A labor productivity improvement project has been completed at PZPS

In November 2024 a large-scale project aimed at raising labor productivity was successfully completed at PZPS. Implementation took place under the national project “Labor Productivity” with support from the Regional Competence Center for Labor Productivity of Saint Petersburg.

The project’s main task was optimizing the process technology for manufacturing strip from precision alloy 40KhKhNM. This unique material is used to produce coiled cylindrical springs operating at temperatures up to 400°C, springs for watch mechanisms, winding mechanisms of relays, frame parts of implants, and surgical instruments.

Project goals and stages

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

The project’s key goals were:

• Reducing product manufacturing time by 15%.
• Increasing output volume per shift.
• Optimizing work processes using lean production principles.

The project included diagnosing the current state of process technologies, analyzing bottlenecks, and introducing modern methods of raising productivity.

Implementation results

During project implementation PZPS achieved significant improvements:

• Reducing production time. Introducing the 5S system, standardizing operations, and eliminating losses made it possible to reduce total product production time by 18% instead of the planned 15%.
• Productivity growth. Ingot production volume per shift increased by 25%.
• Cutting section productivity rose by more than 25% thanks to new workplaces and optimized employee movement routes.

Features of alloy 40KhKhNM

Alloy 40KhKhNM consists of iron, chromium, nickel, cobalt, and molybdenum. Thanks to unique elastic characteristics, corrosion resistance, and property stability at high temperatures, it is used in technologically complex and critical products.

• Composition: high nickel and cobalt concentration provides load resistance, and chromium improves corrosion resistance.
• Application: production of high-precision springs for mechanisms operating in extreme conditions.
• Technological operations: from melting with precise adherence to chemical composition to multi-stage heat treatment to achieve specified properties.

Gratitude for project participation

For active participation in the national project PZPS received a letter of thanks from the Vice-Governor of Saint Petersburg. This recognition underscores the enterprise’s contribution to developing the region’s industry and its drive for innovation.

The project to optimize manufacturing of 40KhKhNM strip became an important step in PZPS development, making it possible to raise process efficiency, improve working conditions, and strengthen the plant’s influence on the high-tech materials market. Participation in national projects strengthens the enterprise’s position as a significant market player and responsible employer.

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