During the Spring Festival, Daqing Petrochemical Woven Bags Plant produced 720,000 woven bags and received orders of 4 million pieces. From 2013 to 2017, Daqing Petrochemical woven bag plant accumulated a total of 262 million woven bags for five years, creating a profit of 188 million yuan. In 2017, the flat-wire widening technology filled the gap of domestic independent production. Recently, the technology for reducing the weight of woven bags has been successfully tested. This year, it will be on-line production. What gave rise to the big benefits and organic sustainable development of a small workshop?
Daqing Petrochemical Woven Bags Factory is a labor-intensive unit engaged in the production of plastic woven bags. There are more than 600 employees in the company. The work intensity is very high. Sometimes even the toilets are ran away. The equipment is old and the environment is hard. Complaints, productivity has also declined with work enthusiasm.
How to change, the consensus is to transform the idea of “exploiting potentials and increasing efficiency”. It is not clear that tapping potentials requires employees to “excavate money”, but rather “diving potentials” on employees first, and actively tapping internal potential to create benefits.
Exploring potential 'employees' first 'friendship'
The woven bags workshop has a history of more than 30 years and covers an area of 12,000 square meters. It has been certified by a professional department that it does not have the ability to resist earthquakes. Rainy days may even cause rain outside the house and the surrounding areas. There are four air leaks; the cold can't be blocked, and you need to wear it during operation. Cotton clothing. Due to the old exhaust system, smoke and dust is flooded into the factory building.
Employees are very interested in doing things. The development company is improving the work environment, replacing the plastic windows, adding color plates to the roof, replacing all the cracked concrete floors with epoxy resin floors, spacing out the dining rooms, and restrooms. The large-volume exhaust system, can not absolutely face off work can be 'perfect debut'. From grayheads to earn enough 'face', win is the people's heart, there are employees who said: 'The workshop is not reinforced factory, is our heart. In summer, the temperature inside the factory reached 45 degrees Celsius, and the employees sweated. Behind the overalls was a circle of white perspiration. Washing the clothes was commonplace. To do this, the work clothes were changed to two sets of comfort per year.
During the survey, I learned that most employees ride bicycles to work, slippery roads in the winter, and often fall through the night shifts. After a series of transformations to improve work efficiency, the night shifts are cancelled and the employees are motivated.
By the beginning of 2018, the output of woven bags had quadrupled, and the cumulative effect reached 188 million yuan.
Convergence of processing workshops to production operations
Breakthrough workshop only manages production regardless of the pattern of operation and realizes the parallel management mode of production and operation.
Five years ago, the development company realized for the first time that production and operation should be in parallel, and the management of woven bags was devolved into workshop management. Since then, weaving bag workshop organization technicians have specially established after-sales service teams to penetrate customer groups and understand customer needs. The sales of woven bags began to increase.
In the market research, the after-sales team found that the high-density woven bags are of good quality, but they are relatively hard. The suction cups cannot be adsorbed during the packaging process. For this purpose, the workshop organization professional technicians re-wrote the production process of the woven bags and performed key technical indicators. Strict calibration, design and trial production of new products that are 12 grams to 18 grams less than the original packaging bags, not only reduce production costs, but also meet customer needs. Calculated by annual production of 40 million woven bags, can save packaging costs 690 More than ten thousand yuan.
In the past, the production of woven bags in the workshop was to paint the plastic film inside the woven bag. It was necessary to manually turn each bag over and cover the film. However, the labor intensity was too great to achieve continuous production. After proof, the workshop decided to adopt the outer film packaging method to achieve continuous Production increased work efficiency, and more importantly, there was only one outer film packaging bag in China PetroChina at the time, which had great market potential. After the outer coating film woven bag was officially put into production, 180 million pieces of outer coating film woven bags were produced in five years. Film woven bag more than 9700 million effect.
In 2017, after numerous trials, the woven bags workshop successfully widened the flat yarn from 2.4mm to 3.9mm, filling the domestic technical gap at one stroke. The female woven workers can produce more than 2,000 meters of fabric per person per shift, and the female worker Pei Boxiu The hands are particularly fast. One class can open two machines at the same time, producing up to more than 5,000 meters of base fabrics. After transformation, the production efficiency of the circular fabrics in the workshop is increased by 60%, which provides guarantee for the workshop to cancel the night shift.
In the process of large-scale technological transformation, small technical renovations of the workshop are also carried out simultaneously. Even if the printing machine is equipped with flattening rollers to reduce the number of defective products, the drawing sink is used to reduce the energy consumption, and the electricity consumption of the workshop is eventually reduced to the whole country. The industry is the lowest. In 2017, the electricity consumption was 816 kWh per ton. Compared with 2013, the electricity consumption was reduced by 225 degrees per ton, and it was calculated at 40 million per year, saving more than 1.4 million yuan annually. 2013 to 2017 , The cost of single bags of woven bags decreased continuously, the difference was 1.13 yuan, and the cumulative reduction was 100 million yuan.
Sell 'Before and After' Equal Quality
The production of a woven bag has to go through several links. Under the old condition of the workshop equipment, the stamping and seaming electric fitter picked up the banner of the first quality, insisted on taking the lead in advance, and inspected the equipment at the same time, and timely corrected the employee's influence on the equipment. The normal operation of the wrong action, reduce equipment failure, to ensure the continuous production of fabric.
The workshop shifted the after-sales focus from the initial 'after-sales' service to 'pre-sales' and 'sales', and changed the 'fire-fighting' service afterwards into an early-warning type. The workshop organizes quality inspection staff to in-depth the production site to master product quality, process adjustments, etc. Situation, communicate with users in advance about potential quality fluctuations. At the same time, organize employees to visit the user units to see the use of their own products to create a sense of honor and dishonor. The workshop has established two information platforms both inside and outside the market, creating more than 130 user profiles. Article, timely processing of user's questions.
In 2015, the workshop struck a heavy blow, changing the previous mode of heavy supervision, reducing the number of over 20 quality inspectors to 10, and returned to work in groups to manage the situation. The workshop dispatched the quality inspectors to their own locations. The previous process of the process goes to work and the bonus is still assessed by the original team. This effectively ensures that the non-conforming product is banned from entering the 'home'.
After five years of reform, the annual output of the woven bags workshop has been increasing year by year, and the quality has also been increasing year by year. In the five years, 262 million woven bags have been produced and sold, and the user satisfaction rate has reached over 97%.