A technological innovation, investing 180,000 yuan, increasing gross profit by nearly 2.5 million yuan a year. Yihua Filament Center under the excessive competition of conventional products, in 2007 through the transformation of the device line can only produce FDY, the development of high value-added POY fine denier porous filaments, widen the device's product production capacity, reduce Loss of production of conventional products. This is just one case in which the Center has adapted to market competition in the past two years, extensively carried out technological transformation and technological upgrading, upgraded the technical capabilities and quality of the device, and realized potential and efficiency enhancements.
Two-pronged introduction of new products At present, there is a serious overcapacity in the domestic filament market. The production lines of advanced private enterprises are generally invested after 2004. The technology is advanced, the ability to produce high value-added products is strong, the efficiency is high, the product uniformity is good, and the market competitiveness is strong . The final production line of the filament center was also before 2001. In response to the gap with its rivals, the center has established a technical innovation plan, implemented responsible departments and responsible persons, focused on technological transformation, and focused on technological breakthroughs, actively developing new products. Improving the added value of products and constantly reducing the gap with competitors.
Compared with other FDY production lines, the FDY52 line has the disadvantages of duplicity and low added value, and has always been the focus of the loss of the center. In 2007, the Filament Center and the Shanghai Sales Branch conducted extensive market research and decided to retrofit 52 lines that can only produce conventional FDY, and the production price is higher than that of conventional products. This move has broadened the product's production capacity and improved its market competitiveness. Next, they also promoted this innovative idea in the production of ordinary FDY products on the 53, 54 line, and carried out a double-end spinning transformation, so that 53, 54 lines have the ability to produce fine denier FDY, each ton of products increased year-on-year to other lines. The profit of about 300 yuan, to solve the severe Dan FDY strong market season, the off-season market prices fell seriously, the issue of marginal losses, reducing the risk of FDY production line operating parking.
Technical breakthroughs are another important way for the filament center to introduce new products. A joint venture in Zhejiang mainly produces high-end home textile products for export. The requirements for raw materials are very strict. Their marketing staff once said: "If we don't meet the requirements of our products, even if they are cheaper at 1,000 yuan/ton, we don't need to use them." To such high-end customers, the Filament Center started its research on FDY 55 and 56 lines from the second half of last year. Process technicians have broken through the range of high and low shrinkage rates of the original device design by strengthening the control of spinning temperature, draw ratio, and enhanced spindle position management to produce a very popular felt special material on the market. The stability exceeded the advanced level of the local private enterprises in Zhejiang and was recognized by the joint venture company. Orders continued to expand over the past six months.
Adding power to improve quality Due to the particularity of filament products, each cake issue will result in one customer complaint. Filament Center in the long-term communication with the user, get such a conclusion: good quality of filament products is not only a good indicator, the user's use of good reflection is really good. Therefore, continuing to meet the quality needs of users, even if it is an inadvertent confession, has become another direction of the center's technological innovation. In 2007, they focused on the long-term existence of black and yellow paste components affecting the quality of the product, the organization of the module structure of technical improvements, the use of a new design of umbrella filter and modification of the distribution board (φ85), so that the proportion of black yellow paste inside the component From the original 35-40% to zero. In 60, 61 lines through the lengthening of the component connection block technology, so that product quality to meet the YIHUA YUHUI production KDY demand. Especially after the completion of the FDY double-spinning spinning, due to the production of fine denier products, the cakes are unstable in the warping and unwinding of users. Once the users complained more, the center organized the site management technicians to wind the molding. The parameters were improved, and the quality of the paper tube was also made more stringent. The key issues affecting the quality were solved. By the fourth quarter of last year, the user complaints had dropped to zero.
Supporting energy conservation and consumption reduction In 2007 and 2008, the company respectively gave a 3-5% energy saving target to the Filament Center. For this purpose, the center has established a number of technical research teams to adopt new technologies, new processes, and new materials. Technical transformation measures were implemented in the production process and operation equipment, and the role of science and technology innovation in energy conservation and emission reduction was brought into full play. In 2007, the comprehensive energy consumption ratio decreased by 3.11% compared with the previous year, a decrease of 6.68% year-on-year.
The just-concluded replacement of chilled water by the power plant's circulating water is a problem that the center's technical staff has been trying to do but failed to put into action. After the original power plant chiller was shut down in winter, cooling and cooling were still needed due to filament oil, some electric air conditioners, and the cold water pump was operating normally for cold water circulation, which greatly shortened the downtime of the chiller. If you can use recycled water instead, you can completely stop the refrigerator in winter. However, how to achieve the docking of the circulating water pipe and the frozen water pipe is a technical bottleneck when the circulating water is not stopped. In this transformation, the center has repeatedly used a new pressured open hole technology to repeatedly press a hole with a diameter of 500 mm in a circulating water pipeline with a diameter of 1100 mm to successfully connect the circulating water to the cooling water system. The on-site technical staff said proudly: “This technology is still being used for the first time in the company!†After the completion of this transformation, it is expected that the refrigerator can be completely shut down from mid-November of last year to the end of March of the following year. Savings of nearly 370,000 yuan, and the cost of transformation is only less than half of this fee.
At present, the center is rushing to implement innovative projects such as the implementation of the recirculating cooling towers, steam condensate recycling, and full-scale promotion of dew point ventilation, which will surely achieve better results and ensure the center's annual energy saving, emission reduction and cost reduction. New breakthroughs have been made in efficiency gains.
Die casting is a Aluminium or Zinc metal casting process that is characterized by forcing nolten metal under high pressure into a die mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mould during the process. Most die castings are made from non-ferrous metals, specifically zinc, copper, aluminium, magnesium, lead, pewter, and tin-based alloys. Depending on the type of metal being cast, a hot- or cold-chamber machine is used.
The casting equipment and the metal dies represent large capital costs and this tends to limit the process to high-volume production. Manufacture of parts using die casting is relatively simple, involving only four main steps, which keeps the incremental cost per item low. It is especially suited for a large quantity of small- to medium-sized castings, which is why die casting produces more castings than any other casting process. Die castings are characterized by a very good surface finish (by casting standards) and dimensional consistency.
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