

Some enterprises have done a solid job, not only to enhance technological pformation, but also to pursue zero failure, zero maintenance and value stream creation for key parts and critical equipment with high failure rate, emphasizing the whole process management of equipment life cycle.

At the beginning of each year, the equipment, varieties and management of the previous year should be demonstrated. It is reasonable to reduce the number of people, rather than setting the quota of employment.

Some enterprises do not work well enough, so we must do well in basic work first and not simply reduce people. Otherwise, we can not only reduce the efficiency of people, but also decide their own future.

In short, only when the basic work is done well, can the platform trolley be managed and everyone has the responsibility to make the most of it.

And efficiency, in order to reduce employment.

To save labor in spinning enterprises is a systematic project. It should be combined with improving efficiency and strengthening details to consolidate the foundation of management, technology and equipment so as to ensure effective protection.