Research On The Zinc Consumption Control Of CGL In S Company Based On Six Sigma Management

Zinc ingots need to be consumed in the production process of galvanizing.In recent years,the price of zinc ingots has remained high level,and the higher the price of zinc ingots,the greater the pressure on the cost of galvanizing in production enterprises.Statistics show that the cost of zinc ingots consumed in the production of galvanized steel steel strip is about 300 yuan per ton,which accounts for about 70%of the total production cost.Reducing zinc consumption in the galvanizing line can greatly reduce the cost of galvanizing line and form the core competitiveness.During the periods of July to December in 2016 the consumption of zinc is 6%to 8%.the average level is 7.34%.In the same period,the zinc consumption rate of advanced galvanizing lines in China was only 5.6%.Therefore it is necessary to tackle the problem of high zinc consumption.This paper uses six Sigma management concept,combined with DMAIC method to study the zinc consumption reduction method of galvanizing production line in S company.The purpose is to find the reasons for the high zinc consumption of galvanizing production line in S company,find control plans,and control key factors.The zinc consumption of galvanized production line will be reduced to a reasonable level,reduce the production cost of the process,and improve the competitiveness of S company.This thesis finishes the work of the following aspects:Firstly,taking zinc consumption of the galvanizing production line of S company as the research object,zinc consumption is the weight of the zinc layer coated on the surface of the galvanized plate during the production process of galvanizing.Through the horizontal comparison with the domestic advanced level,the goal of zinc consumption control is determined.This paper studies the measuring system of zinc consumption in the production process of galvanizing,and analyzes the influence of personnel and measuring equipment on the measuring system.Based on flow chart and causal matrix tool,the primary causes of zinc consumption problems in the galvanizing production line of S company are initially investigated,and the key factors affecting zinc consumption are selected through FMEA and variance analysis.Secondly,analyze the key factors which were found,Such as speed of production line,distance of air knife,pressure of air knife,and detecting deviation of in-line and off-line instrument.Find out what was wrong with the previous controls.Find out the reduction method of zinc consumption in S galvanizing production line.Thirdly,the zinc consumption reduction method of the galvanizing production line of S company was implemented and controlled,forecast benefits of implementation,the measures were improved to solidify,increase the checking procedure of parameters setting by production system,increase the downtime and quality evaluation procedure when steel coil zinc consumption exceeds the limit,introduce performance incentives at the plant level and team level to make zinc consumption control effective for a long period of time.