Forging Scrap Reuse: Small Initiatives for Cost Reduction

The scraps generated during forging production, though seemingly insignificant, can accumulate into a substantial cost over time. Recently, the cutting and forging teams at Qingliang Mould have collaborated to reuse small steel pieces that were previously sold as scrap, effectively reducing the company's raw material costs through incremental improvements.

Previously, the cutting process produced small steel blocks of palm or fist size, which were often sent to scrap piles and sold at scrap metal prices due to limited usability. A senior cutting technician with over 20 years of experience proposed an optimization idea: many small-sized forgings such as bolts and washers can be produced directly using these scraps, eliminating the need to cut full-length steel bars. The teams immediately implemented the measure: the cutting team set up dedicated sorting racks to organize scraps by material (carbon steel, alloy steel, etc.) and size with clear labels for easy identification; when receiving small orders, the forging team first checks the scrap racks for suitable materials, prioritizing scrap over new stock whenever possible.

This seemingly minor initiative has delivered significant long-term results: the company now reuses 70-80 kg of forging scraps monthly, equivalent to reducing new steel purchases by over half a ton. Employees have also developed a culture of conservation, optimizing material usage during cutting, actively sorting leftover scraps, and reminding each other to avoid improper mixing. These small daily savings have effectively reduced production costs and boosted employee morale.