Sukreml Iron Foundry Team Results of Lean Technologies Implementation

2024

Results of the implementation of the national project "Labor Productivity"

The plant for the production of cast iron casting in the country JSC Sukremlsky Iron Foundry from the Lyudinovsky District of the Kaluga Region summed up the results of the implementation of the national project "Labor Productivity." The operator of the national project was the Regional Competence Center (RCC), operating on the basis of the Kaluga Region Business Development Agency, which announced this on September 16, 2024.

source = Kaluga Region Business Development Agency

Within the framework of the national project, at the primary stage, the working group of the plant was trained in the basics of lean production and consolidated the knowledge gained at the training "Process Factory." The members of the working group learned to analyze and revise the organization of production using the example of the gas gearbox assembly process.

During the implementation of the project, a system for organizing and rationalizing workplaces was introduced at the reference site: the system for storing tools and accessories was debugged, the places for storing scrap, finished products and semi-finished products in the CNC machine area were delimited. Workplace and stand-alone equipment maintenance standards were developed. Also, the storage locations of the workpieces were changed, which allowed machine operators not to waste time searching for them. In some areas, it was possible to achieve an increase in productivity by 20%. But the plant does not stop at the results achieved and continues to develop production processes.

We have done a lot of work to implement motivating provisions for improving jobs and rationalizing proposals, monitoring equipment operating time and staff workload. We believe that productivity growth is obliged to the introduction of the Standardized Work tool, - said Vitaly Avdyushkin, General Director of Sukremlsky Iron Foundry JSC.

It is pleasant that despite serious experience and great success in work, the enterprise team decided to participate in the national project and actively joined in the work on improvements. Thanks to the work done, it was possible to reduce marriage, and this is one of the main results of the project, - said the head of the Regional Competence Center Ivan Shirokov.

Lean Technology Interim Results

The team of the Sukreml iron foundry summed up the interim results of the introduction of lean technologies. This was announced on July 2, 2024 by the Agency for Business Development of the Kaluga Region, GAU.

Within the framework of the national project, at the primary stage, the working group of the plant was trained in the basics of lean production and consolidated the knowledge gained at the training "Process Factory." The members of the working group learned to analyze and revise the organization of production using the example of the gas gearbox assembly process.

The acquired knowledge and skills made it possible with the methodological support of specialists of the Kaluga RCC working on the basis of the Business Development Agency, Implement the first phase of the change implementation project - Diagnostics and Planning.

A system for organizing and rationalizing workplaces was introduced at the reference site: the tool and tooling storage system was debugged, the places for storing scrap, finished products and semi-finished products in the CNC machine area were delimited. Workplace and stand-alone equipment maintenance standards were developed. Also, the storage locations of the workpieces were changed, which allowed machine operators not to waste time searching for them. In some areas, it was possible to achieve an increase in productivity by 20%.

At any machine-building enterprise with a machine-tool fleet, the work must be digitized. Our production automation service has already begun to implement monitoring of equipment operation time and personnel workload, shared by the general director of the enterprise Vitaly Avdyushkin.

A lot of work has been done, but in order to consolidate the results obtained, we need to organize an information center for the mechanical workshop for carrying out short shift planers. We will soon complete work on motivating provisions for improving jobs and rationalizing proposals. Overall, productivity growth owes itself to the implementation of the Standardized Work, supplemented the head of the enterprise by the project curator and specialist of the RCC Maxim Davydov.

For the next three months, the plant team, together with RCC experts, will scale the result received at the pilot site for the entire enterprise.

The start of primary training in the basics of lean production

The team of the Sukreml Iron Foundry has begun primary training in the basics of lean production. This was announced on January 25, 2024 by representatives of the Business Development Agency.

The project operator in the Kaluga Region is the Regional Competence Center (RCC), which operates on the basis of the Business Development Agency.

After the primary training, the team will go through the "Diagnostics and Planning" stage, where the reference area will be determined. After that, under the guidance of the production wizard, the current state of workflows will be digitized. Within 3 months, the company will then establish a project office of instructors-employees of the company for the subsequent implementation of changes and replication of successful experience.

2023: Participation in the National Project "Labor Productivity"

The Sukremlsky Iron Foundry enterprise (Lyudinovo, Kaluga Region) became the 91st enterprise in the Kaluga Region participating in the national project "Labor Productivity." This was announced on August 16, 2023 by the Business Development Agency.

The process of introducing lean technologies will be supervised by experts from the Regional Competence Center (RCC). The center operates on the basis of the Business Development Agency and is the operator of the national project in the Kaluga region.

As of 2023, Sukremlsky Iron Foundry is one of the leading domestic iron casting enterprises in Russia. The company produces, among other things: brake locomotive pads, socket-free cast-iron pipes, sewer hatches and rain traps of various types. The production capacity of the plant is 70 thousand tons of casting per year.

I am very glad that one of the oldest industrial enterprises in Russia has entered the national project. The company's management sees great potential in the use of lean technologies. Since the company produces important products for the country, it will be an honor for us to work on it, to help move to a higher level of productivity, "said Ivan Shirokov, head of the RCC.

Kaluga Region joined the national project "Labor Productivity," initiated at the federal level by the president, in Russia Vladimir Putin 2018. As of August 2023, 91 enterprises take part in it. region

The national project is supervised by the First Deputy Chairman. Governments of the Russian Federation Andrey Belousov To achieve the goal of annual productivity growth, a to the country set of business support measures has been developed and is being implemented, which includes financial incentives, employment support and expert assistance in optimizing processes.