For over a year, the subsidiaries of JSC Kuzbasskaya Toplivnaya Company (JSC KTK) have been implementing lean production projects aimed at increasing the efficiency of using the company's existing production capacities and resources. To monitor the implementation of projects, meetings are regularly held during which the results of implementing innovations are assessed and new ideas are discussed.
Thus, at the Vinogradovsky open-pit mine, the practice of introducing an electric cargo trolley, which reduces the load and increases the service life of the Yale loader, was recognized as effective. The author of the proposal, Gennady Sadovnikov, notes that the movement of goods within the production areas has become more mobile and maneuverable, and the use of the trolley allows reducing fuel costs by up to 200 thousand rubles per year or by 25%.
Open-pit specialist Alexander Vavilov successfully initiated the manufacture and implementation of a tilting stand for assembly and disassembly of internal combustion engines (ICE) into repair work practice. The device allowed to reduce the repair time by an average of 12 hours per ICE.
Head of the Mining and Transport Department Igor Ustyuzhanin became the author of a successful project for installing a modular compressor station for pumping tires directly on the mining site. This solution significantly reduced the equipment downtime, reduced the number of trips to the repair and technical shop and, as a result, reduced fuel consumption per shift.
Among the implemented "lean" practices, there are many that are aimed at the efficient use of production spaces.
"A properly organized workplace allows you to perform routine operations with the least amount of labor and frees up time for other tasks. For example, in the BelAZ repair shop, a special platform was introduced - a fixing structure with a rotating mechanism, which allows for quick and minimal effort repair and technical inspection of engines. Also, clear zoning of work areas for repair operations was carried out and a standard for storing consumables was introduced," says Dmitry Serg, Deputy Director of the Vinogradovsky open-pit mine of JSC KTK for repair and operation.
At the locomotive depot of the transport and forwarding company "Meret" (a subsidiary of JSC "KTK"), on the initiative of the head of the repair service Alexander Trubnikov, a device for washing the radiator cooling sections was introduced. This allowed to extend the service life and eliminate cases of damage to these sections. The implementation of this project allowed to minimize potential losses in the amount of up to 800 thousand rubles per year.
Alexander Trubnikov also became the author of another successfully implemented innovation - a device for dismantling the high-pressure fuel pump (HPFP). Before this, the company's mechanics dismantled the HPFP using crowbars, spending about 1 hour on this process. With the introduction of the new device, the same work now takes no more than 20 minutes of working time, and productivity has increased by 3 times.
As noted by the company's managers and specialists, work in the direction of lean manufacturing will continue in order to minimize losses in the current difficult market conditions and to find new production solutions within the framework of import substitution.
