The concept aims to increase operational efficiency, reduce costs, eliminate all types of losses, increase productivity, create a production culture and involve employees in the process of continuous improvement achieved through the use of lean manufacturing tools.
Production of rolling rings at the Uralskaya Kuznitsa factory. Illustrative photo: "Mechel".
The most effective tools used within the framework of the project were suggestions for improvements and problem—solving techniques - the economic effect of their implementation amounted to 443.5 million rubles and 454.5 million rubles, respectively.
The effectiveness of the application was also demonstrated by such tools of the production system as the problem solving board and SMED (quick changeover), improvement cycles and implemented projects.
Since the beginning of 2024, about 9,000 problems have been submitted to the decision boards, and by the end of the year, the number of solved problems amounted to 77% of the total number of reported problems. Thanks to the development and refinement of SMED practice, the duration of the transition from one production process to another was reduced by an average of 28% for all enterprises. This, in turn, made it possible to reduce labor costs and increase the number of production operations performed.
Along with the introduction of a Production System on industrial sites, the development of a methodological framework and the establishment of a unified educational process for employees involved in the implementation of the elements of the concept continues.
The conveyor line of the universal rail and block mill of the Chelyabinsk Metallurgical Combine. Illustrative photo: "Mechel".
This year, a special training class "Process Factory" was opened on the basis of the Chelyabinsk Metallurgical Combine. Within its walls, managers and employees from all the Group's enterprises not only receive theoretical knowledge, but also exchange the best implemented practices of the Production System at their enterprises, and practice practical skills on simulators.
