Mechel Beloretsk Plant Introduces Lean Manufacturing System
Mechel Group’s Beloretsk Metallurgical Plant is introducing a lean production system aimed at increasing operational efficiency and reducing costs. The goal of the project is to create a culture of production in such a way that all employees, each in their place, are involved in the process of initiating improvements, which ultimately will lead to the elimination of all types of waste and increase productivity. The project involves the introduction of lean manufacturing tools into production processes: the 5C system for organizing and rationalizing the workplace, improvement methods, quick changeover, universal equipment maintenance, mapping and production analysis.
The high-strength wire shop CVP 16 has become a pilot facility for the implementation of a lean production system at BMK. The project, designed for two years, is being implemented jointly with ANO "Center" Kaizen ". The enterprise has established a project management committee and a production system improvement department. In workshop No 16, the stage of diagnostics of the current state of production is being completed, a roadmap of changes is being developed, as well as a map of the value creation stream, a "standardized work" is being introduced - it allows you to determine deviations and losses in the production cycle. After analyzing the identified problems, passports for their solution are developed. An information center was organized in the workshop for the prompt collection of data on all topical issues of production. The work of the workshop is assessed by a number of indicators: safety, product quality, order execution, costs, corporate culture.
The lean production project is also being implemented at other metallurgical enterprises of the Mechel Group.