Rimera begins to Implement Kanban System at Izhevsk Plant

25.03.2013



The Izhneftemash petroleum engineering company, a member of Rimera Group, plans to improve its production process to conform to the just-in-time production strategy, thus reducing turnaround time by half for core products.

Rimera begins to Implement Kanban System at Izhevsk Plant

Rimera begins to Implement Kanban System at Izhevsk Plant

The sucker rod pump (SRP) shop at Izhneftemash is the company’s first division to introduce a kanban scheduling system. Every manager and engineer in the SRP shop has undergone training in use of the new system. The company has set up locations in the assembly area for storing of strictly specified quantities of parts and components to be used for supplying of subsequent manufacturing stages. Besides, production tooling and accessories have been produced for on-the-spot completing of SRP assembly kits. Information stands installed in the assembly area enable the workers to track progress against targets. The stands contain information on the number and sizes of pumps made by the shift, the assembly pace, and the causes of possible deviations. 
Similar measures will be implemented in the other areas of the SRP shop: plunger manufacture, tube honing, and ion nitriding. There are plans to spread the kanban ticket system to the Izhneftemash semifinished parts and thermal treatment shop, in order to ensure uninterrupted supply of semi-finished parts to the SRP shop, and to inform and engage the personnel.
“Thanks to the introduction of the just-in-time system by the second half of 2013, we will ensure an uninterrupted flow of materials and components while reducing sucker rod pump manufacturing lead time by 50 percent,” said Izhneftemash Executive Director Igor Mochalin. “This will enable us to reduce by half the time to deliver these products to our customers.”
Production process improvement systems are in place at other Rimera companies as well. The Almetyevsk-based Alnas manufacturing company has used a kaizen proposals system for several years. As many as 121 proposals in areas including safety, quality, productivity and reduction of inventories were received in the seven and a half months of the year 2012 alone. For instance, the automation shop introduced a method to reduce usage of diamond wheels by boring these after they reach an acceptable degree of wear. Implementation of this idea has helped prolong the useful life of a diamond wheel by 25 percent at minimum cost.
The Chelyabinsk-based SOT pipe fittings maker has utilized kaizen production principles since 2007. The kaizen measures at SOT are aimed at improving the management of both the core and auxiliary manufacturing processes, including the warehouse complex and workplace equipment. The annual cost of implementing these measures is RUB 100,000 to RUB 150,000, while the annual economic benefits generated by the measures reach RUB 2 mln to RUB 5 mln.

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