Spinning mill production cost management
Under the influence of many unfavorable factors, the profits of textile enterprises, especially spinning enterprises, are particularly meager. So where does the profit come from? Only strictly control the production costs in order to strive for greater profits. Dongguan City Theshow Garment Co., Ltd , https://www.theshowjacket.com
The production cost involves many factors such as process, equipment, operation, public works, management, etc. The raw materials are the key points, the energy should be firmly grasped, the work must be streamlined, and the consumption should be strictly controlled. The implementation of each aspect of work will play a vital role in production costs. Therefore, it is necessary to strengthen the management of various tasks, strictly assess, reduce production costs, and achieve the goal of improving economic efficiency.
The use of cotton to control raw cotton is based on quality, different fiber lengths, different grades of raw cotton prices vary greatly, raw cotton in the cost of cotton yarn accounts for about 60% to 80% (depending on the variety), to make the best For economic effects, we must first pay full attention to the economic use of raw materials, maximize the spinnability of raw materials, and make products as high-grade as possible. Secondly, under the premise of ensuring the quality requirements of finished products, the raw material consumption should be reduced as reasonably as possible. It is the essence of spinning to produce yarns of the highest quality to meet the requirements of users with the cheapest raw materials.
After the raw materials enter the factory, the raw cotton is required to record the weight of the steamed bread. The number of the steamed bread is not allowed to be estimated. In addition, the special batch number should be set to pack the pounds. The results of the complex pounds should be recorded in detail. The actual weight and loss should be reflected to the competent authorities in a timely manner.
The cost of cotton for reasonable blending is determined by the amount of cotton used and the unit price of raw cotton. The amount of cotton used is closely related to technical factors. The technical factors affecting the cost of cotton include yarn quality requirements, raw cotton spinnability, and process design.
Different quality yarns have different quality requirements, and some quality items will affect the cost of cotton. Quality and cost are often contradictory. We must say "quality first", but not "quality only." To make a yarn that meets certain standards with different properties of raw cotton, it must go through different processes. Therefore, both the yarn quality and the raw cotton performance are reflected in the process design, which are essential.
Formulating a reasonable consumption quota The cotton quota in the “Measures for Calculating the Fixed Cost of Cotton Textile Products†(2000 Edition) of the State Textile Industry Bureau is formulated according to the industry average. The spinning mill should be based on this. The cotton quota should be determined through technical measurement, test and calculation, combined with historical statistics, and strive to control cotton, save cotton, reduce costs and increase profitability under the premise of ensuring quality. The use of cotton quota is a comprehensive figure. Its composition content is many, including the use of recycled flowers, re-use of cotton, super-accumulation, profit and loss and other factors, including the production rate of each process, cumulative production rate, production of flowers, cotton and other factors.
Reasonable control of combing and combing in the process design, the most important relationship between the use of cotton costs is the elimination of impurities and short velvet. Because the impurity removal and the discharge of the short piles are required to produce various kinds of losses such as cotton that cannot be used equally.
To control the cotton, you must pay attention to the point that it is more cost-effective to fall where and where it should fall. Therefore, to control the quality and control cotton, the three processes of cleaning, carding and combing can be used as the key points to control the cleaning and carding according to the degree of raw strips, combed strips or cotton mesh neps impurities. And combed cotton.
Reducing the returning flower and improving the production rate of the finished product will not only directly reflect the operation management and operation level of the workshop, but also directly affect the amount of cotton used. The less the recycled output, the less the recycling, and the more stable the life. The lower the wear and the lower the amount of mixed cotton. To this end, each process must strictly control the amount of returning flowers, and the indicators should be decomposed and implemented.
The yarn breakage rate, which is also an indicator closely related to actual production and consumption, is also a comprehensive indicator reflecting the management level of spinning enterprises. Reducing the rate of yarn breakage is an important aspect of saving cotton, and it is also the direction of enterprise efforts, and has a close relationship with cotton, process, equipment, operation, air conditioning and so on.
Reinforce the management of the lower foot. Re-use cotton, silk return, scraps, etc. produced in the spinning process should be sent to the lower leg to sort over the weight, fix the stacking location, specify the treatment method, reuse or storage. Therefore, the role between the lower feet is very critical. Acceptance between the lower feet, statistical work should be accurate, should be set up by a special person, and must have a sampling system, strictly according to the number of varieties to distinguish all types of feet, mixing is strictly prohibited. When returning flowers and reusing cotton blends, the quality should be checked regularly, and the mixing method and proportional use should be specified.
Energy-saving management saves electricity using frequency conversion technology, air-conditioning fans and pumps use variable-frequency control; it is a mature technology to install inverters for motors that require frequent shifting adjustment, and should be actively promoted and applied.
Reactive power compensation is adopted. Since the equipment used in the spinning mill is basically driven by electric motors, it is an inductive load, and its reactive current is relatively large, which increases the line loss invisibly. Therefore, in the high-voltage power distribution room and the low-voltage power distribution room, Capacitors are installed in high-power motors to save power and have significant effects.
Of course, the merger of the machine, the use of peak and valley electricity price difference, production synchronization and enhanced lighting management are also the main means of saving electricity.
Save steam to avoid steam consumption just below the price rating of the price bureau; avoid small flow (ie flow below 1/3) and large flow (super rated gauge), because the specified steam flow is less than 1/3 of the rated amount According to 1/3 metering, the super-rated metering quantity is doubled; the workshop insulation work is done; the measuring and detecting mechanism and the thermal power plant are kept in close contact to ensure the accurate measurement of the steam; the leaky valve is repaired in time, and the insulation layer of the steam pipeline is maintained. .
Save water to stop running leaks and find leaks in time for repairs.
It is necessary to save the use of air compressors and the use of gas equipment such as cloth machines; it is forbidden to use compressed air for personal cleaning; air leaks are found and repairs are carried out in time.
The labor-saving workers use equipment with relatively high degree of automation, such as automatic winder, carding, and fine yarn collective doffing devices.
Improve the operation method. If the operation division is further refined, the spun yarn is blocked, the roving is changed, and the cleaning is separated, so that the division of labor is more refined and the labor can be saved.
Increase the ability of the guards to stand. The measures are: reducing the rate of yarn breakage. Involving equipment, technology, cotton blending, air conditioning, etc.; appropriately reduce the speed of the vehicle and reduce the rate of broken ends. This item needs to be carefully calculated before it can be implemented.
Strictly control the number of second and third line employees.
Strengthening equipment management, reducing machine material consumption, strengthening equipment management, and maintaining equipment in good condition are prerequisites for reducing machine material consumption.
Ensure the sensitivity and reliability of the cleaning and self-stopping device; establish a reasonable quota for equipment maintenance and consumption; for the grinding and replacement of the carding equipment and the rubber roller, it should be based on the product quality and reasonable arrangement; the variety change arrangement machine should be considered and equipment Supporting; actively develop and find domestically produced parts that can replace imports.
Integrated management to strengthen program management, reducing downtime and increasing production are also important aspects of cost savings. Reasonably arrange the production plan, reduce the host stop time as much as possible, and reduce the cost per unit of product. When arranging the front spinning machine, it should be ensured that the front spinning equipment has a certain load, so that the front spinning has too early closing time.
Reasonable control of temperature and humidity to control the temperature and humidity of each process to stabilize the cotton and workshop life. First of all, it is necessary to tighten the management of doors and windows, do a good job of insulation and moisturizing, especially the moisturizing work in the packaging room is very important. As the package is carried out for a period of time after the resurgence of the tide, the reduction in humidity will cause the yarn to be sold as water, a phenomenon that is particularly noticeable during the spring and autumn seasons.
Before the finished product is packaged daily, the laboratory samples and checks the cotton yarn regain. According to the measured resurgence, the weight of the cotton yarn is accurately calculated. The packager according to the pound bar produced by the laboratory, that is, the weight of the cotton yarn for each package, is weighed and packaged. The weight of the packaged package should be ±0.1kg of the official weight. The quality supervision department should check the package weight according to the l0% sample of each variety, and the package should be unloaded according to the requirements of the weight tolerance range.
Innovative rewards establish an innovative reward system, which annually includes technical transformation of equipment and components, improving product quality and output, reducing energy consumption and machine material consumption, and rewarding projects with significant economic benefits.