In-line production: organizational and economic characteristics. Types of machine-building production and their characteristics according to technological, organizational and economic features The term release cycle is typical for production
Production type:
The volume of output - the number of products of certain names and sizes, manufactured or repaired by the enterprise during the planned time interval.
Release program - a list of products manufactured at the enterprise, indicating the volume of output for each item during the calendar period.
The product release cycle is understood as the time interval between the release of two successive machines, parts or blanks.
That is, the release cycle is the length of time required to manufacture one part with 100% completion of the release program. When designing technological processes, the value of the release cycle is determined by the formula:
The actual annual fund of equipment operation, hour;
m is the number of work shifts;
N is the annual product release program, pcs.
Coefficient definition.
The serialization coefficient shows the number of different operations assigned to one machine and is calculated by the formula:
Tact of production of products, min;
Piece time for operations, min.
The criterion for serialization is the coefficient of consolidation of operations () - the ratio of the number of all technological operations performed or to be performed within a month to the number of jobs.
There are three main types of production: single, serial and mass. Values = 21-40 are typical for small-scale production, 11-20 for medium-scale production, and 2-10 for large-scale production.
Single production is characterized by a small volume of production of identical products, the re-production of which, as a rule, is not provided.
It is this kind of production that is typical for technical service enterprises, repair shops and mechanical repair shops of timber industry enterprises.
Serial production is characterized by a limited range of products manufactured or repaired in periodically repeated batches and a relatively small output. Depending on the number of products in a batch or series, small-batch, medium-batch or large-batch production is distinguished.
Mass production is characterized by a large volume of products produced continuously for a long time. Most workplaces perform one constantly repetitive operation (=1).
Comparative technical and economic characteristics of production types are presented in Table. 4.
Table 4. - Comparative technical and economic characteristics of production types:
|
Production types |
|||
|
unit |
serial |
mass |
|
|
Product range |
Unlimited |
limited series |
One name |
|
Nomenclature constancy |
Doesn't repeat |
Repeats periodically |
Constant release of products of a narrow range |
|
Job specialization |
Is absent. Miscellaneous operations |
Periodically recurring operations |
One repetitive operation |
|
Operations pinning coefficient () |
Small-scale 20…40 |
Medium series 10.. 20 Large series 1…10 |
|
|
Equipment |
Universal |
Universal, CNC, Specialized |
Mainly special |
|
Location of production (technological) equipment |
Technological principle (by groups of machines) |
Subject and technological principle (by groups, by sections, by technological process) |
Subject principle on the technological process |
|
Technological equipment (devices, cutting and measuring tools, etc.) |
Universal, standard normalized and unified. |
Standard, normalized and specialized. Versatile and ultimate. |
Special and normalized. Ultimate and Special |
|
Detailing the development of technological documentation |
Route |
Route operating room |
Detailed route-operational up to the development of individual techniques |
|
Qualification of key workers |
Medium, high on CNC machines |
Low on production lines, high on GAL |
|
|
Product cost |
|||
|
Production cycle |
Long |
Minimum |
|
|
Labor productivity |
low |
Maximum |
|
|
Labor rationing |
Experimental-statistical |
Estimated and experimental-statistical |
Estimated with experimental verification |
The type of production has a decisive influence on the efficiency of the use of enterprise resources.
Pilot production belongs to an independent type. Its purpose is to produce samples, batches or series of products for research work, testing, fine-tuning the design and, on the basis of this, the development of design and technological documentation for industrial production. Pilot production products are not commercial products and usually do not go into operation.
Engineering technology- a science that studies and establishes the patterns of the flow of processing processes and parameters, the impact on which most effectively affects the intensification of processing processes and increase their accuracy. The subject of study in engineering technology is the manufacture of products of a given quality in the quantity established by the production program, at the lowest cost of materials and the minimum cost.
Detail- is an integral part of the product, made of a homogeneous material without the use of assembly operations. characteristic feature details - the absence of detachable and one-piece connections in it. A part is the primary assembly element of every machine.
assembly unit is a product made up of constituent parts collected separately from other elements of the product. As part of assembly unit both individual parts and components of lower orders can act.
Manufacturing process is a set of interrelated actions, as a result of which raw materials and semi-finished products are converted into finished products. In concept manufacturing process includes:
In engineering, there are three type of production: massive, serial and singular.
AT mass production, products are manufactured continuously, in large quantities and for a long time (up to several years). AT serial- batches (series) of products that are regularly repeated at certain intervals. AT single- products are made in small quantities and, often, individually.
criterion, which determines the type of production, is not the number of manufactured products, but the assignment to the workplace of one or more technological operations (the so-called. coefficient of fixing technological operations k ).
This is the ratio of the number of all technological operations performed or to be performed to the number of jobs.
So, for mass production, it is characteristic that most jobs are assigned only one constantly recurring operation, for serial production - several periodically repetitive operations, for a single one - a wide variety of non-repeating operations.
Other hallmark types of productions is the release cycle.
, - the time interval through which the release of products is periodically produced.The release cycle is determined by the formula:
where F E- annual, effective time fund of the workplace, section or workshop, h
P- annual production program for the release of a workplace, section or workshop, pcs.
AT- the number of days off in a year;
P p - quantity public holidays per year;
t p days - the duration of the working day, hour;
n cm - the number of shifts.
Manufacturing program factory- this is the annual number of manufactured products expressed in labor intensity:
where P 1 ,P 2 and P n- production programs for products, man-hour.
Production program of the shipyard (SRZ)
| Labor intensity of work by quarters, person · hour. | |||||
| Name | I | II | III | IV | TOTAL: |
| Ship repair: | |||||
| - navigational | XXX | XXX | XXX | XXX | P 1 |
| - current | XXX | XXX | XXX | XXX | P 2 |
| - average | XXX | XXX | XXX | XXX | P 3 |
| - capital | XXX | XXX | XXX | XXX | ... |
| Shipbuilding | XXX | XXX | XXX | XXX | ... |
| mechanical engineering | XXX | XXX | XXX | XXX | ... |
| Other works | XXX | XXX | XXX | XXX | P n |
| TOTAL: | XXXX | XXXX | XXXX | XXXX | 320000 |
NOTE: The symbol XXXX or XXXX in the table refers to any number of man-hours. Nomenclature - the annual number of manufactured products, expressed in items.
Shipyard nomenclature
| Name | Quantity, pcs. |
| Ship repair: | |
| Passenger ship (PT) pr. 544 | 4 |
| PT pr. R - 51 | 8 |
| Cargo-passenger ship (GPT) pr. 305 | 2 |
| Dredger pr. 324 A | 4 |
| Towing ship (BT) pr. 911 V | 8 |
| ................... | ............ |
| Shipbuilding: | |
| barge project 942 A | 5 |
| barge pr. R - 14 A | 4 |
| BT pr. 1741 A | 1 |
| Engineering: | |
| winch LRS - 500 | 25 |
| etc. | ... |
Mass-flow creation is characterized by the fact that parts after processing on one machine or workplace are immediately transferred for processing to another workplace during the technological process. The movement of parts is carried out using the assembly flow, trolleys, hoists, etc. With flow- mass production perform synchronization of operations, i.e. the time for each operation is taken equal to or a multiple of the cycle.
The organization of in-line production is associated with a number of calculations and preliminary work. The starting point in the design of in-line production is to determine the volume of output and cycle.
Tact - this is the time gap between the launch (or release) of 2 adjacent products on the strip. It is determined by the following formula (see formula 1 in the text).
The reciprocal of a beat is called pace strip work. When organizing in-line production, it is necessary to ensure such a pace in order to fulfill the production plan. Rhythm determines the number of parts produced per unit of time (see formula 2 in the text).
The general once-through creation is also characterized by the arrangement of equipment in the order of the sequence of the technological process. But unlike mass production, the time of individual operations is not synchronized with each other, i.e. does not always equal tact. As a result, at workplaces with a long duration of operations, stocks of parts are sometimes created and their movement from machine to machine is irregular. Therefore, they strive to have a thread-mass creation as more perfect shape production.
What is a production cycle and how is it determined?
Flow-mass creation is characterized by the fact that parts after processing on one machine or workplace are immediately transferred for processing to another workplace in the course of the technological process. The movement of parts is carried out using the assembly flow, trolleys, hoists, etc. In mass production, operations are synchronized, i.e. the time for each operation is taken equal to or a multiple of the cycle. Organization of flow...
Non-flow type - the movement of blanks at different stages of production is interrupted by aging at workplaces or in warehouses. The release cycle is not respected. The non-flow type of organization is used in single and small-scale types of production.
Rhythm of release - the number of products of a certain name, size and design, produced per unit of time. The essence of this term can be established by considering an example when the equipment (machine, line) processes two parts simultaneously, produced every 20 s: release rhythm - 6 parts per minute, production operation cycle - 20 s, release cycle - 10 s.
One of the performance indicators production activities subdivision of the plant (workshop, production site) is the performance production process carried out by the release rhythm.
The value of this indicator depends not only on the productivity of equipment and labor of workers, but also on the level of organization, planning and management of the production process.
Indeed, the capabilities of high-performance machine tools and the labor of workers will not be fully utilized if blanks, cutting tools and the necessary technical documentation if there is no coherence in the work of all parts of the production system.
The release cycle is a time interval through which the release of products of a certain name, size and design is periodically performed.
When designing machining details of in-line production - in-line mass and in-line serial - the cycle of release of parts from the production line, i.e., the period of time separating the release from the production line of two parts following one after the other, must be determined.
The value of the release cycle t in (min) in mass production is determined by the formula:
where F d is the actual (calculated) annual number of hours of operation of one machine when working in one shift (the actual annual fund of machine time in hours); m is the number of work shifts; D is the number of parts of the same name to be processed per year on a given production line.
The dependence of the type of production on the volume of production of parts is shown in Table 1.1.
With a part weight of 1.5 kg and N=10,000 parts, medium-scale production is selected.
Table 1.1 - Characteristics of the type of production
Serial production is characterized by a limited range of manufactured parts manufactured in periodically repeating batches and a relatively small volume of output than in single production.
The main technological features of mass production:
1. Assigning several operations to each workplace;
2. The use of universal equipment, special machines for individual operations;
3. Arrangement of equipment by technological process, type of part or groups of machines.
4. Wide application of spec. Fixtures and tools.
5. Compliance with the principle of interchangeability.
6. Average qualification of workers.
The value of the release cycle is calculated by the formula:
where F d - the actual annual fund of the operating time of the equipment, h / cm;
N - annual program for the production of parts, N = 10,000 pcs
Next, you need to determine the actual fund of time. When determining the fund of operating time of equipment and workers, the following initial data for 2014 were adopted at a 40-hour working week, Fd = 1962 h / cm.
Then by formula (1.1)
The type of production depends on two factors, namely: on a given program and on the complexity of manufacturing a product. On the basis of a given program, the cycle of product release t B is calculated, and the labor intensity is determined by the average piece (piece-calculation) time T pcs for the operations of an existing production or similar technological process.
In mass production, the number of parts in a batch is determined by the following formula:
where a is the number of days for which it is necessary to have a stock of parts, for = 1;
F is the number of working days in a year, F=253 days.
Analysis of the requirements for the accuracy and roughness of the machined surfaces of the part and a description of the accepted methods for ensuring them
The part "Intermediate shaft" has low requirements for the accuracy and roughness of the machined surfaces. Many surfaces are machined to the fourteenth grade of accuracy.
The part is technological, because:
1. Free tool access is provided to all surfaces.
2. The part has a small number of precise dimensions.
3. The workpiece is as close as possible to the shape and dimensions of the finished part.
4. The use of high-performance processing modes is allowed.
5. There are no very exact sizes, except: 6P9, 35k6, 30k6, 25k6, 20k6.
The part can be obtained by stamping, so the configuration of the outer contour does not cause difficulties in obtaining the workpiece.
In terms of machining, the part can be described as follows. The design of the part allows it to be processed for a pass, nothing interferes this species processing. There is free access of the tool to the processed surfaces. The part provides for the possibility of processing on CNC machines, also on universal machines, does not present difficulties in basing, which is due to the presence of planes and cylindrical surfaces.
It is concluded that, from the point of view of the accuracy and cleanliness of the machined surfaces, this part generally does not present significant technological difficulties.
Also, to determine the manufacturability of a part,
1. Accuracy factor, CT
where K PM is the accuracy factor;
T SR - the average quality of the accuracy of the surfaces of the part.
where T i - quality of accuracy;
n i - the number of surfaces of the part with a given quality (table 1.2)
Table 1.2 - The number of surfaces of the part "Intermediate shaft" with a given quality
that, the kinematics of surface or joint formation, the parameters of technological media (heating, cooling, chemical treatment, etc.) -
A similar element for the assembly process is a connection - a technologically continuous cycle of forming a connection between two parts.
Technological transition is a technologically continuous ordered complex of working steps that form the final part of the technological operation, forming the final required quality characteristics of a given surface of a part or a given connection. It is carried out by the same means of technological equipment with constant technological modes and installation.
The working moves within one transition are technologically ordered. For example, you can only thread a hole after you have made that hole.
Reception - a complete set of actions aimed at performing a technological transition or part of it and united by one purpose. For example, the transition "set the workpiece" consists of the following steps: take the workpiece from the container, move it to the fixture, install it in the fixture and fix it.
Installation - the process of giving the required position and, if necessary, fixing the workpiece (part) in a fixture or on the main equipment. It reflects the options for combining different transitions on this equipment.
Technological operation - an organizationally separate part of the route with all the accompanying auxiliary elements of the process, implemented on certain technological equipment with or without the participation of people. All the main technological documentation is usually developed for the operation.
A route is an ordered sequence of qualitative transformations of objects of labor into a product of labor. For example, blanks into a part or a sequence of obtaining an assembly unit from a set of parts. This is a specific variant of the combination of technological operations, which provides obtaining quality characteristics part or assembly unit.
The considered elements of the technological and production processes can be performed sequentially, in parallel or in parallel-sequentially in time. The combination of these elements is one of the methods for reducing the duration of the process.
The concept of "functional combination of elements" and their association on an organizational basis should not be confused.
Thus, a multi-purpose machine is traditionally
onnoy design with one worker
spindle connects to the construct
active basis different methods techno
logical interaction (point
cutting, milling, etc.), but not
accommodates them technologically in time
me and in its structure remains
sequential machine.
A, c - surface
WHEN THE CONDITIONS ARE BREACHED TECHNOLO-
boots; one . 3 - working strokes
logical continuity of the implementation of process elements, they are divided into parts, attributing
related to the same structural level of decomposition this process. Let's consider this using the example of processing a part (Fig. 1.1). To obtain the required quality of surface A, three working strokes "(/, 2, J), and for surface B - two working strokes (/, 2). Possible the following options processing.
First option:
1) complete surface treatment in two working strokes
2) complete processing of surface A with three working moves (/, 2, J), which corresponds to the manufacture of the part in two settings with two transitions performed, respectively, in two (/, 2) and three (/, 2, 3) working moves.
Second variant:
1) surface treatment B in one stroke (U);
2) processing of surface A with two working strokes (/, 2);
3) surface treatment B in one working stroke (2);
4) processing of surface A with one working stroke (J), which corresponds to the manufacture of the part in four settings with four transitions, respectively, performed in one (7), two (7, 2), one (2) and one<3) рабочих хода.
Third variant:
1) simultaneous processing of surfaces A and B, respectively, in one (7) and two (7, 2) working strokes;
2) processing of surface A in two (2, 3) working strokes. Consider an example of manufacturing a part in two setups.
The first one was implemented by combining two transitions performed in one (7) and two (7, 2) work passes, respectively, and the second one, in one transition with two work passes (2, 3).
To present the whole variety of technical and organizational structures of the technological process, let us turn to Fig. 1.2.
As can be seen, the simplest technological process in terms of organization can consist of one operation, which consists of one installation, which, in turn, contains one transition, carried out in one working move. Accordingly, in
Rice. 1.2. Process structure
In an organizationally complex technological process, each structural element of the upper level contains several elements of the lower level.
In each operation, the worker expends a certain amount of labor. Labor costs at normal intensity are measured by its duration, i.e. the time during which it is consumed.
The labor intensity of an operation is the amount of time spent by a worker of the required qualification under normal labor intensity and conditions to perform a technological process or part of it. The unit of measurement is man-hour.
To calculate the employment of machines and their number to perform this work, the concept of "machine intensity" is used. Machine capacity - the time during which the machine or other equipment is busy for the manufacture of a part or product. The unit of measure is the machine hour. For assembly machines, the indicator of the machine intensity of the operation is used.
For the rationing of labor and planning the production process, the time norm is used - the time set for a worker or a group of workers of the required qualification, necessary to perform any operation or the whole technological process under normal production conditions with normal intensity. It is measured in units of time, indicating the qualification of the work, for example, 7 hours, work of the 4th category.
When rationing low-labor-intensive operations, measured in fractions of a minute, a more tangible idea of the time spent is given by the production rate - a value that is inverse to the time rate.
The production rate is the set number of products per unit of time (h, min). The unit of measurement is the quantity of products in standard measures (pieces, kg, etc.) per unit of time, indicating the qualifications of the work, for example, 1000 pieces. at 1 o'clock, work of the 5th category.
The production cycle is a period of calendar time that determines the duration of periodically repeating processes for manufacturing a product from launching into production to obtaining a finished product.
Release program - the number of pieces of a product of a given nomenclature or the number of standard measures of some products to be manufactured in a specified calendar unit of time.
Output volume - the number of products to be manufactured in the established calendar unit of time (year, quarter, month).
Series - the total number of products to be manufactured according to invariable drawings.
Launch batch - the number of pieces of blanks or sets of children simultaneously launched into production.
The release cycle is a period of time after which the production of machines, their assembly units, parts or blanks of a certain name, standard sizes and execution is periodically performed. If they say that the machine is manufactured with a cycle of 3 minutes, then this means that every 3 minutes the factory starts the machine.
Rhythm of release - the value, the reverse of the beat of the release. One of the performance indicators of production
activity of a plant unit (workshop, production site) is the productivity of the production process carried out by it. The value of this indicator depends not only on the productivity of equipment and labor of workers, but also on the level of organization, planning and management of the production process. Indeed, the capabilities of high-performance machine tools and the labor of workers will not be fully utilized if blanks, cutting tools and the necessary technical documentation are not delivered in a timely manner, if there is no coherence in the work of all links of the production system.
The productivity of the production process is an integral indicator of the activity of the entire labor collective directly involved in the manufacture of the established range of products. This indicator is most convenient to use when evaluating the efficiency of an automated production process, in which the direct participation of the main workers is minimal, but the role of the plant's auxiliary personnel, which ensures the functioning of technological processes for manufacturing products, increases.
The productivity of the production process is estimated by the volume of products, measured in pieces, tons, rubles, produced per unit of time.
Increasing the productivity of a manufacturing process can be achieved in three ways.
The first way is to intensify, i.e. in increasing the modes of technological processes and their combination in terms of execution time. For example, in the process of processing a workpiece on a machine, a tool is replaced, new workpieces are brought in, etc.
The second way is to increase the duration of the production system, the natural limit is 24 hours a day, which corresponds to three-shift work. This trend is becoming increasingly important due to the sharp increase in the complexity and cost of production equipment.
At the same time, serious social problems related to the negative aspects of the regime of multi-shift work of people should be taken into account. A successful solution to these problems is seen in the integrated automation of all production processes. Obviously, this poses serious scientific and technical challenges related to the autonomous operation of production systems in automatic mode and issues of reliability and safety.
c o c o b is to increase the production
capacity of the production system at the expense of internal reserves: improving the organization of its work and expanding the technological capabilities of the equipment. This is realized by upgrading existing equipment or acquiring new equipment, increasing the productivity of production personnel through the use of advanced methods and ways to shorten the product manufacturing cycle. For example, optimizing the cutting of parts from sheet material, finding ways to improve the accuracy of processing lead to a reduction in the number of working moves and even the elimination of further processing of products on another machine.
1.3. Types and types of production
The difference in the production program of products led to the conditional division of production into three types: single, serial and mass.
Single production - the manufacture of single non-repeating copies of products or with a small volume of output, which is similar to the sign of the uniqueness of the technological cycle in this production. Unit production products are products that are not widely used (prototypes of machines, heavy presses, etc.).
Serial production - periodic technologically continuous production of a certain amount of identical products for a long period of calendar time. Products are manufactured in batches. Depending on the volume of production, this type of production is divided into small-scale, medium-scale and large-scale production. Examples of series production are machine tools, pumps, and gearboxes produced in repetitive batches.
Mass production - technologically and organizationally continuous production of a narrow range of products in large volumes according to unchanging drawings for a long time, when at most workplaces
the same operation is performed. Mass production products are cars, tractors, electric motors, etc.
The assignment of production to one type or another is determined not only by the volume of output, but also by the characteristics of the products themselves. For example, the production of prototypes of wristwatches in the amount of several thousand pieces per year will represent a single production. At the same time, the manufacture of diesel locomotives with a production volume of several pieces can be considered mass production.
The conditionality of dividing production into three types is also evidenced by the fact that usually at the same plant, and often in the same workshop, some products are manufactured in units, others in periodically repeating batches, and others continuously.
To determine the type of production, you can use the coefficient of fixing operations
the number of various technological operations performed or to be performed on the site or in the workshop during the month; M is the number of jobs, respectively, in a section or workshop.
GOST recommends the following values of the coefficients for fixing operations, depending on the types of production: for a single production - over 40; for small-scale production - over 20 to 40 inclusive; for medium-scale production - over 10 to 20 inclusive; for large-scale production - over 1 to 10 inclusive; for mass production - 1.
For example, if there are 20 pieces of metal-cutting equipment in the production area, and the number of operations of various technological processes performed in this area is 60, then the coefficient of consolidation of operations
^3.0 = 6 0: 2 0 = 3,
which means large-scale type of production.
Thus, from an organizational point of view, the type of production is characterized by the average number of operations performed at one workplace, and this, in turn, determines the degree of specialization and features of the equipment used.
Tentatively, the type of production can be determined depending on the volume of output and the mass of manufactured products according to the data given in Table. 1.1.
Depending on the area of use, production is divided into two types: in-line and non-in-line.
T a b l e 1.1
Indicative data for determining the type of production
Number of machined parts of one standard size
(weighing more than 10
(weighing up to 10 kg)
In-line production is characterized
and uniformity. In flow production, after the completion of the first operation, the workpiece is transferred without delay to the second operation, then to the third, and so on, and the manufactured part immediately goes to the assembly. Thus, the manufacture of parts and the assembly of products are in constant motion, and the speed of this movement is subject to the release cycle in a certain period of time.
Non-flow production is characterized by uneven movement of the semi-finished product during the manufacturing process of the product, i.e. the technological process of manufacturing a product is interrupted due to different duration of operations, and semi-finished products accumulate at workplaces and in warehouses. The assembly of products begins only when there are complete sets of parts in stock. In non-flow production, there is no release cycle, and the production process is regulated by a schedule drawn up taking into account the planned deadlines and labor intensity of manufacturing products.
Each type of production has its own area of use. The in-line type of organization of production is found in mass production, while the non-in-line type is associated with single and mass production.
1.4. Key Benefits of Factory Automation
Automation of production processes (APP) is understood as a set of technical measures for the development of new progressive technological processes and the creation of
based on them, high-performance equipment that performs all the main and auxiliary operations for the manufacture of products without the direct participation of a person. AMS is a complex constructive, technological and economic task of creating a fundamentally new technology.
Automation has always been preceded by the process of mechanization - partial (primary) automation of production processes based on such technological equipment, which is controlled by the operator. In addition, he exercises control over the production, adjustment and adjustment of equipment, loading and unloading of products, i.e. ancillary operations. Mechanization can be quite effectively combined with the automation of a specific production, but it is the AMS that creates the possibility of providing high quality products with high productivity of its manufacture.
Qualitative and quantitative assessments of the state of mechanization and automation of production processes are envisaged. The most important quality indicator is the level of automation a. It is determined by the ratio of the number of automated operations (transitions) n^^^ to the total number of operations (transitions) performed on the machine, line, section "general-
The value of a depends on the type of production. If in unit production a does not exceed 0.1. 0.2, then in mass it is 0.8. 0.9.
An automaton (from Gr. automatos - self-acting) is an independently operating device or a set of devices that perform, according to a given program, without the direct participation of a person, the processes of obtaining, transforming, transferring and using energy, materials and information.
The sequence of programmed actions performed by an automaton is called a work cycle. If the intervention of a worker is required to resume the working cycle, then such a device is called a semiautomatic device.
A process, equipment or production that does not require the presence of a person for a certain period of time to perform a series of repetitive work cycles is called automatic. If part of the process is performed automatically, and the other part requires the presence of an operator, then such a process is called automated.
The degree of automation of the production process is determined by the necessary participation of the operator in the management of this process. With full automation of human presence in
over a period of time is not required at all. The longer this time, the higher the degree of automation.
The unmanned work environment is understood as such a degree of automation in which a machine, production site, workshop or the entire plant can operate automatically for at least one production shift (8 hours) in the absence of a person.
The technical advantages of automatically controlled production systems compared to similar systems with manual control are as follows: higher speed, which makes it possible to increase the speed of processes and, consequently, the productivity of production equipment; higher and more stable quality of process control, providing high quality products with more economical use of materials and energy; the possibility of operation of automatic machines in difficult, harmful and dangerous conditions for humans; stability of the rhythm of work, the possibility of long-term work without interruptions due to the absence of fatigue inherent in man.
The economic advantages achieved by using automatic systems in production are a consequence of the technical advantages. These include the possibility of a significant increase in labor productivity; more economical use of resources (labor, materials, energy); higher and more stable product quality; reduction of the time period from the start of design to the receipt of the product; the possibility of expanding production without increasing labor resources.
Automation of production allows more economical use of labor, materials, energy. Automatic planning and operational management of production provide optimal organizational solutions, reduce inventories of work in progress. Automatic process control prevents wastage due to tool breakage and downtime. Automation of the design and manufacture of products using a computer can significantly reduce the number of paper documents (drawings, diagrams, graphs, descriptions, etc.) required in non-automated production, the compilation, storage, transmission and use of which takes a lot of time.
Automated production needs more skilled, technically competent service. At the same time, the very nature of labor associated with the adjustment, repair, programming and organization of work in automated production is changing significantly. This job requires more
Production is called in-line, in which, in the steady state, all operations are simultaneously performed on an orderly moving set of similar products, except perhaps for a small number of them with incompletely loaded jobs.
In-line production in its most perfect form has a set of properties that correspond to the maximum extent to the principles of rational organization of production. These main properties are as follows.
Strict rhythmic production of products. Rhythm release- is the number of products produced per unit of time. Rhythm is the production of products with a constant rhythm over time.
Release stroke- This is the period of time after which the release of one or the same number of products of a certain type is periodically produced.
There are options for in-line production, in which, in principle, there is no rhythmic release at the level of individual items. Strict regularity of repetition of all flow operations - this property consists in the fact that all operations of mass production of a certain type of products are repeated at strictly fixed intervals, creating the prerequisites for the rhythmic release of these products.
Specialization of each workplace in the performance of one operation for the manufacture of products of a certain type.
Strict proportionality in the duration of the execution of all operations in-line production.
Strict continuity of the movement of each product through all operations of mass production.
Straightness of production. The location of all jobs in a strict sequence of technological operations in-line production. However, in a number of cases, for certain reasons, it is not possible to achieve complete straightness in the arrangement of workplaces, and returns and loops occur in the movement of products.
Types of production lines.
production line - This is a separate set of functionally interconnected workplaces, where the in-line production of products of one or several types is carried out.
According to the nomenclature of products assigned to submarines, there are:
One-subject submarines, each of which is specialized in the production of products of the same type
Multi-subject submarines, on each of which, simultaneously or sequentially, products of several types are manufactured, similar in design or technology for their processing or assembly.
According to the nature of the passage of products through all operations of the production process, there are:
Continuous production lines, on which the products are continuous, i.e. without interoperative decubitions, go through all operations of their processing or assembly
Discontinuous production lines, which have interoperative beds, i.e. discontinuity in processing or assembly of products.
By the nature of the tact, they distinguish:
Production lines with a regulated cycle, in which the cycle is set forcibly with the help of conveyors, light or sound signaling.
Production lines with free tact, on which the performance of operations and the transfer of products from one operation to another can be performed with slight deviations from the established settlement cycle.
Depending on the order of processing on them, products of various types are divided into:
Multi-subject production lines with sequential-batch alternation of batches of products of various types, in which each type of product is exclusively processed for a certain period, and the processing of various types of products is carried out in successive alternating batches. On lines of this type, it is necessary to rationally organize the transition from the production of products of one type to the production of another:
at the same time, assembly of new types of products is stopped at all workplaces of the production line. The advantage is the absence of loss of working time, however, this requires the creation of a backlog of products of each type at each workplace, which are in the stage of readiness that corresponds to the operation performed at this workplace.
products of a new type are launched on the production line until the assembly of a batch of products of the previous type is completed, and the maximum of two possible cycles for the old and new types of products is set on the production line during the transition period. However, during the transitional period, downtime of workers is possible at those workplaces where products are assembled with a lower required tact than that currently set.
group production lines, which are characterized by simultaneous processing on the production line of batches of products of several types.
