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About UsJiaozuo Hanhe Cable Co., Ltd. is a wholly-owned subsidiary of Qingdao Hanlan Co., Ltd. Its predecessor was the Jiaozuo Cable Factory. Established in July 2005, it is a high-tech enterprise primarily engaged in the manufacturing of wires and cables.
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ProductWe can manufacture over ten thousand specifications and models of high-, medium-, and low-voltage wire and cable products, including 500 kV and lower voltage cross-linked power cables, overhead insulated cables up to 35 kV, plastic power cables up to 3.6/6 kV, plastic-insulated control cables, various flame-retardant and fire-resistant wires and cables, and overhead stranded conductors, spanning dozens of series.
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Xiuwu Company improves through continuous improvement.
Release time:2021-07-09
On the morning of April 30, 2021, just before the arrival of the “May Day” Labor Day, Zhao Yuhui, Deputy Secretary of the ShanYang District Committee of Jiaozuo City, accompanied by relevant leaders from the ShanYang District Federation of Trade Unions, the Science and Technology Bureau, the Commerce Bureau, and other organizations, made a special visit to Jiaozuo Hanhe Cable Co., Ltd. to extend his greetings and congratulations to Comrade Zhang Jiangang, the newly elected Model Worker of ShanYang District.
Nothing in the world is and unchanging—everything is in flux, everything is evolving. On February 19, 2021, the first day of work after the Spring Festival, Zhang Tao, the former director of the primary aluminum division at headquarters, arrived at Xiuwu Company to take charge of its operations. Over the past few months, Xiuwu Company has seen significant improvements in all aspects of its work.
I. The following improvements were made to the manufacturing process:
1. Conduct statistical analysis on the aluminum melt supplied by the aluminum plant, collect and record its compositional data, and determine from this data the optimal alloy composition ratios suitable for guiding the production of aluminum rods in the workshop. Specifically, adjust the silicon content in the final aluminum melt to 0.05 and the iron content to 0.14.
2. After process validation, we changed the conventional method of refining, heating, and holding the molten aluminum. Previously, we had been using a high-flame heating approach to rapidly raise the temperature of the molten aluminum. This approach not only easily led to overheating of the molten aluminum, causing alumina formation and slag inclusion in the aluminum billets, but also significantly increased gas consumption and resulted in large fluctuations in the molten aluminum temperature within the furnace. After adopting a low-flame heating and holding method, the molten aluminum temperature inside the furnace was maintained at 750 ± 10℃, reducing temperature differences and thereby minimizing factors that could affect casting stability and stabilizing the process parameters.
3. We have improved the tooling for the casting and cooling zones. Previously, cooling nozzles used a direct, columnar spray method, which failed to provide uniform cooling across the crystallization wheel. Now, we’ve adopted fan-shaped spray nozzles that deliver cooling water evenly throughout each cooling zone, ensuring uniform solidification of the aluminum ingots and minimizing temperature fluctuations. This reduces instability during the rolling process and significantly enhances the stability of the aluminum rod’s strength. Compared to the previous method, the strength variation among aluminum rods produced by different work teams can now be kept within a range of 7 MPa.
4. Xiuwu Company typically uses seven wire-drawing machines for production, yet the actual output has not yet reached the full capacity of these machines. After extensive process validation, we have now gained a thorough understanding of the characteristics of each machine, and their production capacities have improved dramatically compared to the past. Previously, older equipment commonly operated at a drawing speed of 14 meters per minute, while even the newer equipment managed only up to 18 meters per minute. In contrast, today each wire-drawing machine can increase its drawing speed to 20 meters per minute, with some models reaching a maximum speed of 24 meters per minute. The validation, innovation, and optimization of our processes will serve as a strong guarantee for stabilizing process quality and enhancing efficiency.
II. The following improvements were made on-site in the workshop:
1. Disposal of obsolete materials. Take advantage of the current high prices to centrally dispose of obsolete materials that have accumulated over the years. Conduct a review of these inventory items, share relevant information, and determine a plan for their disposal.
2. Cleaning oil contamination from equipment. Focus on thoroughly addressing the aluminum wire-drawing process, identifying and eliminating oil leakage points one by one, and removing accumulated oil around the equipment. As a result, the aluminum wire-drawing site has seen a noticeable improvement.
3. Labor efficiency has been significantly improved. By assigning items to appropriately designated areas, we’ve greatly reduced unnecessary search time, ensuring that all operations are carried out precisely as required, thereby boosting labor productivity. Everyone now has a fresh understanding of their responsibilities and is wholeheartedly committed to maintaining the site in excellent condition. As a result, the work environment has naturally improved, leading to a substantial increase in overall work efficiency.
4. The aging equipment has been revitalized. The Equipment and Maintenance Department carried out a “cosmetic makeover” on the outdated equipment in Xiuwu. This equipment revitalization effort was thoroughly comprehensive: all accumulated oil stains were completely removed, the equipment was polished, buffed, and repainted. The “trade old for new” approach was the key outcome of this equipment revitalization initiative.
III. Gradually improving production equipment:
1. The wire-tying device located before the drawing machine cannot automatically move to one side and stop when winding ceases. This situation can cause indentation on the bottommost single wire when winding resumes, resulting in surface indentations on the finished conductor and compromising product quality. To address this issue, the Equipment & Automation Department took the lead in providing technical assistance by adding a jog function to the wire-tying frequency converter. This allows operators to control the left-to-right movement of the wire-tying mechanism via a knob when stopping, positioning the wire-tying device at either the far-left or far-right end. As a result, the bottommost aluminum single wire will no longer have any indentations during the next winding cycle.
2. Due to high-temperature evaporation, the emulsion tank in the aluminum rolling workshop requires staff to monitor water level changes and replenish water every shift during production. During the replenishment process, there is inevitably some over-replenishment or under-replenishment, which inconveniences the next shift and affects production efficiency. To address this issue, a float valve has been installed at the safe water level of the emulsion tank; when the water level drops below the set threshold, the valve automatically starts replenishing water, eliminating the need for manual water addition.
3. The issue of excessive aluminum powder generation during aluminum rod rolling has long remained unresolved. After carefully inspecting and troubleshooting various parts of the equipment, we made improvements such as refining the surface geometry of the traction rollers to ensure smooth casting ingots, replacing severely worn rolls on the rolling mill, thoroughly repairing areas where oil was leaking from the mill head, and replacing the mill’s outlet pipe with bakelite material. After nearly three months of verification, the aluminum powder problem has been effectively resolved. This has also played a crucial role in extending the service life of the drawing lubricant.
There are many more equipment improvements like the one mentioned above. When encountering malfunctions during production, adopt an improved mindset and awareness to solve problems and reduce the subsequent failure rate!
IV. Strictly and consistently focus on safety work:
1. Supplement and improve the equipment’s safety protection facilities, conduct a comprehensive inspection and rectification of safety interlocks and emergency stop mechanisms, and enhance the operational safety of the equipment.
2. Strictly supervise and rigorously assess any violations of operating procedures—showing absolutely no leniency.
3. Improve and revise the safety management measures and various management systems to continuously enhance the effectiveness of system-based management.
In other areas, specialized knowledge training and safe operating procedures have been implemented in phases, covering all employees and bringing significant benefits to the workforce. Management has been encouraged to think more liberally and to boldly take initiative while simultaneously balancing service delivery with effective supervision. In the process of improving equipment and production quality, we’ve placed greater emphasis on thorough verification and careful summarization of experience, thereby enhancing efficiency in subsequent production stages. As time goes by, Xiuwu Company is quietly undergoing transformation. Attitude determines everything; details determine success or failure. Good habits will gradually become ingrained, and Xiuwu Company’s ongoing improvements are far from over!
Xiuwu Company, Nie Guilin
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To promote the high-quality development of the enterprise and further enhance the core competitiveness of Jiaozuo Hanhe Cable Co., Ltd. in the wire and cable industry, we are now launching a public tender to assist the company in applying for the titles of “Excellent-Level Smart Factory” and “Digital Leading Enterprise.” The relevant tendering details are announced as follows:
Throughout my long journey in the cable industry, I personally took part in the pilot production of the 500kV, 2500mm² cross-linked polyethylene-insulated, smooth-aluminum-sheathed cable manufactured by Jiaozuo Hanhe in Jiaozuo. This experience is like a brilliant pearl, deeply embedded in the annals of my career, constantly inspiring me to keep moving forward.
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Address: Circular Economy Industrial Cluster Zone, Shanyang District, Jiaozuo City
Address: No. 228, Jianshe East Road, Shanyang District, Jiaozuo City