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Can advanced spinning equipment reduce labor usage?



At present, there are two phenomena in spinning enterprises: one is that based on cost pressure, employees are reduced by a percentage every year, while technological transformation fails to keep up. The other …

At present, there are two phenomena in spinning enterprises: one is that based on cost pressure, employees are reduced by a percentage every year, while technological transformation fails to keep up. The other is that it is often difficult to recruit people. There is a shortage of people in the spinning workshop, especially during holidays and high temperature seasons, or the working hours of operating operators are continuously increased from 8 hours to 12 hours, or the increase in salary is used as a bargaining chip. Blindly expanding the station, the maximum salary exceeded 9,000 yuan/month. The equipment is still the same, but the number of maintenance workers has decreased. Some people are responsible for 36 vehicles, and sometimes there are only 4 or 5 people left. Workers’ wages have increased, but the quality of equipment maintenance has not improved, and the failure rate and breakage rate have increased. , it can only be at the expense of product quality. Some companies even have managers replacing workers when they are short of workers. This vicious lack of staff not only causes management chaos, but also aggravates staff turnover.

Of course, many companies choose to use reliable performance, high degree of automation, self-diagnosis and self-monitoring Functional intelligent equipment can replace labor, and the results show that it can produce high-grade, high value-added products even though it requires less labor.

Equipment stability is the basis

Spinning production is labor-intensive Industry, in the early 1980s, the average number of employees per 10,000 spindles was 200 to 300. Although the performance of domestic equipment in the past was far inferior to that now, the old equipment emphasized meticulous maintenance and equipment status, and ensured the quality of equipment operation through multiple employment and decomposition management.

In recent years, technological progress has greatly liberated the labor force. The promotion and use of new equipment such as blowing and carding units, automatic winding, automatic bobbin changing, and automatic transportation equipment has dropped significantly. In addition, The promotion of long machines for collective doffing of spun yarns, the intensive application of technologies such as large quantities, large drafts, large barrels, large packages, integrated barrel changing without wraps, and roving changing have led to lower workmanship levels. This is an inevitable trend for my country’s textile modernization to integrate with the world, but it does not mean that each factory can reduce employees at will.

It is understood that quite a few small and medium-sized spinning enterprises in my country are still using A-frame equipment from the 1980s and 1990s (it is estimated that this proportion accounts for more than 50%). These A-frame The equipment is low-grade equipment with low production efficiency, high failure rate and frequent maintenance. The FA series products developed later adopted preliminary electromechanical integration technologies such as inverters, display screens, and industrial computers, and were of medium grade. There are still a large number of non-standard FA series and even non-model equipment on the market. Such equipment has fewer faults for the first six months to one year, and then the faults begin to gradually increase after 2 to 3 years of stability. Reducing maintenance workers at this time is tantamount to killing the goose that lays the eggs. Finally, there are the high-performance spinning equipment launched in recent years. New blowing and carding units, collective automatic doffing spinning machines, thick and thin rollers, automatic winders, automatic transport devices, etc. use a large number of equipment with reliable performance, high degree of automation and low maintenance. convenient.

Many companies are willing to spend huge sums of money to import equipment. The main reason is that its failure rate is low. Even after 3 to 5 years of use, it will not fail as long as it is maintained according to the manufacturer’s instructions. It would add too much workload.

Operation optimization focuses on details

In addition to equipment factors, comprehensive scheduling is required Enterprise resources must handle the contradiction between saving labor and stabilizing employees, and adopt flexible incentive measures to maximize benefits and ensure the optimization of output and quality.

Strengthen the details of labor management, and the operation items can be separated. For example, stopping the car and changing the roving are separated, and centralized yarn changing is adopted. The spun yarn block is separated from the partial cleaning to expand the layers, reduce the work intensity, and also moderately expand the stand capacity. Based on the above measures, the workload of medium-count and above varieties can reach 30 to 40 units/person. It can also be combined and the long trolley of cluster spinning machine can be used to ensure that under the premise of the end-break rate and end-retention rate, the set-blocking trolley and doffing can be done at the same time. For one post, while keeping the number of car-blocking stands unchanged, the doffing work type is cancelled, the operator’s patrol speed is increased, and a “hand-operated brake pedal pulley” is used to block the car, speeding up the tour speed, and improving the joint efficiency and joint quality, especially for environmental protection. The long spindle and rotor spinning machines are very effective in enlarging the stands.

Maintenance management is critical

The equipment maintenance methods of spinning enterprises are generally Divided into two categories, one is the traditional equipment maintenance model. Security workers conduct inspections of equipment, including daily inspections, regular inspections, precision inspections or key inspections. What is more detailed is to adhere to the principle of “regional responsibility is assigned to the team, responsible charter flights are assigned to the person, and the equipment is in good condition at any time throughout the day”. , including integrity, consumption, and safety. “One link” means that individual work performance is directly linked to performance pay. Shandong Liaocheng Guanxing Textile Group still adheres to the traditional equipment overhaul system, achieving the coexistence and complementarity of periodic maintenance and condition maintenance. We conduct equipment operation competitions every year, reward innovative talents, pay close attention to preventive maintenance, prevent night shift failures, and ensure product quality by improving the level of professional and technical personnel, with good results.

The other type is to adopt a lean state maintenance model. Textile equipment management should do something and not do something, and adopt international advanced management models, such as TPM “total production and maintenance”, to implement lean equipment management. The so-called lean equipment management is to use lean thinking and lean methods to pursue the highest level of fault-free and safe production, and to integrate fault maintenance, regular maintenance, condition maintenance and proactive maintenance.We have adopted an integrated equipment management approach and established an equipment operation early warning system with spot inspection and failure analysis as the core. This maintenance model is a new model of equipment maintenance that has long been implemented in developed countries in Europe and the United States. It is based on the fact that the equipment itself has online detection devices, human-machine dialogue, digital fault display, remote monitoring, and the safety, reliability and durability of the equipment and parts configured. , it is completely possible to use the maintenance mode that integrates spot inspection and fault-free status. By reforming traditional large and small flat cars and focusing on inspection and repair, maintenance and labor costs are reduced. The core of fault-free state maintenance is pre-detection and post-event control. It is a maintenance management model that combines planned state maintenance and random state maintenance. It not only solves the waste of resources caused by repeated and frequent maintenance of equipment in the past, but also achieves the purpose of reducing burden and increasing efficiency. Many large domestic spinning enterprises have achieved successful experience in lean state maintenance.

No matter which of the above two maintenance modes is adopted, good results will be achieved as long as they are promoted steadily. Employment is based on “jobs” and is based on the premise of satisfying product quality. If the employment quota is lowered first, the projects that should be completed will inevitably be missed. In the end, the company’s survival may be affected because the products are not recognized by customers. .

Some companies have done a very solid job, not only strengthening technological transformation, but also pursuing zero faults, zero maintenance and value stream creation for key processes and key equipment parts with high failure rates, emphasizing on Full process management of equipment life cycle. Moreover, at the beginning of each year, the equipment, varieties and management conditions of the previous year are reviewed, and the number of employees can be appropriately reduced if reasonable, rather than setting a number of labor quotas that must be met. Some companies are not doing solid enough work, so they must first do the basic work well and not blindly reduce people. Otherwise, not only will they not be able to reduce people and increase efficiency, they may even jeopardize their future.

In short, only good spinning technology and solid basic work can ensure that every machine is managed by someone. Only when everyone has a responsibility can equipment efficiency and effectiveness be maximized and labor usage reduced. Labor saving in spinning enterprises is a systematic project, which should be combined with improving efficiency, strengthening details and other aspects, and consolidating the foundation of management, technology, equipment, etc., in order to be effectively guaranteed. </p

This article is from the Internet, does not represent Composite Fabric,bonded Fabric,Lamination Fabric position, reproduced please specify the source.https://www.tradetextile.com/archives/34394

Author: clsrich

 
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