For manufacturing enterprises, stability on the production floor directly determines the reliability of order fulfillment and customer satisfaction. Recently, Doit Rubber Products Co., Ltd. (operating under the international brand DoitRubber) addressed key operational pain points by successfully implementing two major improvements: the autonomous replacement of molding machine insulation boards and the conversion of grinding water pumps from electric to pneumatic operation. Driven by the initiative and pragmatic innovation of frontline employees, these measures have simultaneously boosted equipment maintenance efficiency and process continuity, thereby laying a solid foundation for stable delivery capabilities.
Previously, the replacement of heat insulation boards for all molding machines at the DoitRubber workshop was outsourced to external vendors. This long-standing outsourcing model not only resulted in poor turnaround times but also created a reliance on external parties for equipment maintenance expertise, leaving production schedules vulnerable to unplanned interruptions whenever urgent replacements were required.
To eliminate reliance on external technology and secure control over independent maintenance, two key managers at DoitRubber took the initiative to master the disassembly and reassembly procedures; they personally performed the hands-on work of removing and installing heat insulation panels, successfully completing the replacement for six molding machines in a single day. This improvement enabled the company to independently master standardized heat insulation panel replacement techniques, completely breaking its dependence on external technology. Consequently, equipment maintenance efficiency has improved significantly, ensuring smooth and orderly production, while long-term outsourcing costs have been substantially reduced.
To encourage all employees to proactively identify opportunities for on-site optimization, the company enhanced its incentive system for improvements and awarded special bonuses to those involved in this initiative. This move not only boosted employee engagement but also fostered a corporate culture where everyone participates in improvement efforts and strives for lean excellence in every aspect of operations.
The grinding process is a critical stage in rubber product manufacturing; however, the grinding room is consistently humid, leading to issues such as airborne dust upon startup and the frequent jamming or failure of electric water pump impellers. Previously, these pumps malfunctioned on average every two to three days; the resulting frequent downtime for repairs not only delayed production schedules but also consumed a significant amount of the electricians’ time.
To address a long-standing operational pain point, Master Electrician Hu’s team conducted on-site inspections and detailed observations, proposing a solution to switch from electric to pneumatic operation based on actual conditions. The team successfully executed the entire project, including pipeline modification and system commissioning. Post-implementation, the pneumatic pump demonstrated stable, durable performance unaffected by dusty or humid environments, resulting in a significant reduction in failure frequency. Furthermore, the pneumatic system eliminated the need for continuous power consumption — thereby saving energy — and removed the downtime previously required for frequent maintenance, leading to a marked improvement in the continuity of the grinding process.
In today’s increasingly competitive manufacturing landscape, the stability of production operations directly determines a company’s delivery capabilities and market reputation. Through continuous improvement, DoitRubber has not only enhanced equipment reliability and process continuity but also fostered a culture of independent innovation and problem-solving within its teams. This “grounded-in-the-shop-floor” approach to improvement has become a vital pillar supporting DoitRubber’s ability to ensure stable delivery and strengthen its core competitiveness.
Looking ahead, DoitRubber remains committed to deepening its continuous improvement efforts on the production floor. Driven by a pursuit of excellence and pragmatic, innovative action, the company will continue to provide customers with superior, stable, and reliable products and services.