Injection molding machines (IMM) used in production require routine maintenance, including lubrication of carriages, replacement of faulty parts and belt tightening. This requires constant access to certain elements, such as the robotic arm or the hopper.

We have found a solution to ensure safety when working at height. Jointly with the team, we planned the manufacture and installation of special frames and platforms for access to the upper part of the equipment. We calculated the required amount of materials and prepared drawings. Then welders made the structures, machine operators processed the plates, and fitters installed the finished platforms. The work keeps going, since each piece of equipment has unique parameters and requires the manufacture of platforms of different dimensions.

Thanks to the implementation of this project, we will be able to ensure the safety of our staff and reduce the maintenance time of injection machines.

The project idea belongs to my supervisor, Zubarev Igor Valerievich, who suggested creating an application and a single database with all the information on a specific type of equipment and gadgetry, including a passport, weight, dimensions, resource and other specifications. When scanning a QR code, you can quickly obtain all the information in a single package.

We decided to focus on one supplier and identified several categories of equipment and gadgetry: washing machines and for refrigerators.

The primary benefits of the project implementation for the company are as follows: it allows us to get detailed information on the condition of equipment and gadgetry, create a uniform database, simplify the inventory process, and speed up the transfer of gadgetry tooling and equipment to another supplier.

The work started at the beginning of 2024, where we collected and structured a major part of the information. But this is not the final version of the documentation yet - we'll keep updating it and adding new information. In 2025, we will develop the technical specifications of the application, integrate the QR code, create a beta version of the application and launch the system.

We have analyzed the refrigerator assembly line for 2023 and found three areas of improvement: attendance, qualification and employees' satisfaction parameters. To reduce the number of administrative leaves, we introduced additional incentives for employees in addition to performance indicators benefits. For the purpose of their professional advancement, we analyzed the knowledge of each employee according to the "Competence" matrix. Many employees wanted to learn related specialties. So that we launched a training program for everyone both within the department and at some stations.

We began to work on employee satisfaction level and started up a survey to identify the key elements that negatively affect work attitude, and developed a program for non-material incentives: now we chose the employee of the week/month. We changed the bonus criteria by adding extra points. We improved work spaces for comfortable work.

The project implementation gave the following results: the absence percentage decreased (9.6% in 2023, 7.7% in 2024). And staff satisfaction has increased (47% in 2023, 60% in 2024).

To assist the operator in the process of applying the logo to the refrigerator door, a collaborative robot was installed at the assembly line. Using a scanner installed at the previous station, the standby mode robot receives information on the height and width of the refrigerator right in front. This is the starting signal for an automatic application of the logo.

We made an aluminum plate tool with pre-installed sensors for the robot to determine the location of the refrigerator in space, vacuum grippers for transferring the logo, and a silicone roller to press and roll on the surface. Thus, first the position of the refrigerator is determined, then the logo is applied, and then it is pressed and rolled. This helped reduce the time of the operation when applying the logo.

Work on the project lasted for a year, from the end of 2023 to November 2024. The project is now running successfully, but we constantly monitor it in order to make some adjustments to the program if necessary.

Compressed air leaks and massive electricity consumption are common problems when operating compressor equipment.

To detect compressed air leaks, we installed metering units, including a pressure sensor, a temperature sensor, and a flow rate meter.Then our electricians laid cables at about 300 m lengthwise. The metering unit was connected to the monitoring system. Now we can see the readings, analyze them, and eliminate leaks. These units are installed at the plastics shop, the washing machine assembly line, and the paint shop.

There are vacuum and pressure sensors were installed and a video recorder set up in the boiler room and at the refrigerator pre-production shop (for each thermoforming machine). Now we can monitor potential risks online.

The work on the project started in early 2024, and it is now fully implemented in the production process. Now that it is working, we can use electricity wisely and efficiently, as well as reduce financial costs. The payback period is within one year.