Workers' initiatives bring billions in benefits to FDI enterprises

Da Nang Telala Company Limited (Hoa Khanh Industrial Park, Da Nang) is a 100% Japanese-owned enterprise, specializing in the production of small-sized tailings and wire. Of which, the entire weaving workshop of the company is operating 75 DKY 6/45 weaving machines. According to the original design, the equipment's material grille system is powered synchronously with the main rotation axis, the grille speed depends entirely on the speed of the machine, leading to many shortcomings.

Mr. Nguyen Khac Hung - Safety, Health and Environment Management (HSE) of the factory shared: "Before improving, we encountered many difficulties. Because the speed of the clutch cannot be adjusted independently, when the machine changes the speed or when using a clutch with different expansion rates, it is easy for the clutch to be extended or joined unevenly. This directly causes common errors such as uneven fabric edges, fabric deviation, swelling or even broken columns, greatly affecting product quality and overall productivity".

Each time adjustment is needed, workers have to completely stop the weaving machine, causing production disruption. Those concerns urged engineers, managers and technical workers to sit together to find solutions.

"In the first phase, we also encountered certain difficulties. The members of the group must carefully research the core operations of the weaving machine to determine which parts are affected in particular. Then there is the process of finding suitable materials and accessories to ensure that when installed, the machine still operates stably and easily for the operator, Mr. Hung recounted.

After nearly a month of tireless research and testing, the solution "Making and installing a raw material alloy conveyor system through constant changes and separate motor engines" was born. This solution completely separates the grille system from the main structure of the weaving machine. An independent powertrain cluster includes an engine, bien, gearbox and additional clutch. This system allows the operator to easily adjust the speed of the shift flexibly through variation without stopping the machine.

The day the improved system was successfully piloted, Mr. Hung and the entire initiative group could not hide their joy. "My feelings and all the members of the team at that time were very happy. After months of research, when we saw that the machine was put into stable operation and brought clear efficiency, we knew that our efforts had been rewarded," Mr. Hung confided.

With the cost of implementing the improvement of only about 1 million VND for each weaving machine, the initiative helps increase machine productivity by 10-15%, save solder materials by 5-10%, and significantly reduce the rate of defective goods. The profit from a unit after assembly is estimated at 50 million VND/month. With the plan applied to all 10 lace weaving machines, the expected profit can reach 500 million VND/month, or 6 billion VND per year. In terms of quality, the situation of over-stressed fringes is resolved, significantly reducing the errors of curves and swelling on the fabric, helping the ratio of standard goods increase to 97-98%.

Ms. Vo Thi Thu Hien - Director of the Quality Department - said: "For a Japanese enterprise, production must strictly follow the process. However, we always create an environment for brothers to be passionate and creative. This initiative has contributed to making the group in Japan see that Vietnamese workers are not only skillful but also have a very strong and bold mindset in creativity, helping to enhance the position of Vietnamese workers.

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