At present, there are two phenomena in spinning enterprises: one is based on cost pressure, reducing the number of people by a percentage every year, and technological transformation has not kept up. The other is often unable to recruit people, the spinning workshop lacks people to drive the cars, especially during holidays and hot seasons, or constantly increasing the working hours of operating operators, from 8 hours to 12 hours, or increasing salary as a bargaining chip. Blindly expanding Taiwan, the highest salary exceeded 9,000 yuan/month. The equipment is still the same, but the number of maintenance workers has decreased. Some 6 people are responsible for 36 cars, sometimes only 4 or 5 people are left. Workers’ wages have increased, but the quality of equipment maintenance has not improved, and the failure rate and the rate of end breakage have increased. , It can only be at the expense of product quality. Even when some companies are short of people, there is a phenomenon of replacing workers with management. This vicious lack of personnel not only causes management chaos, but also increases personnel turnover.

　　Of course, many companies choose to use reliable, highly automated, self-diagnosing, self-monitoring, intelligent equipment to replace manual labor, and the results show that they can produce high-end, high-value-added products despite fewer labor.

　　 Equipment stability is the foundation

Spinning production is a labor-intensive industry. In the early 1980s, the average number of workers for 10,000 spindles was 200 to 300. Although the performance of domestic equipment in the past was far worse than it is now, the old equipment emphasized meticulous maintenance and equipment status. Management to ensure the quality of equipment operation.

In recent years, technological progress has greatly liberated the labor force. The promotion and use of new equipment such as blow-carding, automatic winding, automatic drum change, and automatic transportation equipment has dropped significantly. In addition, the promotion of spun yarn collective doffing long carts, large quantitative and large drag The intensive use of techniques such as stretching, large barrels, large packages, unwrapped overall drum changing, and roving change have reduced the level of workmanship. This is an inevitable trend for my country's textile modernization to be in line with the world, but it does not mean that every factory can reduce people at will.

It is understood that many small and medium-sized spinning enterprises in China are still using A-line equipment in the 1980s and 1990s (it is estimated that this proportion accounts for more than 50%). These A-line equipment are low-grade equipment, with low production efficiency and high failure rate. , Frequent maintenance. The FA series products developed afterwards adopted preliminary mechatronics technologies such as frequency converters, display screens, and industrial computers, which belonged to the mid-range. There are still a large number of non-standard FA series or even non-model equipment on the market. This type of equipment has fewer failures from half a year to a year, and the failures gradually increase after 2 to 3 years. If you reduce the maintenance work at this time, it is tantamount to killing chickens. Finally, the high-performance spinning equipment introduced in recent years, the new type of blowing-carding unit, collective automatic doffing spinning machine, thick and fine winding, automatic winding machine, automatic transport device and other large-scale use of reliable equipment, high degree of automation, maintenance Convenience.

　　Many companies are willing to spend huge sums of money to import equipment. The main reason is the low failure rate. Even after 3 to 5 years of use, it will not increase the workload as long as the maintenance is performed according to the manufacturer's instructions.

　　Operation optimization focuses on details

　　 In addition to the equipment factor, it is necessary to comprehensively dispatch enterprise resources, deal with the contradiction between labor saving and stabilizing employees, and adopt flexible incentive measures to maximize benefits and ensure the optimization of output and quality.

　　 Strengthen the detail of employment management, and the operation items can be separated, such as the separation of blocking and roving changing, and centralized yarn changing. The spinning block is separated from the part of the cleaning, expands the level, reduces the work intensity, and can also moderately expand the stand capacity. Based on the above measures, the workload of medium-count and above varieties can reach 30-40 units/person, and they can also be combined. The long carts of the colony spinning frame are used to ensure that under the premise of end-breaking rate and retention rate, the set-stopping and doffing are In the first post, under the condition of keeping the amount of stands in the block, cancel the doffing work, increase the speed of the operator’s tour, use the "hand-held brake pedal pulley" to block the car, speed up the tour speed, improve the efficiency of the joint and the quality of the joint, especially the ring Spinning and rotor spinning long wheels are very effective in expanding the stands.

　　Maintenance management is critical

　　 The equipment maintenance methods of spinning enterprises are roughly divided into two categories, one is to adopt the traditional equipment maintenance mode. The security worker conducts round-trip inspections of the equipment, and performs daily, regular, precise, or key inspections. What is more detailed is to adhere to the principle of "area contract to the team, responsibility to charter planes to personnel, and to ensure that the equipment is intact at any time of the day", the "five packages and one link" responsibility system, and the "five packages" refer to the package output and package quality. , The package is intact, the package is consumed, and the package is safe. "One link" means that personal work performance is directly linked to performance pay. Shandong Liaocheng Guanxing Textile Group still adheres to the traditional equipment overhaul system, so that periodic maintenance and condition maintenance coexist and complement each other. Carry out equipment operation and operation competitions every year, reward innovative talents, pay close attention to preventive maintenance, prevent night shift failures, and improve the level of professional and technical personnel to ensure product quality, and the effect is very good.

　　The other category is to adopt a lean state maintenance model. Textile equipment management should do something and not do something, use international advanced management models, such as TPM "full-staff production maintenance", and implement lean equipment management. The so-called lean equipment management is to use lean thinking and lean methods to pursue the highest level of fail-safe production, forming an equipment management method that integrates fault maintenance, regular maintenance, condition maintenance and active maintenance, and establishes an equipment management method based on spot inspection and failure analysis. The core equipment operation early warning system. This maintenance model is a new model of equipment maintenance that has long been implemented in developed countries in Europe and America. It is based on the equipment itself having online detection devices, man-machine dialogue, digital display failures, remote monitoring, and the safety, reliability, and durability of the equipment components. , It is completely possible to use the maintenance mode that integrates spot inspection and trouble-free status. By reforming the traditional large and small flat cars, focusing on overhauling, reducing maintenance and maintenance labor costs. The core of trouble-free state maintenance is pre-detection and subsequent control, which is a maintenance management mode that combines planned state maintenance and random state maintenance. It not only solves the resource waste caused by repeated frequent maintenance of equipment in the past, but also achieves the purpose of reducing burden and increasing efficiency. Many large domestic spinning enterprises have achieved successful experience in lean state maintenance.

　　 No matter which one of the above two maintenance modes is adopted, as long as it is promoted steadily, there will be good results. Employment is based on "things" and is based on the premise of satisfying product quality. If the employment indicators are suppressed first, the project that should be done will inevitably be missed, and the survival of the company may eventually be affected because the product is not recognized by customers .

　　Some companies have done a solid job, not only strengthening technological transformation, but also pursuing zero failure, zero maintenance and value flow creation for key processes and parts with high failure rates of key equipment, and emphasizing the entire process management of the equipment life cycle. Moreover, at the beginning of each year, the equipment, varieties and management situation of the previous year are demonstrated, and the number of people is appropriately reduced when it is reasonable, rather than setting the number of labor targets that must be reached. Some companies do not have a solid job, so they must first do their basic work well, and don't blindly reduce the number of people, otherwise it will not only fail to reduce the number of people and increase the efficiency, but even decide the future.

　　 In short, only with good spinning technology and solid basic work, so that the trolley is managed and everyone has the responsibility, can the equipment efficiency and effectiveness be maximized and labor can be reduced. It is a systematic project to save labor in spinning enterprises, which should be combined with improving efficiency and strengthening details to consolidate the foundation of management, technology, and equipment to be effectively guaranteed.

Jiangxi Donghua Machinery Co., Ltd. specializes in the production of polypropylene spinning machine, polypropylene strong spinning equipment, polypropylene high-strength spinning equipment, polypropylene spinning machine, polyester spinning machine, aramid 1414 fiber spinning equipment, DHP419 series high-strength polypropylene Spinning drafting machine, polypropylene spinning machine, DHP418 series polypropylene spinning drafting machine, DHkv1235-12 type polyester spinning machine, DHPE high-strength high-modulus polyethylene fiber spinning equipment, DHTA type aramid fiber 1414 fiber spinning equipment, HDZF3 High-vacuum dynamic drying-solid-phase viscosifying machine, polypropylene spinning machine.