Thermal power forging industry is an important part of the field of thermal power generation, mainly responsible for the production of key components, such as turbine blades, rotors, etc. With the adjustment of energy structure and the growth of power demand, the manufacture of thermal power forgings is facing increasingly fierce market competition. In order to enhance competitiveness, reducing costs has become a common goal within the industry. At present, the total cost of manufacturing thermal power forgings is high, among which raw material cost, labor cost, energy cost and so on are the key influencing factors.
Strategy analysis
Production process optimization: By optimizing the production process, unnecessary links and waste can be reduced and production efficiency can be improved. For example, improve the mold design, optimize the forging process, improve the level of automation.
Equipment upgrading: The introduction of advanced forging equipment and production lines can improve production efficiency, reduce energy consumption and reduce labor costs. For example, the use of efficient forging press, automated production lines, etc.
Raw material substitution: Finding more cost-effective raw materials can reduce raw material costs. For example, the use of new alloy materials instead of traditional materials can meet the performance requirements and reduce costs.
Lean production: The implementation of lean production mode, through the elimination of waste, reduce costs, improve quality and other means to achieve sustainable development of enterprises. For example, the implementation of 5S management, the implementation of total quality management.
Concrete measures
Production process optimization: Organize an expert team to conduct a comprehensive assessment of the production process, identify bottlenecks and waste points, and formulate targeted optimization measures. At the same time, strengthen staff training and skill upgrading to improve production efficiency. Time schedule: To be completed within six months. Resource allocation: Set up a special team to optimize the production process.
Equipment replacement: research the market of advanced forging equipment and production lines, combined with the actual situation of the enterprise to make procurement plans. At the same time as the new equipment is introduced, the old equipment is modified or sold. Time: Within one year. Resource allocation: Set up equipment procurement team, responsible for equipment replacement work.
Raw material substitution: Cooperate with suppliers to develop new alloy materials with higher cost performance. The performance and cost advantages of the new materials are verified by experiments, and the traditional materials are gradually replaced. Time: Within one year. Resource allocation: Set up material research and development team, responsible for raw material substitution work.
Lean production: Implement 5S management, total quality management and other lean production methods to train employees’ lean thinking. Reduce costs and improve quality through continuous improvement and elimination of waste. Schedule: Ongoing. Resource allocation: Set up lean production promotion team, responsible for lean production work.
Effect evaluation
One year after the implementation of the cost reduction strategy, the effectiveness of the measures was assessed. It is estimated that production process optimization can improve production efficiency by 10%, equipment replacement can reduce energy consumption by 20%, reduce labor costs by 15%, raw material substitution can reduce raw material costs by 8%, and lean production can reduce overall costs by 5%. Overall, the cost reduction is expected to reach about 30%, and the measures are sustainable.
The cost reduction strategy of thermal power forging manufacturing mainly includes production process optimization, equipment replacement, raw material replacement and lean production. Through the implementation of specific measures, it is expected to achieve a cost reduction of about 30% and improve the competitiveness of enterprises. In the implementation process, it is necessary to pay attention to such issues as risk control, staff training and resource allocation to ensure the effective implementation of measures and the sustainable development of enterprises.
