How to Reduce Costs While Maintaining Quality in Customized Rubber Parts Production |

In the more competitive market environment, lowering production costs, improving efficiency has become the only way out for survival and development of enterprises. Therefore, how to cost reduction as much as possible under the premise of product quality assurance, is an important challenge faced by enterprises in the production of customized rubber parts. Thus, through design optimization, material selection, process optimization, production management and supply chain optimization five aspects, this paper systematically elaborates the quality and cost of customer consideration in the production of customized rubber parts strategy, in order to provide reference for relevant enterprises.

First: design optimization: source control, streamline the manufacturing process

It means that one of the factors affecting the product cost is design optimization, which can greatly reduce the material costs consumed, simultaneously can also be to reduce the degree of difficulty in processing, to control the cost from the source.

1.1Functional integration designIntegrate the function of multiple parts into one rubber part, which can reduce the number of parts, reduce mold cost and assembly cost. That means designers have to know the functional requirements and where they are used, and carry out imaginative functional integration.

1.2 light design: under the premise of satisfying the strength and stiffness requirements, it is necessary to adopt lightweight design as far as possible, reduce the amount of rubber materials. Lightweight through optimized geometry, cavity construction or foamed rubber.

1.3 Let standard parts be used as much as possible: Try to use standard-size rubber parts, which can reduce the ratio of customized parts. Off-the-shelf components usually have lower unit pricing and lead times.

1.4 Simplification of mold design: The price of mold manufacturing is reduced as much as possible on the premise of meeting the performance and quality of the product. This is achieved by reducing the mould parting surface and implementing a simple pouring system.

Secondly, selection of the materials: if necessary, according to the process trace of the wind power generator, careful evaluation, the performance and materials feel low cost.

Material cost is one of the main parameter in the manufacturing of the rubber parts, choosing a proper rubber material safe life time of a product, also help to reduce significant cost.

2.1 Material grade optimization: on the premise of meeting performance requirements, select lower cost rubber material grade. [High-grade rubber] Different grades of rubber material have different performance, not all application scenarios need the best grade rubber material, according to the actual needs of reasonable should paper material grade, it can effectively reduce costs.

2.2 Mixed rubber compounds: The mixed rubber materials with different performance and price, cost and ensure the overall performance of the product. For example Natural rubber is blended with the Synthetic rubber without losing the elasticity of the final material, ensuring the reduction of raw-material cost. airer

2.3 Mate ricks recycling Mate ricks recycling refers to rub ber recycling which ca n re cycle raw rubb er from rub b er waste produced in P rod u ction, convert raw material consumption, thereby reducing P rod u ction cost. Lower performance requirements rubber Products can be produced from recycled rubber waste, and resources can be recycled.

2.4 Looking for alternative materials all the time: adjust according to the market change of rubber materials in the new development, actively train similar performance but the lower cost alternative materials. Proper testing and verification of the performance of alternative materials, however, should drive costs down.

3rd process refinement: optimization for perfection in factory productivity

Dynamic production cycle and integration, efficiency and cost reduction by optimizing the production process.

3.1 Automated production: Introduce automated production equipment (automated mixing system, automatic molding equipment, automated testing equipment) to improve production efficiency and reduce labor costs. It is also able to use automation, which drastically stabilizes the quality of its products.

3.2 Optimization of curing process: Therefore, optimizing the curing time, curing temperature, curing pressure and other parameters can greatly shorten the curing cycle and improve production efficiency. It also turns out that this rapid vulcanization technology is a very Good method.

3.3 The use of advanced molding technology: the use of injection molding, transfer molding and other advanced molding technology, can improve production efficiency, product accuracy. Which also save labor because it does not require a secondary process of trimming as is the case with flash molding technology

3.4 Lean production implementation: Lean manufacturing concepts and methods are used to eliminate waste in the production process and improve resource utilization. Yes, it can save costs, by shortening the production cycle, reduce inventory, optimize logistics, etc.

Production Management: Transforming data into actionable production insights

In addition, it requires more powerful production management and more data mining methods, which can continuously optimize the production process, improve the operational efficiency of the enterprise, and reduce the cost of enterprise management.

4.1 Improve production management: Establish a whole-process production management system from raw material procurement, production planning and production execution to product delivery, to realize real-time monitoring and management of the production process.

4.2 Use data analysis technology: Through the analysis of production data, the bottleneck and problems in the production process are determined, and corresponding improvement measures are taken to continuously optimize the production process and improve production efficiency.

(4) In contrast, total quality management: Strictly control every link of the production process, so that we can not produce defective products, as far as possible to avoid rework and scrap.

4.4 Improve employee repair: To carry out extensive technical education and quality awareness training for staff, continue to improve the level of employees and responsibility awareness, to prevent staff errors, to ensure production efficiency and product quality.

Optimize supply chain–Work with strategic partners to reduce procurement costs

In order to reduce procurement costs effectively, it can establish long-term stable strategic cooperative relationship with the suppliers, and optimize supply chain management.

Centralized procurement: The rubber materials are centralized and supplied to a few suppliers to increase the purchase volume and seek a more favorable price.

5.2 Strategic cooperative relationship: establish long-term and stable strategic cooperative relationship with suppliers with good reputation and strong technical strength, jointly develop new materials, optimize production technology, and achieve mutual benefit and win-win situation.

5.3 Optimize inventory management: properly develop the new mode and reasonable inventory management method, reduce the inventory of overhang, reduce the inventory cost. Examples include just-in-time inventory management (JIT) or virtual inventory

5.4 For on-time supplier performance evaluation, identify high-quality suppliers and eliminate inferior suppliers to maintain the quality and stability of supply.

Vi. Conclusion

And to conduct central engineering system of the design, materials, process, management and supply chain overall optimization to complete high quality low-cost requirements for custom rubber parts. While enterprises should constantly strengthen technological innovation and improve production efficiency through continuous optimization of various production processes; establish good cooperative relations with customers and suppliers, carry out collaborative research and development of competitive products and services. So that we can survive in such fierce market competition.