DISOCO: Productivity tripled thanks to technological innovation

Productivity tripled, but labor use dropped by a third; sand consumption for mold making is very low, because it can regenerate up to 95%; waste products are only about 3-5% while old technologies are often over 10%; significantly improved working environment are the benefits that Song Cong Diesel Co., Ltd. (DISOCO) has when investing in innovation of casting technology.

The effectiveness of investment projects

After one year of investment and equipment installation, in mid-December 2019, the automatic sand casting line was transferred to DISOCO by Sinto (Japan) with a total investment of more than VND 245 billion. produce stable quality products, the surface of the product has a high aesthetic, suitable for large-scale production, products with complex shapes.

According to Mr. Hoang Van Minh – Director of DISOCO, as one of the suppliers for multinational enterprises, to join the global supply chain, the company’s products must ensure competitiveness in all 3 criteria: Quality, price and on time delivery. To achieve this, the company requires constant investment in technological innovation and continuous improvement to strengthen its management system.

The new automatic casting line with a designed output of 10,000 tons of billet/year, the new production line needs only 1 automatic mold making machine, but the output is 3 times of the old production line with dozens of mold making machines. The number of employees in the old line is 120 people/3 shifts but the new line only needs fewer than 2/3 employees. Thus, labor productivity calculated by output on the number of employees increases at least 4.5 times.

In particular, the automatic line is equipped with modern induction cookers that best meet the requirements of labor safety and the environment, saving energy, reducing electricity consumption by up to 30% compared to the old ones. The mold making line can regenerate up to 95% of the sand for production; no generation of waste water in production; automatic control system and warning of equipment failures during operation as well as automatic storage of data necessary for production.

Improve competitiveness

“When participating in the supply chain, investing in innovation will give better competitive indicators. Quality improvement is highly appreciated by customers. Increased labor productivity and a decrease in the proportion of waste products, leading to cost savings. The reduction of waste products detected during processing has a very positive meaning for customers as well as manufacturers… However, when producing in large quantities, the management system must meet the maintenance requirements. Stable specifications and technology” – Mr. Hoang Van Minh said.

Along with technological innovation, in recent years, DISOCO has continuously maintained the effective application of international standard systems and productivity improvement tools such as ISO 9001; ISO 14001; ISO 50001; IATF 16949, 5S, Kaizen, etc. At the same time, investing in specialized software with copyright, modern testing equipment, ensuring all requirements on product quality, meeting the highest requirements of customers.

In the coming time, DISOCO will continue to direct investment in supporting industries in the field of embryo production. The newly invested casting line only starts the trend of modern investment. In parallel with the new die casting line, the investment in modern fire-mold casting adds to the ability to meet the diverse needs of castings. In addition, investment in capacity enhancement as well as forging technology innovation is also indispensable to improve embryo production capacity.

Productivity and Quality Office