E C O N O M I C S AND P R O D U C T I O N C O N T R O L

COMPLEX AT THE

PRODUCT

QUALITY

PERVOURALSK

DINAS

G . V. O r l o v , M. Z. a n d A . A. P o z d e e v

CONTROL

SYSTEM

FACTORY

Naginskii,

UDC 658.562: 347.772.3]: 666.762.2

Completing the historic resolutions of the Twenty-Fifth Congress of the CPSU and the socialist responsibilities, the P e r v o u r a l s k Dinas Factory in the Tenth F i v e - Y e a r Plan is working on the task of increasing the effectiveness of production and the quality of its products. It is gradually carrying out the job of speeding up scientific--technical p r o g r e s s by reconstructing and modernizing existing equipment, incorporating new capacity, using modern technology, improving existing, and introducing the latest techniques. The aim of the work is to improve the quality of production; expand the range and output of new goods and m a t e r i a l s so as to meet modern requirements; obtain i n c r e a s e s in output of higher quality categories; and the wide introduction of a complex s y s t e m of quality control (KS UKP), informing every worker of its position and obtaining positive effects from the control system in the working activities of each laborer and engineering-technical operative.

Before the introduction of the control system, the specificationswhich regulated the improvements in the product quality control (instructions, specifications, orders, decrees, etc.) did not encompass the entire combination of problems related to quality at the plant. Therefore, in setting up the system most attention was paid to developing e n t e r p r i s e standards - documents that strictly specify and mutually link all aspects of the plant's quatity work. At present 46 standards a r e being operated. The introduction of KS UKP was started at the factory in 1976 by the coordination group under the control of the chief engineer. The composition of the group and the direction of the work w e r e modified at extended sessions of the factory' s P a r t y office. In 1976-1977 the coordination group consisted of 17 people, but the factory experience indicated that to i n c r e a s e its operational levels it should be cut by 7 persons, and this was done in 1978. The daily work connected with the control s y s t e m was the concern of the operative group in combination with the deputy chief of the technical section and the e n g i n e e r - - r e s e a r c h e r of the factory central laboratory (FCL), which each day checks the completion of m e a s u r e s noted in the annual plans for the creation of the KS UKP system, and at sessions of the coordination group. The completion of each m e a s u r e , in p a r t i c u l a r the development and use of standards related to the definition of functions and problems, is reported to the appropriate executive -- the department head or s e r v i c e s chief. The operational group maintains links with other factories in order to keep them informed of experience with the use of the system, consults a s s i s t a n t s in r e g a r d to certain questions, p r e p a r e s documentation, and checks the p r o c e s s of product preparation and certification for quality categories. The rapid development of new, effective f o r m s of product would have been impossible without the strengthening in 1976-1978 of the link with s c i e n t i f i c - r e s e a r c h institutes. Useful collaboration was effected with the E a s t Institute of R e f r a c t o r i e s , the Ukrainian Institute of R e f r a c t o r i e s R e s e a r c h , the All-Union Institute Uralmekhanobro, UPI, All-Union Institute of Energy in F e r r o u s Metallurgy, U r a l s Research Institute of F e r r o u s Metallurgy, Donets R e s e a r c h Institute of F e r r o u s Metallurgy, Scientific-Research Institute of F e r r o u s Metals, and the Institute of Technical Glass. In accordance with STP 202-14-78 and STP 202-23-78 (standards specifications) for the development of technology and presentation of products for manufacturing all types of new goods and m a t e r i a l s , a close link has been forged with c u s t o m e r s in o r d e r to study the behavior of the goods in service and establish ways of improving them still further. Frequent visits by the c u s t o m e r to the factory take place, and also participation of the factory r e s e a r c h e r s in the implementation of r e f r a c t o r i e s at the c u s t o m e r sites. This practice has a c c e l e r a t e d considerably the introduction of new types of goods. P e r v o u r a l s k Dinas Factory.

Translated from Ogneupory, No. 1, pp. 18-20, January, 1980.

0034-3102/80/0102-0019 $07.50 9 1980 Plenum Publishing Corporation

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A typical example is the development of a method for making quartzite, ~mflred ladle brick as a result of the collaboration between the East Institute and the Chelyabinsk and Western-Siberian metallurgical factories. As a result~ the resistance of the ladle linings rose by 10%, and the n~tional economic savings amounted to 600~000 rubles a year. At present all the unfired ladle goods are being delivered to customers with the State Quality Label. Products that are on a level with the best world standards and producing considerable savings effects a r e now being certified for the Quality Label. By September 1979 the output of goods with the Label reached 21.69o of the total gross output. Certification of goods for quality categories is an important element in the KS UKP control system, and the volume of certified products is the basic c r i t e r i o n for assessing the efficiency of the system. Another objective of the system is to increase the share of exports in the overall output. The factory has introduced one standard for organizing the production and control of exports~ and two standards for ensuring quality stability. Following considerable reorganization in the work of the entire factory, the output of r e f r a c t o r i e s for export in 1978 rose, compared with 1975, by a factor of 8.7 in natural t erm s, and 9.5 times in cost terms. The organization of m a s s production, both of traditional and new goods, is closely linked with the introduction of reexamined and newly developed State mid regional standards and technical specifications. During the period 1976-1978 we introduced three GOST standards, one OST, five modifications to GOST, andfive TU standards in group L We curtailed the effects of 17 outdated technical specifications. The main standard for the enterprise after trial use in 1976 was revised, and in 1977 a new edition was published. Accordingly, the KS UKP system consists of 14 structural elements (subsystems). The function of each subsystem rests on the corresponding servi ce and sections. The coordinating organ is the technical section. Much attention was paid to developing a system of defect-free working. Since Dec. 1, 1978, we have introduced five standards for assessing the quality of the work of operatives and control and metering staff. Beside the implementation of general factory control systems, certain successes have been achieved in setting up a quality control system in all sections and subsections, in December 1978, the State Certification Commission, having carefully studied the state of m a t t e r s in the main and ancillary departments, signed the act for the introduction of KS UKP. The actual results from the use of the system are the increases in output of acceptable goods and a reduction in loss. Thus, with a total reduction in loss for the 9 months of 1979 equal to 17.2%, the loss for the most important types of product -- shapes for coke ovens, dinas for glass furnaces, andother shapes -- was cut, respectively, by 25.8, 12.8, and 41.1%. Due to the introduction of the control system we increased the output of r e f r a c t o r i e s with the State Label by 85~o compared with 1978 figures, increased the level of exports, and also expanded the level of goods yielding savings for the consumers inside the country. The annual savings calculated from this factor and confirmed by the act of the State Commission is 563,000 rubles. The plan for improving the system of quality control specifies improvements in the subsystem for information supply for the KS UKP system the introduction of a system of defect-free working in all structural subdivisions, and the development of a subsystem for predicting quality and grades~ Improvement in the system is closely connected with the plans for introducing new techniques, management and technical measures, and reconstructions. In the next 2 y e a r s the factory intends to put into operation tunnel kilns Nos. 2 and 3 in department No. 2, to develop in them the firing of dinas for coke and glass furnaces, to open a new line for making siliceous compounds for lining steel ladles, to implement a section for making synthetic fused mullite, and to m a s t e r the firing of lime in shaft furnaces. Starting from an actual analysis of the statements of the collective, the factory has accpeted a counterplan for the production of higher quality category goods with a compulsory increase in the propo rtion of such goods to 25% by 1980, a reduction in production scrap by 30%, and achievement of complete deliveries with regard to o r d e r s received.

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