A project to increase labor productivity has been completed at the PZPS

In November 2024, a large-scale project aimed at increasing labor productivity was successfully completed at the PZPS. The implementation was carried out as part of the national project “Labor Productivity” with the support of the St. Petersburg Regional Competence Center for Labor Productivity.

The main objective of the project was to optimize the technological process for manufacturing precision alloy tapes 40KHNM. This unique material is used in the production of coil springs operating at temperatures up to 400°C, springs for clockwork, relay clockwork, implant frames and surgical instruments.

Project goals and stages

The project started on June 3, 2024 and was completed on November 14, 2024. The 40KHNM alloy was not chosen by chance: its production is a complex and multi-stage process, including melting, casting, rolling, heat treatment and cutting. This made it an ideal model for analyzing and implementing improvements.

The key objectives of the project were:

• Reducing product manufacturing time by 15%.
• Increase in output per shift.
• Streamlining workflows using principles lean production.

The project included diagnosing the current state of technological processes, analyzing bottlenecks and introducing modern methods to increase productivity.

Implementation results

During the implementation of the project, the PZPS has achieved significant improvements:

• Shorter production time.
  The introduction of the 5C system, the standardization of operations and the elimination of losses made it possible to reduce the total production time by 18% instead of the planned 15%.
• Productivity growth.
  • The volume of bullion production per shift increased by 25%.
  • The productivity of the cutting section has increased by more than 25% due to new jobs and the optimization of employee movement routes.
• New tools for product labeling.
  Modern tags with improved readability have been introduced, which:
  • We reduced the search time for materials by 30%.
  • We reduced the number of errors in product identification by 20%.
• Optimization of jobs.
  • New specialized workbenches for cutting tape have been installed, which has eliminated unnecessary movement for employees.
  • Thanks to the 5C system, the loss of time spent searching for tools and materials has been reduced by 50%.
  • Additional workspace has been freed up, which has made it possible to improve the convenience of employees.
• Staff growth.
  Three PZPS employees have been trained using lean manufacturing methods and became instructors. This strengthened the company's professional base and made it possible to conduct internal trainings for staff.

Features of 40CHNM alloy

Rafting 40KHNM consists of iron chromium, nickel, cobalt and molybdenum. Due to its unique characteristics of elasticity, corrosion resistance and stability at high temperatures, it is used in technologically complex and critical products.

• Composition: the high concentration of nickel and cobalt ensures load resistance, and chromium improves corrosion resistance.
• Application: production of high-precision springs for mechanisms operating under extreme conditions.
• Technological operations: starting from smelting with strict adherence chemical composition before multi-stage heat treatment to achieve specified properties.

Thanks for participating in the project

For active participation in the national project PZPS received a letter of thanks from the Vice-Governor of St. Petersburg. This sign of recognition emphasizes the company's contribution to the development of the region's industry and its commitment to innovation.

The project to optimize the manufacture of 40KHNM tape was an important step in the development of PZPS, making it possible to increase process efficiency, improve working conditions and increase the plant's influence in the high-tech materials market. Participation in national projects strengthens the company's position as significant player on the market and responsible employer.

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