In the field of quartz sand production, the production efficiency is directly
related to the cost control and market competitiveness of enterprises. With the
continuous change of market demand for quartz sand, many enterprises are
exploring ways to optimize production line efficiency. In fact, the efficiency
improvement of quartz sand production line is not the adjustment of single link,
but the key breakthrough shall be found out through the coordination of
equipment, process, personnel, management and other aspects. The following is a
discussion on how to systematically optimize the production efficiency of quartz
sand production line from several core directions.
1、 Equipment: from "basic support" to "performance upgrading"
Equipment is the core carrier of the production line, and its status directly
affects the production efficiency. Equipment efficiency shall be optimized from
"routine maintenance" to "technical upgrading".
For daily maintenance, a "preventive maintenance system" shall be
established. During the production of quartz sand, the crusher, sand making
machine, screening machine and other equipment are in high load operation for a
long time, which is easy to cause parts wear, insufficient lubrication and other
problems. Detailed maintenance plan shall be formulated: such vulnerable parts
as jaw plate of crusher and impeller of sand making machine shall be regularly
checked for abrasion degree according to service time, and goods shall be
prepared for replacement in advance to avoid shutdown of production line due to
sudden damage of parts; The lubricating system shall be supplemented or replaced
with lubricating oil according to the specifications to ensure smooth operation
of key parts such as bearings and reduce the efficiency loss caused by
mechanical friction. At the same time, the operator shall check whether the
connecting bolts of the equipment are loose and the protective devices are in
good condition before starting each shift, and eliminate the small hidden
dangers in time to avoid "small faults drag into big faults".
The technical upgrading shall be based on the actual needs of the production
line. If the production capacity of the existing equipment can not keep up with
the production plan, the key equipment can be upgraded: for example, the
traditional jaw crusher is replaced by the high-efficient hydraulic crusher,
which has higher crushing efficiency, lower energy consumption and can reduce
the time cost of raw material crushing; If the sand making machine has problems
such as uneven finished sand grain size and excessive returns, it can replace a
more suitable impeller or adjust the gap of the crushing chamber to improve the
yield of sand making. In addition, it is also very important to introduce
intelligent equipment to assist, for example, install a material level sensor on
the conveyor to monitor the conveying volume of materials in real time, so as to
avoid blocking due to excessive materials or idling of equipment due to
insufficient materials; Install temperature and vibration monitoring devices on
the key equipment, master the equipment operation status in real time through
the data background, give early warning of abnormalities and reduce the
unplanned downtime.
2、 Process: from "poor connection" to "efficient linkage"
The connection efficiency of each link of the production line is often the
"invisible bottleneck" restricting the overall production capacity. The
optimization process shall focus on the two key points of "material flow" and
"process matching", so as to form a highly effective linkage of all links.
In terms of material flow, "stagnation and waste" shall be reduced. For many
production lines, the raw materials are overstocked in the silos and the
intermediate materials are stuck in the conveying link, so the material path
shall be re-planned: for example, the layout and capacity of the silos shall be
adjusted according to the processing capacity of each equipment, so as to ensure
smooth conveying of raw materials from the silos to the crusher and avoid
"material interruption" or "material blockage" caused by unreasonable silo
design; The speed and angle of the conveyor shall match the capacity of the
front and rear equipment. For example, when the discharging speed of the crusher
is fast, the operating speed of the subsequent conveyor shall be increased
accordingly to prevent the materials from accumulating at the outlet of the
crusher. At the same time, the "pretreatment" link of materials shall be
standardized. Before the raw materials enter the production line, the impurities
(such as magnetic separator and screening machine) shall be removed by the
impurity removal equipment (such as magnetic separator and screening machine) to
prevent the impurities from entering the follow-up equipment to cause blocking
or equipment wear and affecting the continuity of the process.
Process matching shall achieve "balanced capacity in each link". The "short
plate link" of the production line will directly reduce the overall efficiency,
and the "capacity balance" needs to be achieved through process adjustment: for
example, if the efficiency of the screening link is low, a large number of
semi-finished sand needs to be screened repeatedly, which will cause the
discharge of the sand-making machine unable to be handled in time. At this time,
the number of screening machines can be increased or the equipment with a larger
screening area can be replaced to improve the screening efficiency; If the
particle size of the finished product in the crushing link does not meet the
sand making demand, the load of the sand making machine will be increased. The
crushing parameters of the crusher (such as the size of the discharge opening)
can be adjusted to make the crushed materials more suitable for the sand
preparation link. In addition, it is also very important to reasonably arrange
the production batch to avoid too long equipment adjustment time caused by
frequent change of product specifications. Centralized production of products of
the same specification can reduce the efficiency loss caused by process
switching.
3、 Personnel: from "simple operation" to "skill enabled"
The operator is the "executor" of the production line, and its skill level
and responsibility directly affect the operation efficiency of the equipment. To
improve personnel efficiency, it is necessary to start with "skill training" and
"responsibility management".
Skill training shall be "accurate and practical". Many operators are only
able to start and stop the equipment simply, and insufficient judgment on the
abnormality in the operation of the equipment easily leads to the expansion of
small problems. Training shall be carried out in combination with specific
posts: for example, crusher operators shall master the judgment method of
"listening, watching and touching" - listen to whether the sound of the
equipment is normal during operation (abnormal noise may be caused by loose
parts), check whether the motor current and bearing temperature are within a
reasonable range, and whether the vibration of the equipment shell is abnormal,
so as to find out hidden dangers timely through these details; The operators of
sand making machine shall understand the influence of different raw material
characteristics on sand making parameters. For example, when the hardness of raw
material is high, the feeding speed shall be appropriately reduced to avoid
overloading of equipment. At the same time, "case review" shall be organized
regularly. Combined with the past cases of efficiency reduction caused by
improper operation of the production line (such as the reduction of screening
efficiency due to failure to clean the screen in time), the operator can
intuitively understand the importance of standard operation and improve the
awareness of actively avoiding risks.
Responsibility management shall be "clear and detailed". Divide the
production efficiency indexes into specific posts and individuals, such as
setting post indexes such as "effective operation time of equipment" and
"material handling capacity", and link the performance of operators with indexes
to stimulate their initiative. At the same time, establish "post patrol
inspection system" to define the patrol inspection scope and frequency of
operators - such as patrol inspection of equipment lubrication every hour,
cleaning of impurities around the screen screen every two hours, and implement
the patrol inspection contents into written records to avoid "missing
inspection" and "idling inspection". In addition, the operators are encouraged
to participate in "efficiency improvement suggestions". The front-line personnel
are most familiar with the detailed problems in production. If the reasonable
suggestions (such as adjusting the material feeding angle to reduce blockage)
proposed by them are adopted, they can be rewarded to form an atmosphere of
"everyone pays attention to efficiency".
4、 Management: from "extensive control" to "data drive"
Scientific management is the "guarantee line" for stable production line
efficiency. The shift from traditional extensive management to "data-driven"
detailed management can make the efficiency optimization more targeted.
Data monitoring shall be "comprehensive and real-time". Establish the
production line data monitoring system, and record the key data of each link in
real time through the sensor and data acquisition equipment: such as the
crushing capacity of the crusher, the qualified rate of finished sand of the
sand making machine, the operation time and downtime of each equipment, and the
energy consumption indicators (such as the power consumption of unit product).
These data can directly reflect the operation status of the production line -
for example, if the number of downtime of the sand-making machine suddenly
increases in a certain period of time, whether it is caused by abnormal hardness
of raw materials or untimely maintenance of equipment can be traced through the
data; When the energy consumption index rises, analyze whether it is caused by
equipment aging or unreasonable operating parameters. At the same time,
regularly summarize and analyze the data to form "efficiency report", compare
the production data of different time periods and batches, and find out the rule
and reason of efficiency fluctuation.
Precise improvement "based on data. Based on the problems found in the
monitoring data, the targeted improvement measures are formulated: for example,
the data shows that the blocking problem of the conveyor is mainly concentrated
in a certain period of time. Check whether the material humidity in this period
is too high (too high humidity is easy to cause material caking), and then
adjust the parameters of the raw material drying link; If the energy consumption
of a certain equipment is significantly higher than that of the same type of
equipment, technical personnel can be arranged to carry out a comprehensive
overhaul of the equipment to check whether there is any wear or abnormal
transmission system. In addition, the "efficiency reference value" is set
through data, for example, the "ideal operating parameter range" and "daily
average processing capacity target" of each equipment are set according to the
optimal historical data. The operator adjusts the operation according to the
reference value, and the management department evaluates the production progress
according to the reference value, so that the efficiency optimization has a
clear "target orientation".
In a word, the efficiency optimization of quartz sand production line is a
"system project", which needs to link equipment, process, personnel, management
and other links, and gradually promote from "discovering problems" to "targeted
improvement". Based on the actual situation of the production line, enterprises
can give priority to the links easy to break through (such as daily maintenance
of equipment and basic training of personnel), and then gradually promote the
in-depth optimization (such as equipment technology upgrading and data
management), so as to continuously improve the stability and efficiency of the
production line and take the advantage in the market competition.