"Komtelenergo" by 50% reduced the time of working processes

2023

50% reduction in workflows

The enterprise "" Komtelenergo summed up the results of six months of the national project "Labor Productivity." The operator of the national project is, Regional Competence Center (RCC) operating on the basis of the Business Development Agency, Kaluga region which announced this on August 11, 2023.

The pilot flow for the introduction of lean production was the process of manufacturing spiral reinforcement. Products are one of the main in the company's revenue and participate in the import substitution program. During the diagnosis, 30 problems were identified here, 97 measures were formed to achieve the target state.

In order for the project to be implemented efficiently, a separate group is needed to carry out all activities. I thank the employees responsible for the implementation of lean technologies. They devoted a lot of time to these processes. During the first stages, many obvious and long-silenced problems surfaced. Those that can be solved promptly and without unnecessary costs, but about which everyone is silent because they are used to them. The production analysis helped to identify them, and eliminate the tools of lean production, - Vsevolod Plyasov, head of the working group on lean production of the Komtelenergo enterprise, shared his observations.

As a result of the implementation of the first measures of the national project, it was possible:

• 78% reduction in the time of equipment re-installation and reduction of the level of adjustment scrap due to the development and manufacture of a new type of tooling;
• reduce the adjustment time of molding machines by 41% due to the purchase of additional components;
• Reduce workflows by almost 50%
• Increase employee production by 21%.

As a result of the main stage, we see the implementation of all measures at the plant, and the greater involvement of employees in processes. This was noted by federal experts when certifying the regional competence center in May 2023. In August 2023, the results became even higher. There are even more opportunities ahead, both in the field of applying new production experience, and in the direction of business development, entering new sales markets, participating in the national project "International Cooperation and Export." In turn, we are ready to help in this, using all available tools of state support, - said the acting Head of the Business Development Agency Nikolai Tubenshlyak.

Diagnostic and Planning Deliverables

At the enterprise "Komtelenergo" summed up the results of the stage "Diagnostics and planning" of the national project "Labor productivity." The operator of the national project is the Regional Competence Center (RCC), operating on the basis of the Kaluga Region Business Development Agency, which announced this on May 25, 2023.

The company at the end of 2022 became a member of the national project. The production of spiral fittings was chosen as the pilot flow for improvements. Products are one of the main in the company's revenue and participate in the import substitution program. A twist section is selected as a reference.

During the analysis of production processes, such losses as waiting for raw materials, unnecessary movements during the shift, manual transportation were identified. In total, during the diagnostics, 30 problems were identified, 97 measures were formed to achieve the target state of spiral reinforcement production. To date, many of them have shown effectiveness:

• The development and manufacture of a new type of tooling made it possible to reduce the changeover time by 78%.
• Ordering additional reel sets to wind up the product by 41% reduced the time required to retool the equipment.

The company also introduced a system of autonomous maintenance of equipment performed by the operator himself. The equipment storage area was organized, operational and adjustment standards were created.

All employees are involved in the improvement process - both production workers and company management. The system of primary training and mentoring was launched. At the next stage "Implementation" we will minimize equipment downtime, develop employee competency matrices. We plan to introduce a system for submitting racialized proposals, a system for effective organization of the 5S workspace throughout the enterprise. We will develop a plan for the replication of lean tools to all areas. These measures will increase labor productivity and, accordingly, the volume of products produced, - Sergey Averkin, project manager of the RCC, shared his plans.

Start of activities of the national project "Labor productivity"

Activities of the national project "Labor Productivity" have started at the Komtelenergo enterprise. The operator of the national project is the Regional Competence Center (RCC), operating on the basis of the Business Development Agency of the Kaluga Region. This was announced on February 8, 2023 by representatives of the Business Development Agency.

Helical Reinforcement Manufacturing Area

As reported, the Comtelenergo company at the end of 2022 became a member of the national project. Immediately, a working group was formed to implement lean tools. Employees were trained and trained at the Process Factory. The production of spiral reinforcement was chosen as the pilot flow for the changes. Products are one of the main in the company's revenue and participate in the import substitution program.

There are several key tasks that we want to solve on the pilot stream. These are: optimization of the time of processes, as a result, a decrease in cost, a decrease in re-adjustment time, and minimization of scrap. All these measures will lead to the optimization of production - the productivity of each employee. Everyone should fight for this indicator - both the master and the employee. But the main goal is to transfer the methodology of lean production to specialists so that they themselves optimize processes in other areas. voiced tasks at the launch meeting Sergey Averkin, RCC Project Manager

As of February 2023, the stage "Diagnostics and Planning" is underway at Komtelenergo, the current state of production is being analyzed. Employees implement production analysis, create an information center, select a reference area for changes.

Shop

As of February 2023, we do not analyze movements, operations, the entire chain of the production process. And this is necessary. We need a smart, lean employee ideology, efficiency and engagement. I want people to never leave us, so that they trust us in everything. And we have to be sure of them. I would like to achieve stability of both the team and the processes. summed up Chubin Andrey, founder of Comtelenergo LLC

2022: Joining the Labor Productivity Project

Komtelenergo LLC joined the national project "Labor Productivity." The company will be helped to introduce lean production by experts from the Regional Competence Center (RCC), which is the operator of the national project. The center operates on the basis of the Kaluga Region Business Development Agency, which announced this on December 7, 2022.

Since 2008, Comtelenergo under the Install brand has been producing line fittings for fiber-optic communication lines, optical cable and cable network components. As of December 2022, the company is represented by branches in 16 Russian cities. Comtelenergo products are used by representatives of the domestic communications and telecommunications market. A large production site is located in Kaluga and produces more than 2 million products per month.