China's manufacturing industry has developed into an important part of the national economy. The industrial added value of manufacturing industry accounts for 44.88% of the added value of GDP. China has become a big manufacturing country. But China is not yet a manufacturing power. According to reports, China's labor productivity is only 1/18 of Germany, 1/3 of the United States, and 1/25 of Japan. For tool manufacturing companies, China’s labor productivity in 2004 was 141,000 yuan, while Sandvik’s labor productivity was equivalent to 1.38 million yuan, Walter was 1.348 million yuan, and Kennametal’s 2005 fiscal year. The year (from July 1, 2004 to June 30, 2005) was 1.366 million yuan. From these data, we can see that the absolute price of our labor force is relatively low, but sometimes due to the extremely low labor efficiency, the cost of distributing products to individual products, especially high value-added products, is not low. Therefore, it is often seen that some products have a small living space only in labor-intensive industries.
The competitive advantage gained by relying on a low-cost workforce will not last. Governments or laborers are working hard to improve people's lives, and the improvement of people's living standards requires an increase in the income of workers. This increase means an increase in labor costs. If it is not improved, it will gradually lose its competitiveness as living standards improve.
In the past 20 years, China's reform and opening up has achieved some results by increasing investment, using market-for-technology and low-cost strategies, and the people's living standards have also been improved. However, it has already emerged that the production cost of Chinese mainland cars is higher than that of Detroit in the United States. Many processing and manufacturing industries have caused losses or even losses due to market competition or government price limits. It is time to pay attention to processing efficiency, thereby reducing manufacturing costs and improving competitiveness.
Why reduce manufacturing costs and increase competitiveness by improving processing efficiency rather than other methods? According to the relevant data, the analysis of various factors constituting the processing cost shows that the cost of tools as consumables accounts for only about 4% of the total cost of manufacturing, while the main cost is spent on machine time, enterprise management and labor. The cost (75%) and the workpiece material (21%).
So what happens to our efficiency gains? If we increase the cutting speed by 20%, although the tool cost may increase by 50%, the machine tool cost, management cost, factory depreciation, etc. are all reduced due to the shortened occupation time, and the total processing cost is reduced by nearly 15%. According to the data, if we increase the feed and increase the depth of cut while slightly reducing the cutting speed, we can reduce the processing cost by increasing the efficiency while reducing the cost of the tool. The cost can be reduced by more than 15%. However, due to the small proportion of tool costs in processing costs, the rate of change in overall cost is not significant.
Achieving efficient processing will greatly help to improve the competitiveness of enterprises. It can reduce manufacturing costs, increase profits, provide financial support for the development of new products, provide more profit for shareholders, and attract excellent employees to serve the enterprise. By improving processing efficiency, we can also shorten the manufacturing cycle, thus achieving rapid manufacturing and self-made By creating value, customers can become a trusted part of the customer's supply chain and accelerate capital turnover and reduce financial expenses.
Efficient machining can be achieved by increasing the machining efficiency and reducing the non-machining time during the cutting time.
First, improve cutting efficiency
The cutting process itself has three major elements: cutting speed, feed rate, and depth of cut. We say that the improvement of cutting efficiency is to improve the metal removal rate.
1. Improve cutting speed
Increasing the cutting speed is a very effective way to improve the cutting efficiency. In the past 100 years, through the continuous efforts of cutting experts, the mainstream tool materials have passed several stages from high carbon steel, high speed steel, hard alloy, coated carbide tools, and the cutting efficiency has been greatly improved. For example, a steel turning with a diameter of 65 mm and a length of 1 m takes about 100 minutes 100 years ago, and the current mainstream processing method takes only about 1 minute. Due to the improvement of processing efficiency, the metal processing industry has also obtained considerable economic benefits. A valve factory has undergone a process improvement in valve flange drilling. The factory used high-speed steel twist drills to machine bolt holes on the flange for a long time, and the processing efficiency has become a bottleneck for its productivity improvement. But they have doubts about the use of highly efficient indexable drill bits, because the price of indexable drill bits is more than ten times higher than the high-speed steel drills they are using, and the high-speed steel drills can be sharpened a few times. The economics of indexable drill bits may not be ideal. After a series of tests and analyses, they saw that due to the improvement of cutting efficiency, the processing time was greatly reduced, the cost of apportioning on each workpiece was greatly reduced, and the cost of tool consumption was also reduced, so they were on a working day. The savings in processing costs are sufficient to cover the cost of purchasing an indexable drill body.
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