QC results - 200 liter steel drum once coated (2)

QC results - 200 liter steel drum once coated (2)

Lanzhou Barrel Factory Xin Qiaojuan

5. For the main reasons, formulate measures and propose an action plan. Countermeasure table (5WH)

Serial number
main reason
Influencing factor
aims
Measure
location
Completion person
Date of completion
1
The quality of the glue 1. Viscosity
2, curing ingredients
3, adhesion Select high-quality sealant test to determine the performance of various plastics laboratory Zhao Xinchang
Qu Xingyuan 91-11-20
2
Personnel quality 1. Technical level: no job training; new workers.
2, management level: production beat imbalance; no daily inspection; no assessment of process discipline. Adapt to production requirements. Can complete various tasks according to process requirements, carry out post training and develop management system.
Office Hao Huilan
Xin Qiaojuan 91-11-7
3
Equipment tooling accuracy 1. The flanger has a non-uniform flange size.
2. The pre-roller pre-roll size is small: the upper plate is not tight; the pre-rolling roller is unstable.
3, the crimping machine is not tightly crimped: the precision is poor, unstable; there is a problem with the rolling groove. Meet the process requirements, produce qualified products, update and adjust according to the actual situation, a workshop
Three workshops Wang Sen, Xin Qiaojuan,
Hao Huilan, Wang Jincheng,
Liao Jufang, Ding Baolan,
Sun Xiang, Chen Wenlong

91-11-12

to

91-11-20

Sixth, implementation measures

1. Measurement test: After repeated measurement, the following set of data is obtained, and the number of measurements is 10 times (average value)

project
Place of origin
Xiamen
Lanzhou
Xi'an
Baoji
Viscosity (centipoise)
1800
3800
4000
4000
Curing composition (%)
30
38
71
64
Adhesion
weak
weak
Strong
Strong

It can be seen from the above table that the quality indicators of Xi'an rubber are higher, so we selected Xi'an rubber.

2. Conduct post technical training and strengthen post operations

Situation Analysis
Implementation plan
Implementation and effect
The number of participants
Pass rate(%)
There is no systematic understanding of the sealant, and the quality and use of the glue are determined by the feeling. Describe the performance, specifications, quality standards and methods of use of sealants. Have a clear understanding of the performance, quality standards and methods of use of sealants and can be used correctly. Do not meet the requirements and do not use.
10
100
The product size does not meet the process requirements; the on-site management is poor, the waste and defective products are piled up in chaos, the process hygiene is not up to the requirement, and the job rotation is frequent. Serious process discipline, linking process assessment and economic responsibility system, so that the process qualification rate rises. The implementation of the "three fixed" is the fixed, fixed, and fixed types of work, serious process discipline, and improved the skill level of employees.
54
100
Poor management awareness, there is no system to implement. Strictly assessed and linked to the economy. The process discipline has improved significantly, and the first pass rate of the product has increased.
54
100

3. Update equipment and tooling to improve accuracy

Situation Analysis
Implementation plan
Implementation and effect
Complete time
Completion person
1. The flanger does not meet the product process size requirements. At present, the flanger is unstable in rolling forming. 1 update the edging machine.
2 Adjust the old flanger before the new equipment arrives. 1 The forming mechanism of the newly purchased edging machine is the forming of the mold, and the hem is even.
2 Adjust the old cuffing machine at any time to make the flanging size meet the process requirements. 92-9-25
The whole process of production Hao Huilan
Xin Qiaojuan
Chen Wenlong 2. The pre-roller is not tightly pressed, displaced, and the pre-crimped size is small, and the edge between the upper disc and the lid is in line contact. Rebuild the nut on the pre-roller's upper disc and roller positioning. 1 Re-engineering the pre-roller on the upper plate, changing the line contact to face contact, that is, widening the edge of the upper plate, so that the upper plate can be pressed.
2 Rework the roller positioning nut. 91-12-10
The whole process of production Xin Qiaojuan
Wang Sen
Liao Jufang 3. The crimping machine does not bite mechanically and the steel drum leaks. There is a problem with the rolling wheel groove. Poor precision, unstable, and subject to change. 1 Redesign the crimper wheel.
2 Adjust the device at any time. 1 Processing trial crimping machine roller. The curled edge is seven. Layer, no leakage.
2 Adjust the movable arch on the crimping machine with the elbow, the head of the crimping machine, the front, back, left and right dimensions of the two rollers, and the rolled out barrel does not leak. 91-11-12
The whole process of production Xin Qiaojuan
Hao Huilan
Wang Sen
Wang Jincheng
Sun Xiang
Ding Baolan

Note: Regarding the groove shape of the crimping machine, it is introduced here, because the key process of the barrel is here. The following is a schematic diagram of improving the groove shape of the front and rear crimping head.

Pre- and improved improved roll-to-roller head groove forming curve

The improved roller groove is composed of two arcs tangent, and the improved roller groove is composed of an arc and an involute of a circle having a diameter of 4. The improved roller groove is easily formed by crimping.

VII. Checking the implementation of plans and measures

1. Effect test: We verify and check the results of the above plans and measures. The leakage of the steel drum after one gluing was measured. The statistical data of the measurement are shown in the statistical table.

Data statistics

Serial number
Number of barrels
Big circle
On the big circle
One pass rate (%)
Remarks
1
700
1
2
99.57
After 45 minutes of spraying the sealant, crimping was completed in 4 hours.
2
700
2
3
99.28
3
700
1
1
99.71
4
650
3
1
99.38
5
700
2
2
99.43
6
750
1
2
99.6
total
3200
10
11
99.5

It is obvious from the above statistics that our activities are fruitful.

Compare the effect after the event with the target value and status

2, economic benefits: from the above bar chart can be seen, after the event:

(1) The first pass rate of the steel drum is improved. The pass rate of steel drums has increased from 60% to 99.5%, an increase of 39.5%. It is 3.5% higher than the target value.

(2) Saving sealant and increasing economic benefits.

The unit price of glue: 9.7 yuan / kg, saving glue O. 03kg / only, a total savings of 0.3 × 9.7 × 15 = 4.365 (ten thousand / year)

Steel barrel capital increase: 5.0 yuan / only, the pass rate increased by 39.5%, a total of 5 × 39.5% × 15 = 29.625 (10,000 / year)

Total 33.99 (ten thousand yuan / year)

3.5% higher than the target value, saving 5 × 3.5% × 15 = 2.625 (ten thousand / year)

Note: The annual output is calculated based on 150,000.

(3) It improves the cleanliness of the equipment on the production site, improves the working conditions of the operators, and is conducive to civilized production.

Eight, standardization

After the successful test of the process, after five months of consolidation, it is confirmed that the result is in full compliance with the actual situation of the production of steel drums in our factory. For this reason, we will incorporate the relevant projects into the management standards of the Japanese production, and incorporate them into the project system map. Said.

Nine, experience and next activities

After this event, all of our members have a deep understanding. Everyone agrees that it is very necessary to carry out QC group activities. It can be a collection of 100 families and a short family. It is possible to solve many difficult and long-standing problems in a short period of time, so it is necessary to regularly exhibit QC group activities. Our team is not satisfied with the achievements we have made. Based on the success of this research, we are going to renovate the edging machine and the crimping machine, and also apply glue to the other steel drum products in the workshop without leakage. Process. These issues leave a PDCA loop to resolve.

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