会员风采

会员风采丨兴发铝业三水公司用“三精管理”破解模具上机质量难题——三水公司2#2200T机模具质量改善实录

发布时间：2025-08-07 广东省清洁生产协会浏览量：

在铝型材生产过程中，模具上机合格率直接影响挤压产量和成材率。兴发铝业三水公司改善小组，运用三精管理中精益改善周方法，将2#2200T机模具上机合格率从81%提升至87%，日均减少返工2套模具，年化改善收益达10万元。

Xingfa Aluminium Sanshui Company Cracks the Mold Quality Challenge with "Three Refinements Management"—— A Record on Mold Quality Improvement for Machine #2 (2200T) at Sanshui Company

In aluminum profile manufacturing, the qualification rate of molds directly impacts extrusion output and product yield. The improvement group at Sanshui Branch Company implemented the Lean Improvement Week method from Three Refinements Management, boosting the qualification rate of mold mounting on Machine #2 （2200 T） from 81% to 87%. This reduced an average of two set of mold reworks per day, generating an estimated annual benefit of RMB 100,000.

一、精准定位：直击痛点，目标明确

Precise Positioning: Target Key Pain Points with Clear Goals

痛点聚焦Focus on Key Issues

1.新模未合格下单导致上机率下降

New mold designs often fail to meet order specifications, limiting their usability in production planning.

2.煲模工序质量问题（碰崩、压烂、冲洗不干净）影响抛光质量

Defects in the mold heating process (e.g.,

collapsing, deformation and incomplete cleaning) affects final polishing quality.

3.返修/修模质量不理想，导致多次返工

Inconsistent repair and modelling quality leads to repeated mold reworks.

靶向施策Targeted Measures

1.将各个工序作业内容精细化、把模具质量做到预期

Refine the operation procedures of each step to ensure mold quality meet the expectation.

2.监督各工序的模具质量，达到预期才能流向下工序

Supervise the quality of molds in each process to achieve expectations before proceeding to the next process.

3.每天把不合格原因列出来分析原因，并制定可执行的作业要求

List the reasons for unqualified every day, analyze the reasons, and formulate executable operation requirements.

三精启示：

The Enlightenment of Three Refinements :

建立《模具上机质量日报表》，每日分析不合格原因，确保“问题不解决不流向下工序”。

Establish the "daily report on mold machine quality", analyze the reasons for unqualified products every day, and ensure that "no problem will be passed to the next process until it is solved".

二、精细管控：全流程标准化

Refined control: whole-process standardization

关键改善Key improvements

1.煲模工序标准化：

Standardization of mold heating process:

制定《煲模作业规范》，明确冲洗标准

Formulate the "Mold heating operation specification" and clarify the flushing standard.

改善后煲模质量问题，可视化质量

Improve the quality of post-heating mold and visualize the quality.

2.抛光质量双管控：

Double quality control of polishing:

建立首件检验+末件复核制度

Establish the first piece inspection and end-of-batch review system.

制定《抛光质量标准作业指导书》

Formulate polishing Quality Standard Operation Manual.

3.模具上机质量跟踪：

Machine quality tracking of molds:

建立《模具使用情况跟踪表》，实现全流程可追溯

Establish the "mold usage tracking table" to realize the whole process traceability.

三精启示：

The Enlightenment of Three Refinements :

从“凭经验操作”到“按标准执行”，精细化管理让质量波动无处遁形。

From "operating by experience" to "implementing by standard", refined management makes quality fluctuations nowhere to hide.

三、精细管控：持续优化创效益

Lean improvement: Continuous Optimization for Tangible Benefits

改善亮点Improvement highlights

1.每日站立会议：改善团队每日15分钟进度同步

Daily standing meeting: The improvement team synchronizes their progress every day for 15 minutes.

2.5Why分析法：深挖拉钩粗纹问题根源，发现模具抛光质量和过程挤压工艺至关重要

5Why analysis: In-depth root cause analysis on surface cracks in hook sections, and the polishing quality of the mold and the process of extrusion are very important.

3.年改善收益：

Annual improvement benefits:

模具上机成本*套模*月天数*6月，300*2*28*6=100800元

Mold-related machine costs were calculated as RMB 300 × 2 sets/day × 28 days × 6 months = RMB 100,800.

三精启示：

The Enlightenment of Three Refinements :

当员工真正理解“1套模具=300元成本”时，改善就从任务变成了本能。

When employees truly understand that "one set of molds =RMB 300 in cost", improvement becomes instinct from task.

今后，兴发铝业三水公司将深植“三精管理”精髓，将其转化为全员自觉的行动纲领。我们将夯实数据基座以支撑精准决策，雕琢流程细节以提升运行效率，更将全员激发为持续改善的“发动机”与问题解决的“狙击手”，让“数据精准、流程精细、改善精益”形成强大的上升螺旋。以此构筑坚不可摧的质量长城，驱动公司不断提质增效，在高质量发展的征程中行稳致远，持续领先。

In the future, Sanshui Company will deeply embed the essence of "Three Refinements Management" and transform it into a conscious action guideline for all employees. We will strengthen data foundations to support precise decision-making, refine process details to enhance operational efficiency, and further energize every staff member as both an "engine" for continuous improvement and a "sharpshooter" for problem-solving. This will create a powerful upward spiral where "data precision, process refinement, and improvement leanness" reinforce each other. By building this unbreakable quality fortress, we aim to drive the companys continuous enhancement of quality and efficiency, ensuring steady progress and sustained leadership on the journey toward high-quality development.

来源：广东兴发铝业有限公司

整理：广东省清洁生产协会融媒体中心

返回列表 [上一篇]会员风采丨华昌集团荣获中国专利优秀奖 [下一篇]会员风采丨中金岭南韶冶厂检验检测中心获得中国合格评定国家认可委员会（CNAS）实验室认可证书

会员服务

会员风采

会员风采丨兴发铝业三水公司用“三精管理”破解模具上机质量难题​——三水公司2#2200T机模具质量改善实录

会员风采丨兴发铝业三水公司用“三精管理”破解模具上机质量难题——三水公司2#2200T机模具质量改善实录