Projects participating
in the presentation
“Fast Replacement”
"Washing molds"

Ivan Vatutin

Engineer

Equipment Repair and Maintenance Department

Project Leader

The first project, “Fast Replacement” relates to the polystyrene foam production shop and represents optimization of the mold change process on equipment for casting polystyrene foam parts. Each specific model requires different configurations of parts. In this regard, when changing technical specifications, workshop employees have to disassemble the frame and mold for casting and install new ones. Previously, this process took at least two hours. The “Fast Replacement” project reduced this time by four times to 30 minutes, significantly increasing productivity and simplifying the process.
Together with the project team, we developed a universal frame. We made a prototype with the help of colleagues - welders and metalworking machine operators. The model has confirmed its effectiveness and will be put into production.

The second project – “Washing molds” (for a plastics workshop) – makes it possible not only to speed up the production process, but also, in addition, to save energy. The idea is as follows: after casting, still hot plastic parts are cooled due to the water circulation through the mold. The high temperature makes water boiling, salt deposits and scale generate on the mold surface. As a result, the water flow is reduced, what prevents effective cooling of the parts processed. Therefore, the mold channels must be washed. We have special equipment for washing, but it processes each channel separately, and the procedure takes about an hour. Considering that the mold can have include 10 to 15 channels, complete rinsing takes minimum 10 hours.
The project team was faced with the task of creating a unit that would speed up this process. We examined existing machines and fabricated a stainless steel tank with a pump for acid circulation. We installed a water pump with several connections for input and output ports. This device allows to reduce mold washing time to one hour. The project has already been successfully implemented and brings its results.
Project Team
Participants of the “Fast Replacement” project
Technical Development Department:
Alexey Andreev, senior specialist, technologist;
Sergey Soldatov, technician;
Mikhail Markov, foreman.

Participants of the “Mold Washing” project
Equipment repair and maintenance department:
Dmitry Nazarov, chief;
Evgeny Ukrashchenok, head of the group of electronics engineers.
Technical Development Department:
Sergey Soldatov, technician;
«Если двери, то HD Mech»

Alexander Makarov,

Engineer

Workshop of Mechanical Production

Project Leader

The goal of the project was to increase door line productivity per hour in the Mechanical Production workshop. In particular, to reduce the die replacement time from model to model. Having analyzed die replacement methods, my colleagues and I increased the area of fixation (fastening) of the door with grips during stamping and removed racks between two stations. Now the stations converge on each other, which allows operators to roll out the die along the rollers, remove it with a forklift to storage areas and install new die. After modernization, it is became possible to optimize die replacement time by 2–2.5 times and increase productivity by 8 pieces per hour. We also managed to increase productivity on the Grundig line and reduce defects in doors made of stainless steel.
Project Team
Workshop of Mechanical Production:
Denis Efimov, Technician;
Alexey Krasnoshchekov, technician.
Technical Development Department:
Sovetbek Aydarov, Head of the Automation Group;
Bakhrom Abdullaev, electric and gas welder.
“Going against the flow”
“Moving up”

Tatiana Goncharova

Engineer

Quality Department

Project Leader

The “Going Against the flow” project was initiated in response to requests from customers who complained that the powder compartment ­was leaking. A special device was developed to determine the leakage causes. Having found out the problem origin, we developed several prototype options and chose the one that would give the maximum effect with minimal disruption to the mold design during modification. After the project implementation, the number of calls to service centers decreased by 3 times. Our second project, “Moving Up,” is scheduled to be completed by February next year. This program will streamline work with washing machines coming from the conveyor, help adjust their quantity and duration of storage outside the conveyor and their status when sent to the warehouse, so that they do not reach consumers by mistake.
Project Team
Participants of the “Going Against the flow” project:
Alekander Krotov, Enterprise Process Group Manager;
Anastasia Brykhina - tester of electrical machines, units and devices.
Technical Development Department:
Igor Zubarev, Chief Process Engineer.
Product Development Department:
Mikhail Denisov, Lead Design Engineer.
Vladimir Remnev, Design Engineer.
Qality Department:
Pavel Nevzorov, product quality and process controller.
Artyom Oganov, engineer.
Unit for Repair of Production Accessories:
Anton Bogometov, specialist

Participants of the “Moving Up” project
IT department:
Alexander Sukhin, senior software developer;
Ivan Raskov, software developer;
Ilya Tsvetkov, specialist.
Washing machine assembly workshop
Ivan Bogdanov, Head of Workshop
"50 shades of color"

Alexey Sidorov,

Technician

Plastics Processing Workshop

Project Leader

The goal of our project was to eliminate defects during painting of the parts. After analyzing the problem and studying the defects under a microscope, we ­identified­ several reasons for deviations from the standard and outlined our own solutions for each of them. The first problem detected was the appearance of small specks or fluff on the painted part surface . As a solution, it was proposed to install a new fan and seal the premises The second problem was certain painting defects. The solution was to optimize the process of preparing parts and select the optimal proportions of paint components. The third problem was paint sagging on parts. To eliminate them, new nozzles have been developed.
Team of the “Plastic production workshop” project:
Kistaman Alibekova, engineer.
Workshop of Mechanical Production and Painting:
Maxim Vaganov, engineer.
Technical Development Department:
Ivan Antropov, engineer.
Outsourcing Development

Igor Zubarev

Chief Process Engineer

Technical Development Department Project Leader

The Outsourcing Development project was started two years ago and will continue.
Together with the purchasing department, we find contractors who can carry out certain work, for example, those who are engaged in plastics injection molding, and transfer part of our molds to them for processing. In future, we plan that these companies will not only manufacture parts, but also assemble finished units. This will allow us to optimize the operation of our assembly lines: speed up and simplify the assembly process, and distribute personnel on the line in more efficient way. The final purpose of the project is to transfer all processes prior to assembly to external contractors, and just engage in assembly at the plant. We plan to keep control over complex parts only, such as the washing machine tank, transparent parts for refrigerators that are difficult to transport, etc. This can save up to 8 thousand euro per year. For the moment we have already outsourced 156 of the 219 forms.
Project team
Technical development department:
Daria Bulina, technician.
Product Development Department:
Ivan Ermilov, Design Engineer;
Vladimir Remnev, Design Engineer.
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