While ensuring the quality of forgings, how to improve production efficiency has become an important goal pursued by forgings manufacturers. As a new breakthrough in forging production, improving the striking efficiency of the press plays a vital role in achieving this goal.

1. Influencing factors

The low efficiency of the press is mainly affected by the following four aspects:

Equipment itself: equipment aging, frequent failures, unreasonable structure and other problems will lead to a decline in the efficiency of the press.

Process: unreasonable production process design, imperfect operating procedures, improper process parameter control, etc., will have a negative impact on the efficiency of the press.

Raw material quality: poor quality of raw materials, inconsistent specifications, and low material utilization rate will also lead to low efficiency of the press.

Operation technology: Insufficient skill level of the operator, insufficient mastery of the equipment and lack of effective communication and collaboration will lead to reduced efficiency of the press strike.

2. Practical application

In the actual production process, the application effect of the above optimization measures may be different. The following takes a forging manufacturer as an example to introduce the specific application of these optimization measures:

In the face of intensifying competition in the forgings market, the manufacturer has taken the following measures to improve the efficiency of the press strike:

Improve the equipment structure: the existing press is reformed, and the new high-precision servo forging press is adopted, which reduces the number and time of maintenance and improves the production efficiency.

Adjust the process flow: Through the re-planning of the production process, the multi-batch and small-batch production is realized, and the waste and unnecessary links in the production process are reduced. At the same time, strengthen the mold management and plan management, improve the accuracy of the production plan and the utilization rate of the mold. These improvements have resulted in a 20% increase in productivity.

Selection of high-quality raw materials: Establish long-term cooperation with reliable raw material suppliers to ensure that the specifications and quality of raw materials meet the requirements. At the same time, the inspection and inventory management of raw materials are strengthened to prevent the quality and production schedule of forgings from being affected by material problems. These measures have reduced the waste rate of raw materials by 15%.

Optimize operation technology: strengthen the training of operators, promote new operating methods, and improve the skill level of operators and the degree of equipment mastery. At the same time, the communication and collaboration between various departments have been strengthened to ensure that problems in the production process can be solved in time. These improvements increased the press striking efficiency by 30%.

In the process of implementing these optimization measures, the manufacturer has also encountered some problems and challenges. For example, the transformation of some old equipment is more difficult and requires more investment of funds and technical strength; The adjustment of process flow may affect the normal work arrangement and salary level of some employees; Choosing high-quality raw materials may increase costs, etc.

To solve these problems, the manufacturer has adopted corresponding solutions: reasonable arrangement of capital investment and technical support, as far as possible to reduce the impact of the transformation on normal production; Strengthen employee communication and coordination, reasonable arrangement of working hours and wage level adjustment; Strengthen cost management and raw material procurement management, and reduce the cost as far as possible under the premise of ensuring the quality of raw materials.