Creates conditions for uniform output throughout the entire planning period. Moscow State University of Printing Arts
- Tests 2
- Task #3 21
- Problem #6 23
- Task #12 24
- Problem #15 27
- References 30
Tests
1. Why production research began to be actively carried out in XVIIIcentury?
b) it is connected with the formation and development of the capitalist mode of production.
2. Who was asked to plan in advance the methods of work and all production activities the enterprise as a whole?
c) F. Taylor.
3. Who developed the motion microanalysis technique?
b) F.B. Gilbert and L. Gilbert;
4. Do the main elements of production operations depend on the content of the work?
This position was proved by the Gilberts in the process of developing a technique for microanalysis of movements.
6. Can the activity of the enterprise be considered as a complex unified system consisting of a network of subordinates, less complex;
The activity of an enterprise is a complex, multifaceted process that can be considered as a system consisting of a number of subsystems. The efficiency of the entire enterprise depends on the coordinated work of these subsystems.
7. What does the "research" subsystem include?
c) development calendar plan work.
The "research" subsystem may also include: determination of project development directions; calculation of cost estimates and cost control methods; determination of the reliability of the developed product, etc.
8. Are there special services for organizing production at Russian enterprises?
The overwhelming majority of Russian enterprises do not have a special service for organizing production, since the size of production often does not allow maintaining additional staff. The presence of such services is typical for large enterprises, which have a complex and large-scale production process.
9. Are planning, analysis and control separate stages of the study of the system as a whole?
Planning, analysis and control are functions production system generally.
10. Planning and control of the current functioning of the system are the responsibilities of:
a) production managers;
11. Which subsystem can be attributed to machine shop engineering plant:
a) processing;
12. Which of the subsystems should include the scientific and technical library of the machine-building plant:
b) security.
13. Which subsystem should include quality control:
b) planning and control subsystem.
14. Is it true that the production management cycle begins with planning?
Since planning allows you to determine the nature, form and sequence of future actions.
15. Should medium-term and operational plans be subordinated to strategic goals?
Since medium-term and operational plans are tools for achieving strategic goals.
16. Do you agree with the statement that strategic planning is central to modern management?
Since strategic goals determine the main directions of development of the organization for a long period.
17. How many levels strategic planning highlighted in management?
18. Are there any differences between strategic plans and functional strategy?
Strategic plans generally consider the possibility of taking a certain position in the market in a certain period of time. The functional strategy takes into account specific functions: sales, inventory management, purchasing, production, optimal use of human and material resources and etc.
19. Which of the following strategies is aimed at reducing costs:
Cost control strategy.
This strategy is based on reducing own costs in comparison with the costs of competitors. Mandatory cost control is carried out, due to which it is achieved high efficiency production. At lower costs, the firm strives to maintain a high level of profit, although prices are lower than those of competitors.
20. Are there differences between differentiation and focus strategies?
The differentiation strategy is aimed at supplying the market with goods or services that are more attractive in their qualities than those of competitors. The focusing strategy is based on determining the most profitable and effective type of activity and focusing on it.
21. Do you agree with the statement that the main strategy of the focus idea is to focus on what works best?
22. Are there any differences between strategic plans and functional strategy?
The functional strategy or the strategy of the production process is aimed at supporting the company's strategy by solving problems that are formed taking into account the needs of the client.
23. Can a production strategy be implemented without an advertising plan?
24. The final sales plan is specified:
After developing an implementation plan.
25. Should structural decisions on vertical integration, production capacity, scale and orientation of production be linked?
Because all structural solutions are part of the complex production solutions. They consider various aspects of the manufacturing process.
26. Information on the dynamics of the total demand for goods and services comparable in the market is needed for:
To justify the likely transition to the production of interchangeable goods;
27. Are there any differences between the structure of the organization and temporary (project) structures?
The general structure of the organization can operate for quite a long time. However, the enterprise may have temporary tasks associated with the implementation of the plan. In this case, temporary (project) organizational structures are created.
28. Do you agree with the statement that the structure of the organization needs to be changed?
This provision is more typical for foreign enterprises, but it is also applicable in Russian practice. If the organization develops, then its structure must undergo changes in order to best meet the goals of the activity.
29. Do you agree with the statement that the most important component of the "define conditions and organization" phase is the assessment of one's own position in the market?
The assessment is carried out in order to determine the position of the enterprise in the industry market; to attract funds from investors in promising production; development of programs for entering new markets.
30. Are classical theories in the field of leadership applicable in production management?
In general, the classical theories in the field of leadership are also effective in modern conditions, however, modern management is based on taking into account the achievements of theory and practice in the field of leadership.
31. If the answer to item 30 is positive, give examples of the use of various theories in the field of leadership in production management.
32. Are there any requirements for the formulation of the goal?
Goals must meet the following requirements: specificity, visibility, consistency and realism.
33. Should there be feedback between the leader and subordinates?
Availability feedback between the leader and the subordinate provides a more accurate understanding of the instructions of the leadership, allows you to adjust the methods of influencing subordinates and exercise control.
34. Does the type of consumer affect the structure of the organization?
Enterprises are interested in such an organization of work, which allows, as fully as possible, to satisfy the needs of all groups of customers. Based on market segmentation, appropriate divisions within the organization can be created.
34. The method of transferring parts, in which processing is performed in batches, and the transition from operation to operation only after processing the entire batch:
b) consistent;
35. In single and small-scale production usually used:
c) parallel-serial;
36. The main PP is divided into the following functions:
a) procurement, processing and assembly;
37. The equipment sections are arranged in the order of TP:
a) consistency;
38. The duration of the production cycle is:
a) the time during which the processed products are in production;
39. Parallel-sequential type of movement:
a) parts are transferred from operation to operation individually or in small batches;
40. The parallel type of movement is applied:
c) in large-scale and mass production;
41. The production process proceeds:
b) in time and space;
42. Completed part of the TP, performed at one workplace:
b) technological operation;
43. The main PP is:
b) the process by which raw materials and materials are converted into products;
44. The technological process is:
a) a process that changes the shape, dimensions, properties of the product;
45. According to the formula: T=S tPCS. i + /n - 1/x/S tPCS. b - S tPCS. m/ is determined by the processing time of the party at:
a) parallel;
46. The process of labor, as a result of which no product is created, is:
c) serving PP;
47. The non-technical process is:
b) all control and transport operations from the moment of the first production operation to the moment of delivery of the finished product;
48. product, this:
b) any object of labor to be manufactured in production;
49. The duration of the production cycle is determined by the formula:
a) Tc \u003d T main + T obs + T per
50. Proportionality is:
d) there is no correct answer.
Proportionality is the correspondence of the throughput (relative productivity per unit of time) of all departments of the enterprise - workshops, sections, individual jobs for the release finished products.
51. Simultaneous execution in time of different parts of a single complex software program is:
1. Parallelism.
52. The production process is:
1. A set of interrelated labor processes, as a result of which raw materials are converted into finished products.
53. Ccreatesconditions for a uniform release of products duringethroughout the planning period:
1. Rhythm.
54. New technology in the process of creation goes through the following stages:
1. Scientific research, design and technical development, production development.
55. Development technological process produced:
1. After testing the design for manufacturability.
56. The degree of detail of the design depends on:
1. Type details.
57. The coefficient of useful use of the material is calculated by the formula:
2. Kim \u003d Md / Mz * 100
58. Debugging of technical processes in general and design documentation completes:
3. Design training.
59. The initial stage of product design is the development of:
1. Terms of reference.
60. Indicators of production manufacturability can be:
2. Absolute and relative.
61. The process of experimentation applies to:
1. Single production.
62. Costs dependent on the processing method are called:
1. Technological cost.
63. The purpose of the product, scope, operational, technical and economic requirements determines:
1. Terms of reference.
64. The general view of the product, its main idea determines:
1. Draft design.
65. Calculation of the geometric shapes and dimensions of parts, the choice of materials and workpieces is determined when compiling:
1. Technical project.
66. Do you agree with the statement that effective production management is impossible without a scientific organization of labor?
The organization of labor should be based on the achievements of science and best practices, ensure an increase in labor productivity and the preservation of human health.
67. Which of the components of production management should include "organization of labor":
B) definition of conditions and organization
68. Professional and qualification division of labor is associated with:
69. Do you need additional terms for the introduction of scientific organization of labor?
The introduction of a scientific organization of labor requires the following conditions:
Development of an implementation plan;
Establishing a unit or executor responsible for this work (responsibility center);
Clear definition of responsibilities and control functions;
Creation of a system of training and certification of personnel;
Creation of a system of material and moral incentives for work.
70. Do you agree with the statement that the organization of the workplace involves equipping with means and objects of labor placed in a certain order?
This stems from the definition of workplace organization.
71. The number and complexity of constantly performed work reflect:
C) the organizational level of the workplace.
72. Where does the planning of workplaces begin:
A) determining the location of the workplace on the site in accordance with its specialization;
73. Do I need to take into account the flow of applications when planning service areas?
The flow of service requests per unit of time is the initial characteristic that should be taken into account when planning service areas.
74. Is knowledge of the flow and intensity of service enough to evaluate the accepted service system?
It is also advisable to study the degree of use of the equipment included in the service area, for which it is necessary to analyze the element-wise structure of the equipment operation time.
75. If the ratio of service time and machine operation time is greater than one, the service area:
B) unacceptable.
76. Does labor rationing matter in the work of a production manager?
Labor rationing makes it possible to provide conditions for equal intensity and intensity of labor not only in the same, but also in heterogeneous jobs.
77. Should labor rationing be applied to employees?
The work of employees can also be measured by time frames and performance indicators.
78. Are there any differences between the concepts of "norm of time" and "norm of output"
79. Is it advisable to apply microelement rationing for employees?
The system of microelement standards makes it possible to study the methods of work. This is important to detect changes in the way work is done and changes in time spent.
80. What is the preferred method of measuring labor productivity for performance management?
Labor.
Since labor intensity indicators can be calculated by work areas and categories of workers.
81. What is the essence logistics system with a fixed order size?
A system with a fixed order quantity controls the stock level. When the stock level falls below the set level (reorder point), a restocking order is issued. In this system, the determination of an economically reasonable (optimal) order size is of great importance.
82. What is the essence of the logistics system with a fixed time interval?
A system with a fixed time interval between orders involves placing orders for replenishment of stocks at a given frequency.
83. How is the need for materials determined?
There are three methods for calculating the need for materials: deterministic (defined); stochastic (probabilistic, random); heuristic. The most common and reliable is deterministic method or the direct count method.
84. What is the practical significance of ABC-analysis and XYZ-analysis?
ABC analysis is commonly used to allocate materials based on quantity and price (or some other characteristic).
With the help of XYZ analysis, the assortment of parts in stock is distributed depending on the frequency of consumption.
85. What are the features of systems with« pushing out» and« pulling» products put into production?
The “push” system for products launched into production assumes that the production of products begins at one end of the production line, goes through a sequential series of technological operations and ends with processing at the other end of the production chain.
The system of "pulling" products involves receiving products from the previous site as needed. The central control system does not interfere in the exchange of material flows between different sections of the enterprise, does not set current production targets for them.
86. What is a warehouse?
c) buildings, structures, devices designed for the acceptance, concentration and storage of various material assets, preparing them for production consumption and rhythmic release to consumers
87. What is the most standard type of product movement?
a) two-tier;
88. How many service classes are there?
89. How many components total area warehouses?
at four.
90. How many groups are loading and unloading machines divided into?
91. What determines the sequence of events of the serving system?
a) the flow of requirements;
92. What is the type of dependence of the expansive load factor on the operating time of the machine?
a) straight
93. What changes in the performance of the machine will result from the maximum use of the load capacity of the mechanism and speed?
a) to intensify;
94. What areas of internal economic risk can be distinguished by responsibility centers?
Transport, supply, production, risk of storage of finished products, marketing, management.
95. What structural units enterprises can be accumulators of its expenses? What else can serve as the basis for the distribution of costs?
The cost center, as the classification basis adopted for the previous stage, is used as an organizational unit for accumulating expenses before their subsequent distribution on any basis.
Depending on the degree and direction of detailing costs, small structural divisions of the enterprise, types of products, production factors, etc. can serve as such a basis.
96. Why are factors of production preferred as a feature for identifying risk groups than, for example, a range of products, when conducting comparative analysis economic risk of two enterprises?
Identification of risk groups on the basis of production factors is universal for all enterprises.
97. What situation is characterized by a compliance index equal to 1.1?
There is no risk of unclaimed products in this production.
98. What managerial decision and why will you make with a compliance index of 1.1 regarding the price of manufactured products? What are the possible consequences of your decision for the enterprise?
A conformity index of 1.1 indicates that the demand for a product exceeds its supply. Under these conditions, the price of manufactured products can be increased, which will lead to an increase in the profits of the enterprise.
99. Why, with a compliance index of 0.85, can production costs increase and product quality decrease?
The conformity index equal to 0.85 indicates a high risk of unclaimed products. In this situation, the volume of production will be minimal, as well as the amount of investment per unit of output. This will increase production costs and reduce product quality.
100. Why and what part of the production time, when the risk of not being in demand for products, is more correct to attribute to losses than to useful labor expended?
If there is a risk that the products will not be in demand, these products have already been produced and must be used in one way or another. Losses will include part of the production time of a service nature spent on transporting and storing finished products, as well as its disposal.
101. Can inflation be the cause of the risk of lack of demand for products?
Yes, inflation can negatively affect the cost of production factors, which in turn will inevitably affect the cost of production and its price. If the demand for a given product is elastic, then an increase in price will lead to a decrease in the volume of consumption of the product and an increase in the risk of being out of demand.
102. Why is the risk of lack of demand for products classified as a mixed risk?
Because it can be associated both with the uncertainty of the external environment, and with the activities of the enterprise itself, which produces and (or) sells products.
103. Can the risk of lack of demand for products be attributed to intra-industry?
No. This risk exists due to deviations from normal conditions in two industries: manufacturing and selling products. Therefore, at this classification level, it is diversified.
104. Why is the price both an internal and an external factor in the demand for an enterprise's products?
Because the price of products depends on both internal factors(cost of production), and from external factors(state of demand, competition, etc.).
105. Why does an increase in the number of consumers of an enterprise's products reduce the risk of its lack of demand, and an increase in the number of distribution channels increases it?
An increase in the number of consumers increases the demand for products and therefore reduces the risk of their being out of demand. The increase in sales channels increases the geographical coverage of its distribution, therefore, the risk of lack of demand for products in certain markets with unfavorable market conditions increases.
106. Due to what the detection of risk in the process of manufacturing products will bring the enterprise higher losses compared to the stage of its development?
Termination of production at the stage of development is associated with smaller losses, because at the stage of development of products, the volumes of its production are relatively small, as well as the costs of its development and implementation.
107. Would it be correct to make a managerial decision to stop the production of products that are in limited demand due to high prices? In this case, what are the components of the economic losses that the firm will suffer?
If the high price of products is caused by high production costs of these products and high cost, then the management decision to stop production will be correct. In this case, it is necessary to consider the possibility of reducing the cost of production, due to which a price reduction is possible.
In this case, the components of the economic losses that the company will incur will be the costs of producing this product, its storage and disposal. When selling products at a reduced price, the firm will incur losses in the amount of the difference between the costs of its production and the profit from its sale.
108. What are the main stages of the circulation of material working capital of an enterprise?
These stages can be combined into three groups: the first - materials at the production stage, the second - materials in the production process, the third - the sale of finished products.
109. If an enterprise in reporting period replaced some types of material resources with others, in what units of measurement can general change his material costs?
By quantity and value.
110. If the quality of the finished product deteriorated during the replacement of the material, what can reduce the profit of the enterprise?
The deterioration of the quality of the finished product may lead to the buyer's refusal of the product and the imposition of penalties on the manufacturer.
111. What method of accounting for materials allows minimizing profit in the reporting period?
A method of accounting in which the price of materials in the reporting period is the maximum.
112. What (what) method of accounting for materials allows you to more accurately determine the amount of material costs for production and their stocks?
To avoid the risk of unclaimed products, an enterprise should choose such a method of accounting for materials, which, firstly, will most accurately reflect the real cost of the material resources consumed in the course of its activities, and, secondly, will minimize the cost of materials consumption from the standpoint of their accounting. This method is the Fifo method.
113. Is risk assessment carried out in the course of risk diagnostics?
Yes. The diagnostic function consists in a detailed identification of the causes and factors of deviations of the actual values of economic risks at the object under study from the planned values of the indicators. However, it is not limited to identifying cause-and-effect relationships of a given subject of analysis, and also allows you to make recommendations on methods and indicators that identify emerging inconsistencies.
114. At what stage of making a managerial decision and why is an integral qualitative assessment of its risk given?
At the last stage, preceding the adoption of the final decision, a summary, integral assessment risk, which includes two interrelated aspects: qualitative and quantitative.
115. If a management decision has two ways according to the criterion of costs, and the time for its implementation is the same in both cases, then what will determine the choice of a single decision?
To solve such a problem, you can use one of the combinatorics methods - building a "tree of possibilities", which allows you to quickly sort through possible indicators that quantify the risk, costs and time for the project (or any other set of quantitative and qualitative estimates), and see the most acceptable one.
116. How are indicators of probability, danger and importance of risk related?
They are characterized by:
I group - the greatest danger, the highest probability and, therefore, the greatest importance of the risk;
II group - moderate danger, average probability and average degree of risk importance;
Group III - of low danger, low probability and insignificant importance of the risk.
117. Which group of absolute or relative indicators You turn on the indicator« expected revenue from products sold» ? Why?
The indicator "expected revenue from the sale of products" can be attributed to the group of absolute indicators if it is calculated as the amount of expected revenue. Relative this indicator will be when comparing it with another indicator.
118. What are the differences and what are the advantages and disadvantages of objective and subjective methods for calculating the probability of an event occurring?
An objective method for determining probability is to calculate the frequency with which the event under study occurs. subjective method the definition of probability is based on the use of subjective criteria based on certain assumptions.
119. Does a possible decrease in sales by 5% indicate the onset of a risk situation and why?
A real decline in sales even by 5% may indicate the onset of a risk situation. To prevent the realization of this risk, it is necessary to analyze the reasons that caused the decrease in sales volumes and take measures to stabilize the situation.
Task #3
Determine the critical program and establish how many parts per year it is advisable to process them on a four-spindle machine instead of a turret machine with the following data:
Solution
The cost of manufacturing a batch of parts Cn, determined during the design of the technological process, is considered as a sum consisting of two types of costs: dependent and independent of the number of parts in the batch. It is determined by the formula:
FROMn = pn + v
To the number of processing costs per part p , lot size dependent P, includes the cost of basic materials and wages production workers, as well as some other expenses. Among the costs v , not dependent on the number of parts in the batch, include the costs of preparing the work (operation) and its technological equipment, setting up equipment, instructing, etc. These costs are determined first for the batch as a whole, and then lead to one part.
The cost of manufacturing one part Sd when starting to process a batch of parts P PCS. is determined by the formula:
Sd=p+v/n
1. Let's determine the cost of manufacturing one part on a turret machine (RS) and on a four-spin machine. machine (NA) by the amount of costs, depending on the number of parts in the batch:
RS \u003d 13 + 3 + 2 + 3 \u003d 21 kopecks / piece.
NA \u003d 4 + 5 + 2 + 6 \u003d 17 kopecks / piece.
2. Note that the sum of the costs that do not depend on the number of products in the batch (the cost of setting up and operating the tooling) on a turret machine is more than three times lower (10 rubles / year) than the same indicator for four spools. machine (32 rubles / year). These costs will be distributed evenly over the entire number of parts in the batch, so the number of parts in a batch made on four spins. machine should be 3.5 times more than the number of parts made on a turret machine.
3. Let's determine the total cost of products (according to the sum of costs that depend and do not depend on the number of products in the batch), with a batch size of 100 pieces.
RS \u003d (0.21 * 100 + 10) / 100 \u003d 0.31 kopecks / piece.
NA \u003d (0.17 * 100 + 32) / 100 \u003d 0.49 kopecks / piece.
If the batch volume is 350 items per year, then the cost of one part in the batch will be:
RS \u003d (0.21 * 350 + 10) / 350 \u003d 0.24 kopecks / piece.
NA \u003d (0.17 * 350 + 32) / 350 \u003d 0.26 kopecks / piece.
If the batch volume is 700 items per year, then the cost of one part in the batch will be:
RS \u003d (0.21 * 700 + 10) / 350 \u003d 0.22 kopecks / piece.
NA \u003d (0.17 * 700 + 32) / 350 \u003d 0.22 kopecks / piece.
If the batch volume is 800 items per year, then the cost of one part in the batch will be:
RS \u003d (0.21 * 800 + 10) / 350 \u003d 0.22 kopecks / piece.
NA \u003d (0.17 * 800 + 32) / 350 \u003d 0.21 kopecks / piece.
Thus, when the number of parts is more than 800 pieces/year, it is advisable to process them on a four-spindle machine instead of a turret machine.
Task #6
The product is sold at a price of 4 rubles, but a 10% discount is provided for a batch of more than 150 products. A firm consuming 20 items a day wants to decide whether to take advantage of the discount. The cost of placing an order for one batch is 50 rubles, the cost of storing one product is 0.03 rubles. in a day. Is it appropriate for the company to take advantage of the discount?
Solution
1. The cost of placing an order for a batch of 20 items will be:
20 * 4 + 50 = 130 rubles.
130 / 20 \u003d 6.5 rubles.
2. The cost of placing an order for a batch of 155 items, including storage costs, will be:
(155 * 4) - 10% + (155 * 0.03) + 50 \u003d 620 - 62 + 4.65 + 50 \u003d 612.65 rubles.
In this case, the price of one product will be:
612.65 / 155 = 3.95 rubles
Thus, the price of one item purchased at a discount, even including storage costs, is lower than when buying a batch of 20 pieces. Therefore, it is advisable for the company to take advantage of the discount provided.
Task #12
Identify possible types of external and internal risks of the enterprise producing woolen quilted products (blankets, jackets, overalls, etc.). Build a block diagram of the analysis of its economic risk and give suggestions on how to minimize possible internal economic risk this enterprise.
Solution
The number of possible risks is quite large and it is not possible to take into account absolutely all risks. Depending on the place of occurrence, all risks can be conditionally divided into external and internal. External risks include those whose causes are in the external environment, and it is customary to refer to internal risks those types of risks that arise as a result of the activity of the enterprise itself.
It is advisable to single out the categories of mixed risks. This is due to the fact that there are types of economic risk generated partly by the external environment of the enterprise, and partly by its internal actions.
General Analysis Flowchart economic activity is presented in Appendix 1. Here we will consider the main types of economic risks in more detail.
External risks include general economic, market, socio-demographic, natural and climatic, informational, scientific and technical and regulatory.
Causes causing external economic, market, natural-climatic, informational, scientific-technical and regulatory types may lie in the actions of subjects of both the external environment and the internal one. Therefore, they fall into the category of mixed risks.
Internal risk is distinguished by cost centers, i.e. according to the areas of its formation. Cost centers are individual business units to which costs can be allocated. Internal risks may include: transport, supply, production, the risk of storage of finished products, marketing, management.
As with external risks, these subspecies of internal risk may be partly due to causes that lie outside the object of analysis. Such subtypes should be considered mixed risks. These include: transport, supply, marketing.
In the situation described in the engagement, the external business risks for a wool quilting business would be:
General deterioration of the economic situation in the country;
Change in market conditions in an unfavorable direction;
Decreased demand for the company's products among certain consumer groups;
Changes in natural and climatic conditions towards warming;
Leading by competing enterprises in terms of information and scientific and technical parameters;
Change in economic legislation, increase in taxation.
Internal risk factors for an enterprise producing woolen quilted products include:
Rise in the cost of transport tariffs;
Risk of undersupply of raw materials, increase in the cost of supplied materials or lowering their quality;
Failures in production leading to an increase in production costs or a decrease in the quality of the finished product;
The risk of deterioration in the quality of finished products due to inappropriate storage conditions;
The risk of lack of demand for products, a decrease in demand for it;
The risk of irrational organization of production and marketing.
Measures to minimize the possible internal economic risk of this enterprise can be:
1. Conclusion of long-term contracts with transport and supply organizations. The terms of the contract should ensure maximum stability of the terms of supply and transportation.
2. Rational organization of production, which allows to reduce costs and maximize the quality of finished products. Organization optimal conditions storage of finished products.
3. Study of market conditions, consumer requests. Identification of factors influencing the state of demand, control of pricing policy, competent communication policy, advertising.
4. Improving the quality of work of the managerial level. Justification of decision-making on production and marketing, search for more profitable, alternative options.
Task #15
Among the indicators listed below, select those characterizing the possibility of a risk of unclaimed products associated with the quality of the production fixed assets of the enterprise. Combine the selected indicators into groups according to their performance level, technical condition, intensity of use, renewal, sufficiency.
Availability of fixed assets for a certain period.
Wear factor.
The average annual cost of the active part of industrial and production fixed assets.
Time spent in scheduled repairs.
The capital-labor ratio of workers.
The capital intensity of products.
The average annual cost of industrial production assets.
update rate.
Validity factor.
Average age of equipment.
Equipment shift factor.
Dropout rate.
liquidity ratio.
Update intensity factor.
Capital productivity.
The number of hours of actual equipment downtime.
The share of actually working equipment in the installed.
Equipment utilization factor by capacity.
Equipment utilization rate over time.
Worker shift ratio.
The number of unscheduled equipment shutdowns.
Solution
The following factors may influence the emergence of the risk of lack of demand for products associated with the quality of the production fixed assets of the enterprise:
By performance level:
1. Time spent in scheduled repairs;
2. Capital intensity of products;
3. Number of hours of actual equipment downtime.
By technical condition:
1. Wear factor;
2. The coefficient of validity;
3. Average age of equipment;
4. Number of unscheduled equipment shutdowns.
By intensity of use:
1. Liquidity ratio;
2. Equipment utilization factor by power;
3. The coefficient of equipment utilization over time.
Update intensity:
1. Refresh rate;
2. Shift ratio of equipment operation;
3. Retirement rate;
4. Update intensity factor.
For sufficiency:
1. Availability of fixed assets for a certain period;
2. Capital-labor ratio of workers.
Bibliography
1. Ipatov M.I., Turovets O.G. Economics, organization and planning of technical preparation of production. Moscow: Higher school, 1987.
2. Kozlovsky V.A., Markina T.V., Makarov V.M. Production and operational management. St. Petersburg: Special Literature, 1998.
3. Makarenko M.V., Makhalina O.M. Production management. M.: PRIOR, 1998.
4. Management of the organization / Ed. Z.P. Rumyantseva, N.A. Solomatina. M.: INFRA_M, 1995.
5. Management of the organization / Ed. A.G. Porshieva, Z.P. Rumyantseva, N.A. Salomatina. M.: INFRA_M, 1999.
6. Fatkhutdinov R.A. Production management. M.: Banks and stock exchanges, YuMITI, 1997.
The main task of dispatching is to create optimal conditions for the uninterrupted, well-coordinated work of all workshops of the main and auxiliary production in order to fulfill the calendar schedule for the movement of products in production and strictly observe the timing of their release.
Uniform and uninterrupted operation of a machine-building enterprise is carried out only with strict control and regulation of production. To fulfill schedules and schedules, it is necessary to quickly organize the current course of production. At the enterprise, this is done by the dispatching service, which controls and regulates the production process.
Production scheduling is a centralized system of operational management of the current progress of production based on a plan and schedules, aimed at ensuring the implementation production plans. This system creates conditions for the uniform release of products in accordance with the plan in short periods of time - a shift, a day, a week, a decade; prevention and immediate elimination of violations in the production process, for the uninterrupted and coordinated work of all links, the rhythmic work of workshops, sections, jobs, the implementation of schedules, the prevention and elimination of malfunctions and imbalances in production.
In the course of dispatching at the enterprise, the following tasks are solved:
Development of shift-daily tasks based on data from the intrashop level of operational scheduling;
Operational accounting and control of the production process;
Analysis of the causes of deviations from the planned course of production;
Regulation of the course of production.
The organization of the dispatching service of an enterprise depends on the type and scale of production. In large-scale production, a strict order of the current production progress is required, as well as prompt receipt of information about the movement of an order in production, and equipment loading to the dispatcher. In the conditions of in-line production, the dispatching service solves the following issues: compliance with the rules of the flow; control over the volume of output; stock status; adjusting the timing of the release of finished products or semi-finished products according to a certain rhythm. In the conditions of mass production, daily or shift control is carried out at the leading operations of the production process. The company must work in a certain rhythm. The functions of dispatching in the conditions of small-scale production include control of the timing of the release of products, operational regulation of the movement of the order through the main stages of production.
The dispatching service at a machine-building enterprise solves the issues of control and regulation at the intershop level; at the intrashop level; carries out operational management and control of the current course of production.
Dispatching is based on the data of operational accounting of the results of production activities of shops and sections of a machine-building enterprise. In the process of developing intra-shop schedules (equipment loading schedules and work density) and shift-daily tasks, information about the current production progress is used. This information, reflecting the results of the work of the shops of the main, auxiliary and servicing production for the past day or shift, should be accumulated in the dispatching services.
The processed information is presented in the form of corresponding summary data. The timeliness of the receipt of information, its completeness and reliability directly affect the quality of the developed shift-daily tasks. Operational accounting should be carried out in a timely manner and quickly, accurately represent the picture of production, information should be simple and convenient.
Dispatching system on manufacturing plant can function normally only if there is a well-organized system of operational accounting throughout the enterprise. Such a system should have high efficiency in collecting and processing information: exclude the transfer of redundant information; ensure the generalization of the information received in the sections necessary for accounting; minimize manual labor when filling out the primary forms of accounting documentation, be cost-effective.
Accounting objects for different types production are different:
For the conditions of large-scale production - the task in quantitative terms and its implementation;
For the conditions of small-scale production - the loading of equipment and the timing of the processing of each order.
On the machine-building enterprises operational accounting is carried out by operations and by orders.
A shift task is the primary documentation for operational accounting, which defines a shift task for a machine or a section in a workshop, it fixes the amount of work on orders. This document combines the planning task and accounting information, which makes it easier to control the progress of production.
With process accounting, a daily summary (report) is prepared on the fulfillment by the shop of the plan for the main operations. This summary is transmitted to the chief dispatcher or the head of the enterprise.
The most common form of order-by-order accounting is a process flow sheet, which records data on the movement of an order in production. Special order cards are also used. Every day they enter information about the amount of work performed for each operation on an accrual basis.
In the conditions of serial and single production, a route sheet is filled out, which is a convenient form of accounting and monitoring the status of the order. He accompanies the order through all stages of the production process.
In production, graphs occupy a special place as a means of accounting. The advantage of graphical accounting methods is the simplification of registration of accounting data. The graph clearly shows the actual movement of orders. The results of operational accounting are used in operational planning and regulation of production. As a result of comparing accounting data with calendar plans, shift-daily tasks are formed that help to quickly regulate production.
Control, which is carried out by the dispatching service, is aimed not only at the fulfillment of the plan at the end of the month, but also on a daily basis. The objects of control of the dispatching service of machine-building enterprises are the timing of the launch of orders for production and the release of finished products, as well as the movement of orders through the operations of the production process, the completeness of orders, the availability of orders with materials, the efficiency of loading equipment.
The dispatching service of the workshop controls the current progress of production on the following issues:
The volume of output by the shop;
Submission of semi-finished products and materials to the workshop;
Operational preparation of production and provision of jobs with everything necessary.
Control over the volume of output in the workshop is carried out according to calendar plans and shift-daily tasks, control over the receipt of materials and semi-finished products in the workshop - in accordance with the calendar schedule for launching products into production. Control over the operational preparation of production in the workshop is carried out according to the thematic plan and schedules. The current control over the course of production consists in meeting the planned deadlines, performing work at the main operations and by order.
The production process on the production line is controlled by the rhythm of the line. To maintain the rhythm of the production line, it is necessary to maintain inter-operational turnover and reserve reserves at the normative level. An important place in the smooth operation of the production line is given to the timely supply of materials and semi-finished products to the operations of the production process.
Dispatch control at the enterprise is carried out by comparing operational information with the planned information on the stages of production and orders. If deviations from the implementation of the plan are identified, measures are taken to eliminate them, at which point it becomes necessary to regulate the production process.
Monthly operational plans are adjusted by making changes to calendar plans and developing ten-day or weekly schedules for workshops and sections.
The organizational structure of the dispatching apparatus of an enterprise depends on the type, nature and scale of production, and the production structure. At a large enterprise, the dispatching service may be subordinate to the production director. At machine-building enterprises, there may be a dispatching department headed by a chief dispatcher. It is in charge of dispatching groups that interact with various structural divisions to ensure the rhythmic progress of production. The central dispatching bureau includes dispatching groups for the main and auxiliary production, as well as for pre-production.
In modern market conditions the system of operational regulation of production should be focused on obtaining planned indicators that provide a high total income for each enterprise. A decrease in production volumes at many enterprises, possible deviations of the actual production progress from operational schedules, and other market factors significantly increase the role and importance of production planning in general and operational-calendar in particular in the implementation of many important functions of modern engineering production. Under these conditions, the main guideline in the operational regulation of the course of production should not be the elimination of identified deviations, but the creation of the necessary production conditions for the implementation of schedules for the production of products. This will help achieve the planned high financial results, which serve as one of the main market indicators of the growth of production efficiency, the achievement of the main strategic and operational goals of the enterprise.
Most effective work dispatching personnel is achieved on the basis of the functioning of automated workstations (AWP) at the enterprise. When using the AWP-dispatcher, all information about the planned terms of production, planned schedules for loading equipment is stored in the computer. The dispatcher's task in this case is to timely enter information about deviations from the planned production progress into the PC and correct schedules.
Tests1. Why production research began to be actively carried out in XVIIIcentury?
b) it is connected with the formation and development of the capitalist mode of production.
2. Who proposed to plan in advance the methods of work and all the production activities of the enterprise as a whole?
c) F. Taylor.
3. Who developed the motion microanalysis technique?
b) F.B. Gilbert and L. Gilbert;
4. Do the main elements of production operations depend on the content of the work?
b) no.
This position was proved by the Gilberts in the process of developing a technique for microanalysis of movements.
5. Can the recommendations of A.K. Gastev in modern conditions?
a) yes.
Gastaev's recommendations concern general principles rational organization of production processes, so they have not lost their relevance in modern conditions.
6. Can the activity of the enterprise be considered as a complex unified system consisting of a network of subordinates, less complex;
a) yes.
The activity of an enterprise is a complex, multifaceted process that can be considered as a system consisting of a number of subsystems. The efficiency of the entire enterprise depends on the coordinated work of these subsystems.
7. What does the "research" subsystem include?
c) development of a work schedule.
The "research" subsystem may also include: determination of project development directions; calculation of cost estimates and cost control methods; determination of the reliability of the developed product, etc.
8. Are there special services for organizing production at Russian enterprises?
b) no.
The overwhelming majority of Russian enterprises do not have a special service for organizing production, since the size of production often does not allow maintaining additional staff. The presence of such services is typical for large enterprises that have a complex and large-scale production process.
9. Are planning, analysis and control separate stages of the study of the system as a whole?
b) no.
Planning, analysis and control are functions of the production system as a whole.
10. Planning and control of the current functioning of the system are the responsibilities of:
a) production managers;
11. Which subsystem can be attributed to the machine shop of a machine-building plant:
a) processing;
12. Which of the subsystems should include the scientific and technical library of the machine-building plant:
b) security.
13. Which subsystem should include quality control:
b) planning and control subsystem.
14. Is it true that the production management cycle begins with planning?
a) yes;
Since planning allows you to determine the nature, form and sequence of future actions.
15. Should medium-term and operational plans be subordinated to strategic goals?
a) yes;
Since medium-term and operational plans are tools for achieving strategic goals.
16. Do you agree with the statement that strategic planning is central to modern management?
a) yes;
Since strategic goals determine the main directions of development of the organization for a long period.
17. How many levels of strategic planning are allocated in management?
b) three.
18. Are there any differences between strategic plans and functional strategy?
a) yes;
Strategic plans generally consider the possibility of taking a certain position in the market in a certain period of time. The functional strategy takes into account specific functions: sales, inventory management, procurement, production, optimal use of human and material resources, etc.
19. Which of the following strategies is aimed at reducing costs:
Cost control strategy.
This strategy is based on reducing own costs in comparison with the costs of competitors. Mandatory cost control is carried out, thanks to which high production efficiency is achieved. At lower costs, the firm strives to maintain a high level of profit, although prices are lower than those of competitors.
20. Are there differences between differentiation and focus strategies?
Yes.
The differentiation strategy is aimed at supplying the market with goods or services that are more attractive in their qualities than those of competitors. The focusing strategy is based on determining the most profitable and effective type of activity and focusing on it.
21. Do you agree with the statement that the main strategy of the focus idea is to focus on what works best?
Yes.
22. Are there any differences between strategic plans and functional strategy?
Yes.
The functional strategy or the strategy of the production process is aimed at supporting the company's strategy by solving problems that are formed taking into account the needs of the client.
23. Can a production strategy be implemented without an advertising plan?
No.
After the development of the advertising plan, the final marketing plan is specified. The annual sales plan influences the production plan. The production process runs parallel to marketing.
24. The final sales plan is specified:
After developing an implementation plan.
25. Should structural decisions on vertical integration, production capacity, scale and orientation of production be linked?
Yes.
Because all structural solutions are part of a complex production solution. They consider various aspects of the manufacturing process.
26. Information on the dynamics of the total demand for goods and services comparable in the market is needed for:
To justify the likely transition to the production of interchangeable goods;
27. Are there any differences between the structure of the organization and temporary (project) structures?
Yes.
The general structure of the organization can operate for quite a long time. However, the enterprise may have temporary tasks associated with the implementation of the plan. In this case, temporary (project) organizational structures are created.
28. Do you agree with the statement that the structure of the organization needs to be changed?
Yes.
This provision is more typical for foreign enterprises, but it is also applicable in Russian practice. If the organization develops, then its structure must undergo changes in order to best meet the goals of the activity.
29. Do you agree with the statement that the most important component of the "define conditions and organization" phase is the assessment of one's own position in the market?
Yes.
The assessment is carried out in order to determine the position of the enterprise in the industry market; to attract funds from investors in promising production; development of programs for entering new markets.
30. Are classical theories in the field of leadership applicable in production management?
Yes.
In general, the classical theories in the field of leadership are also effective in modern conditions, however, modern management is based on taking into account the achievements of theory and practice in the field of leadership.
31. If the answer to item 30 is positive, give examples of the use of various theories in the field of leadership in production management.
32. Are there any requirements for the formulation of the goal?
Yes.
Goals must meet the following requirements: specificity, visibility, consistency and realism.
33. Should there be feedback between the leader and subordinates?
Yes.
The presence of feedback between the leader and the subordinate provides a more accurate understanding of the instructions of the leadership, allows you to adjust the methods of influencing subordinates and exercise control.
34. Does the type of consumer affect the structure of the organization?
Yes.
Enterprises are interested in such an organization of work, which allows, as fully as possible, to satisfy the needs of all groups of customers. Based on market segmentation, appropriate divisions within the organization can be created.
34. The method of transferring parts, in which processing is performed in batches, and the transition from operation to operation only after processing the entire batch:
b) consistent;
35. In single and small-scale production, the following is usually used:
c) parallel-serial;
36. The main PP is divided into the following functions:
a) procurement, processing and assembly;
37. The equipment sections are arranged in the order of TP:
a) consistency;
38. The duration of the production cycle is:
a) the time during which the processed products are in production;
39. Parallel-sequential type of movement:
a) parts are transferred from operation to operation individually or in small batches;
40. The parallel type of movement is applied:
c) in large-scale and mass production;
41. The production process proceeds:
b) in time and space;
42. Completed part of the TP, performed at one workplace:
b) technological operation;
43. The main PP is:
b) the process by which raw materials and materials are converted into products;
44. The technological process is:
a) process, in cut ltate which changes the shape, dimensions, properties of the product;
45. According to the formula: T=S tPCS. i + /n - 1/x/S tPCS. b - S tPCS. m/ is determined by the processing time of the party at:
a) parallel;
46. The process of labor, as a result of which no product is created, is:
c) serving PP;
47. The non-technical process is:
b) all control and transport operations from the moment of the first production operation to the moment of delivery of the finished product;
48. product, this:
b) any object of labor to be manufactured in production;
49. The duration of the production cycle is determined by the formula:
a) Tc \u003d T main + T obs + T per
50. Proportionality is:
d) there is no correct answer.
Proportionality is the correspondence of the throughput (relative productivity per unit of time) of all departments of the enterprise - workshops, sections, individual jobs for the production of finished products.
51. Simultaneous execution in time of different parts of a single complex software program is:
1. Parallelism.
52. The production process is:
1. A set of interrelated labor processes, as a result of which raw materials are converted into finished products.
53. Ccreatesconditions for a uniform release of products duringethroughout the planning period:
1. Rhythm.
54. New technology in the process of creation goes through the following stages:
1. Scientific research, design and technical development, production development.
55. The development of the technological process is carried out:
1. After testing the design for manufacturability.
56. The degree of detail of the design depends on:
1. Type details.
57. The coefficient of useful use of the material is calculated by the formula:
2. To them \u003d M d / M s * 100
58. Debugging of technical processes in general and design documentation completes:
3. Design training.
59. The initial stage of product design is the development of:
1. Terms of reference.
60. Indicators of production manufacturability can be:
2. Absolute and relative.
61. The process of experimentation applies to:
1. Single production.
62. Costs dependent on the processing method are called:
1. Technological cost.
63. The purpose of the product, scope, operational, technical and economic requirements determines:
1. Terms of reference.
64. The general view of the product, its main idea determines:
1. Draft design.
65. Calculation of the geometric shapes and dimensions of parts, the choice of materials and workpieces is determined when compiling:
1. Technical project.
66. Do you agree with the statement that effective production management is impossible without a scientific organization of labor?
Yes;
The organization of labor should be based on the achievements of science and best practices, ensure an increase in labor productivity and the preservation of human health.
67. Which of the components of production management should include "organization of labor":
B) definition of conditions and organization
68. Professional and qualification division of labor is associated with:
C) the division of workers into categories and categories.
69. Are additional conditions necessary for the introduction of a scientific organization of labor?
Yes;
The introduction of a scientific organization of labor requires the following conditions:
- development of an implementation plan;
- establishment of a unit or contractor responsible for this work (responsibility center);
- clear definition of responsibilities and control functions;
- creation of a system of training and certification of personnel;
- creation of a system of material and moral incentives for work.
70. Do you agree with the statement that the organization of the workplace involves equipping with means and objects of labor placed in a certain order?
Yes;
This stems from the definition of workplace organization.
71. The number and complexity of constantly performed work reflect:
AT) organizational level of the workplace.
72. Where does the planning of workplaces begin:
A) determining the location of the workplace on the site in accordance with its specialization;
73. Do I need to take into account the flow of applications when planning service areas?
Yes;
The flow of service requests per unit of time is the initial characteristic that should be taken into account when planning service areas.
74. Is knowledge of the flow and intensity of service enough to evaluate the accepted service system?
Not;
It is also advisable to study the degree of use of the equipment included in the service area, for which it is necessary to analyze the element-wise structure of the equipment operation time.
75. If the ratio of service time and machine operation time is greater than one, the service area:
B) unacceptable.
76. Does labor rationing matter in the work of a production manager?
Yes;
Labor rationing makes it possible to provide conditions for equal intensity and intensity of labor not only in the same, but also in heterogeneous jobs.
77. Should labor rationing be applied to employees?
Yes;
The work of employees can also be measured by time frames and performance indicators.
78. Are there any differences between the concepts of "norm of time" and "norm of output"
Yes;
79. Is it advisable to apply microelement rationing for employees?
Yes.
The system of microelement standards makes it possible to study the methods of work. This is important to detect changes in the way work is done and changes in time spent.
80. What is the preferred method of measuring labor productivity for performance management?
Labor.
Since labor intensity indicators can be calculated by work areas and categories of workers.
81. What is the essence of the logistics system with a fixed order size?
A system with a fixed order quantity controls the stock level. When the stock level falls below the set level (reorder point), a restocking order is issued. In this system, the determination of an economically reasonable (optimal) order size is of great importance.
82. What is the essence of the logistics system with a fixed time interval?
A system with a fixed time interval between orders involves placing orders for replenishment of stocks at a given frequency.
83. How is the need for materials determined?
There are three methods for calculating the need for materials: deterministic (defined); stochastic (probabilistic, random); heuristic. The most common and reliable is the deterministic method or the direct counting method.
84. What is the practical significance of ABC-analysis and XYZ-analysis?
ABC analysis is commonly used to allocate materials based on quantity and price (or some other characteristic).
With the help of XYZ analysis, the assortment of parts in stock is distributed depending on the frequency of consumption.
85. What are the features of systems with« pushing out» and« pulling» products put into production?
The “push” system for products launched into production assumes that the production of products begins at one end of the production line, goes through a sequential series of technological operations and ends with processing at the other end of the production chain.
The system of "pulling" products involves receiving products from the previous site as needed. The central control system does not interfere in the exchange of material flows between different sections of the enterprise, does not set current production targets for them.
86. What is a warehouse?
c) buildings, structures, devices designed for the acceptance, concentration and storage of various material assets, preparing them for production consumption and rhythmic release to consumers
87. What is the most standard type of product movement?
a) two-tier;
88. How many service classes are there?
at three o'clok.
89. How many components of the total area of warehouses?
at four.
90. How many groups are loading and unloading machines divided into?
b) three;
91. What determines the sequence of events of the serving system?
a) the flow of requirements;
92. What is the type of dependence of the expansive load factor on the operating time of the machine?
a) straight
93. What changes in the performance of the machine will result from the maximum use of the load capacity of the mechanism and speed?
a) to intensify;
94. What areas of internal economic risk can be distinguished by responsibility centers?
Transport, supply, production, risk of storage of finished products, marketing, management.
95. What structural divisions of the enterprise can be accumulators of its expenses? What else can serve as the basis for the distribution of costs?
The cost center, as the classification basis adopted for the previous stage, is used as an organizational unit for accumulating expenses before their subsequent distribution on any basis.
Depending on the degree and direction of detailing costs, small structural divisions of the enterprise, types of products, production factors, etc. can serve as such a basis.
96. Why are factors of production preferable as a sign for identifying risk groups than, for example, the range of products, when conducting a comparative analysis of the economic risk of two enterprises?
Identification of risk groups on the basis of production factors is universal for all enterprises.
97. What situation is characterized by the index, respectively, etc. ..................
3. Organization and management of the production process
3.5. Organization, planning and management of technological preparation of production
Technological preparation of production (TPP) - a set of measures that ensure the technological readiness of production(GOST 14.004–83). Technological readiness of production is understood as the presence at the enterprise of complete sets of design and technological documentation and technological equipment necessary for the implementation of a given volume of output with established technical and economic indicators.
The Unified System for Technological Preparation of Production (UTPP) - (see Fig. 1.) A system for organizing and managing the technological preparation of production, established by state standards, providing for the widespread use of progressive technological processes, standard technological equipment and equipment, means of mechanization and automation of production processes, engineering and technical and managerial work(GOST 14.001–73*).
Rice. 1. The composition of the documentation on the methods and means of the CCI
The main purpose of ESTPP in accordance with GOST 14.001–73* is to create a system for organizing and managing the TPP process, providing: a unified approach for all enterprises and organizations to the selection and application of methods and means of technological preparation of production (TPP), corresponding to the achievements of science, technology and production ; mastering the production and production of products of the highest quality category in the shortest possible time with minimal labor and material costs at the CCI at all stages of product creation, including prototypes (batches), as well as products of single production; organization of production with a high degree of flexibility, allowing for the possibility of its continuous improvement and quick changeover to the production of new products; rational organization mechanized and automated performance of a complex of engineering and management works; interrelation of CCI and its management with other systems and subsystems of management.
The procedure for the formation and application of documentation for the methods and means of the Chamber of Commerce and Industry is determined by industry standards, enterprise standards and documentation for various purposes, developed in accordance with the ECTPP standards.
The main tasks of the Chamber of Commerce and Industry are the development of production and ensuring the release of new products High Quality on time and in a given quantity with high economic efficiency of their production and operation, as well as the improvement of the existing technology for the production of products.
Technological preparation for the production of new products includes solving problems for the following main functions:
a) ensuring the manufacturability of the product design;
b) development of technological processes and control methods;
c) design and manufacture of technological equipment and non-standard (special) equipment;
d) organization and management of the CCI process.
The functions specified in subparagraphs a, b, c and d cover the entire necessary range of work on the Chamber of Commerce and Industry, including structural and technological analysis of products, organizational and technical analysis of production, calculation of production capacities, preparation of production and technological planning, determination of material and labor standards, debugging of technological processes and means of technological equipment.
The content and scope of work on the technological preparation of production depend on the design and technological features of the products and the type of production. The more parts to the assembly units are included in the product, the greater the number of operations and, accordingly, the technological processes for their implementation, the number of units of technological equipment and technological documents, as well as the labor intensity of the CCI.
The main stages of the CCI are developed in a more integrated way in single and small-scale production, often the design of technological processes consists in the development of only technological routes. In large-scale and mass production, when a large number of products are manufactured, a deeper division of labor is needed and, consequently, a greater differentiation of operations, i.e., technological processes and documentation for the CCI are developed in more detail. At the same time, the law of the transition of quantity into a new quality is manifested.
The labor intensity of the CCI of a product in single and small-scale production is 20–25%, in serial production - 50–55 % , and in large-scale and mass – 60–70 % of the total complexity of the technical preparation of production.
Technological preparation of production in the association (at the enterprise) is carried out in the departments of the chief technologist, chief metallurgist, chief welder, in the tool and technological bureaus of the main workshops.
The following workshops serve as the material base of the CCI: tool, model, dies and fixtures, experimental, as well as the corresponding sections in the main workshops,
Depending on the type and scale of production, a centralized, decentralized and mixed CCI system is used. With a centralized system used in mass, large-scale and serial production, the CCI is carried out by research institutes, design bureaus or technological departments of the plant. Technological bureaus of workshops are involved in the implementation of technological processes and their subsequent improvement.
Sometimes design and technology institutes (PTI) or technological departments (bureaus) of research institutes are involved in the CCI, which (except for technological developments for enterprises) perform research work in the field of CCI for the industry.
With a decentralized system used in single and small-scale production with frequent changes in manufactured products, the development of technological processes is carried out in the main workshops. The technological departments of the plant, in addition to the methodological guidance of the plant's technological services, carry out work on the typification of technological processes and the normalization (standardization) of technological equipment, as well as research and experimental work and work to improve technological processes.
In a mixed system, technological processes for new sustainable products are developed in technological departments, and for products that frequently change in production - in workshops. With a centralized and mixed systems, the department of the chief technologist (CDP) may include the following bureaus: technological documentation, design (equipment), standardization, planning of the Chamber of Commerce and Industry, planning and dispatching, as well as technological laboratories (metallurgical, chemical-thermal, welding, cutting); technological bureaus: for procurement, mechanical and assembly processes; subject bureaus (by product groups or their individual parts) and tool management (tool shops, TsIS). Functionally, the CDP is subordinate to the technological bureaus of the main workshops.
Planning and coordination of all the work of the CCI, control over the timing of their implementation and completeness of preparation is carried out by the bureau (department) of pre-production planning (BPPP), usually subordinate to the deputy chief engineer for pre-production.
Ensuring the manufacturability of product design
The general rules for ensuring the manufacturability of the product design are determined by GOST 14.201–83.
Ensuring the manufacturability of the product design is a function of the production preparation process, which provides for an interconnected solution of design and technological problems that are aimed at increasing labor productivity, achieving optimal labor and material costs and reducing the time for production, including installation outside the manufacturer, Maintenance and product repair.
Ensuring the manufacturability of the design includes: testing the design of products for manufacturability at all stages of product development and at the CCI; quantification manufacturability of product design; technological control of design documentation; preparation and modification of design documentation.
The recommended indicators of manufacturability of the design of products are as follows: the complexity of manufacturing the product, the specific material consumption (energy intensity) of the product, the technological cost, the specific labor intensity of installation, the coefficients of material applicability, the unification of structural elements and assembly.
The nomenclature of indicators depends on the type of product (part, assembly unit, complex, kit) and the stage of development of design documentation (technical proposal, draft design, technical design, working documentation).
Development of the design of the product for manufacturability should ensure, on the basis of achieving technological rationality and optimality of design and technological continuity, maximum economic efficiency in the manufacture and operation of the product.
When evaluating the manufacturability of a design, it is necessary to take into account the methods for obtaining blanks, control and testing; possibility of mechanization and automation; provision (with materials, equipment and technological equipment, personnel of workers and engineers); performance and operating costs. The performance properties include performance, efficiency, specific consumption energy and fuel, durability, ease of maintenance and repair, work safety, etc.
The work of ensuring the manufacturability of the product design usually consists of the selection and analysis of the raw materials necessary to assess the manufacturability of the design; clarification of the issue volume; analysis of manufacturability indicators of similar products; determining indicators of production and operational manufacturability and comparing them with indicators of existing structures; development of recommendations for improving manufacturability indicators. At the same time, it is necessary to take into account best practices and new progressive technological methods and processes.
The technical proposal is the identification of options for constructive solutions and the possibility of borrowing constituent parts products, new materials, technological processes and technological equipment; calculation of manufacturability indicators of options and selection of the final design solution; technological control of design documentation.
Draft design is an analysis of the conformity of layouts and division of product design options to the conditions of production, maintenance and repair; calculation of manufacturability indicators of options and selection of product design options for further development; technological control of design documentation.
The technical project is the identification of the possibility of using purchased, standard, unified or mastered by the production of the components of the product; new, including standard and group, high-performance technological processes; calculation of manufacturability indicators of the product design and technological control of design documentation.
Working design documentation: a) prototype(experimental batch) or unit-production products (except for one-time production) includes an analysis of the possibility of assembling the product and its components without intermediate disassembly; identification of the possibility of unification of assembly units, parts and their structural elements; establishment of cost-effective methods for obtaining blanks; element-by-element testing of the design of parts and assembly units for manufacturability; calculation of manufacturability indicators of the product design and technological control of design documentation; b) serial (mass) production - final decision-making on improving the conditions for performing work during production, operation and repair, as well as fixing these decisions in technological documentation; bringing the design of the product to compliance with the requirements of serial (mass) production, taking into account the use of the most productive technological processes and technological equipment in the manufacture of the product and its main components; assessment of the compliance of the achieved level of manufacturability with the requirements of the technical specifications; correction of design documentation.
There are two types of technology: production, which consists in reducing the cost of funds and time for checkpoints, chambers of commerce and for manufacturing processes, including control and testing; operational, manifested in reducing the time and cost of maintenance and repair of the product.
The same GOST establishes two types of assessments: quality, which characterizes the manufacturability of the design generally based on the experience of the performer; quantitative, expressed by an indicator, the numerical value of which characterizes the degree of satisfaction of the requirements for the manufacturability of the design.
Manufacturability indicators of product design are classified by this GOST as follows: according to the area of manifestation - into production and operational; by area of analysis - into technical and feasibility studies; according to the evaluation system - for basic and developed structures; by importance - into basic and additional; according to the number of characteristics characterized - into private and complex; according to the way of expression - into absolute and relative.
Development of technological processes
For CCI services, the source document is the order of the head of the enterprise, which determines the phased implementation of measures for technological preparation for the release of the product. On the basis of the order, the planning and production department (PPO) of the enterprise draws up a network or integrated schedule, in which it establishes the stages of development of the product, the list of works on the TPP and the duration of their implementation, the composition of the executing units and responsible executors for each unit.
Exemplary network diagram shown in diagram 1: what processes, in what order and in what time frame should be carried out for the implementation of the project. The initial and resulting data in tables 1 and 2.
Table 1
Project elements and time to complete them
|
Implementation time, week |
Preceding Process |
|
|
A. Making a working drawing |
||
|
B. Making a model for a casting mold for the body |
||
|
B. Gear turning |
||
|
D. Casting and processing of the housing under pressure |
||
|
E. Procurement and inspection of bearings, seals and special parts |
||
|
E. Shaft turning |
||
|
G. Gear milling |
||
|
3. Heat treatment |
||
|
I. Assembly |
In Figure 13.7, all individual processes are combined into common project in the form of a network plan. In this case, "nodes" are places where the production process stops. They are numbered in such a way that of the two knots connected by an arrow, the next one has a higher serial number. The project has 4 paths, the implementation time of each is given in diagram 13.8. The path that takes the longest time (8.9 weeks in Figure 13.8) can be defined as the "critical path". You can identify the minimum time required to complete the project. Other paths show buffer time: 1.3; 1.6; 0.6 weeks.
Scheme 1. Network plan
table 2
critical path
|
Required time |
|
|
1–2–4–6–7 |
4,0 + 2,3 + 0,6 + 2,0 = 8,9 |
|
4,0 +1,6+2,0 = 7,6 |
|
|
1–2–5–6–7 |
4,0 + 0,8 + 0,5 + 2,0 = 7,3 |
|
1–2–3–5–6–7 |
4.0 + 0.8 + l.0 + 0.5 + 2.0 = 8.3 |
When the schedule is approved by the relevant departments and services, an organizational and technical analysis of production is carried out, which includes: a structural and technological analysis of the product; analysis of existing production capacities and areas; equipment of production with technological processes, equipment and tooling, as well as analysis of the level of mechanization and automation of production processes. At the same time, the program, the range of the product being mastered and the organizational and technical structure of the enterprise are taken into account.
The performance of work on the CCI takes into account the PPO in order to obtain information about the state of the CCI for any calendar period of time and use it to control the performance of work.
For accounting use the following data: nomenclature of work performed; the actual duration of the work; work sequence; movement of labor and material resources.
The frequency and procedure for keeping records, issuing, receiving and storing accounting documentation are determined by the specific conditions of production and are established by the enterprise carrying out the CCI. Accounting information should be formed in accordance with the specialization of the CCI services and be sufficient for analysis and decision-making by all specialized services.
If there are deviations from the established criteria, an optimal decision is made to eliminate them, and then the course of the CCI is regulated.
Proposals to refine work plans in order to regulate the CCI process are made by the controlling body - PPO. Changes made to the planning documentation are approved by the management of the enterprise implementing the CCI. In the process of regulation, it is necessary to take into account: the cost of resources for the implementation of the decisions made, the impact of these decisions on the work of related departments and the further course of the CCI.
Achieving unified technical requirements to products (including international ones) is carried out through their harmonization on the basis of certification of products and the quality system of its production *. Certification depending on the status can be mandatory and optional. Mandatory certification is subject to products, in the NTD for which there are requirements for safety and environmental compatibility. Certification of products for operational properties is carried out at the request of consumers or the desire of the manufacturer, for commercial purposes. When preparing for certification for commercial purposes, the manufacturer, on the basis of marketing research and technical and economic analysis of production specifies the operational properties (indicators) of products, while, as a rule, they are changed (increased or, in some cases, reduced) based on consumer requests and declared in standards or technical conditions. An enterprise, in order to ensure high competitiveness, should strive to inform the consumer about the real differences between its products and competitors' products.
Taking into account the market situation, any product, as it were, goes through a cycle of four stages: the stage of bringing to the market; growth stage; stage of maturity; decline stage. The launch phase is characterized by slow sales growth and minimal profits while the product is being pushed through the distribution channels. If successful, the product enters a growth phase characterized by rapid sales growth and higher profits. At this stage, businesses seek to improve the product, penetrate into new market segments and distribution channels, and slightly reduce prices. Then comes the maturity stage, during which sales growth slows down and profits stabilize. In order to revive sales, enterprises are looking for various innovative methods, including market modification, product modification and complex marketing modification. And, finally, the product enters the decline stage, when sales and profits are reduced. The task of the enterprise at this stage is to identify "decrepit products" and make a decision in relation to each of them either to continue production, or to "decrease the fruit", or to exclude it from the nomenclature. In the latter case, the product can be sold to another company or simply discontinued.
General rules for the development of technological processes are determined by GOST 14.301–83.
This GOST established three types of technological processes: single, typical and group.
A technological process is developed for the manufacture or repair of a product or for the improvement of an existing technological process. The developed technological process must be progressive. The progressivity of the technological process is assessed by the indicator established by the industry system of certification of technological processes. The technological process must comply with safety requirements and industrial sanitation.
Documents for technological processes should be drawn up in accordance with the requirements of the standards of the "Unified System of Technological Documentation" (ESTD). The initial information for the development of technological processes is divided into basic, which includes the data contained in the design documentation for the product, and the release program for this product; leading, containing data that is in following documents: industry standards that establish requirements for technological processes, as well as standards for equipment and tooling; documentation for existing single, standard and group technological processes; classifiers of technical and economic information; production instructions; materials for the choice of technological standards (processing modes, allowances, material consumption rates, etc.); documentation on safety and industrial sanitation; reference, including data contained in the following documents: descriptions of advanced manufacturing and repair methods; catalogs, passports, directories, albums; production site plans.
The main stages in the development of technological processes are: analysis of the initial data; selection of an existing standard, group technological process or search for an analogue of a single process; selection of the initial workpiece and methods of its manufacture; selection of technological bases; drawing up a technological processing route; development of technological operations; regulation of the technological process; determination of safety requirements; calculation economic efficiency technological process; design of technological processes.
A typical technological process must be rational in specific working conditions and be developed on the basis of an analysis of many existing and possible technological processes for the production of typical representatives of product groups. The typification of technological processes is based on the classification of production facilities and is carried out at three levels: state, industry and enterprise. The classifier of parts (products) must be created using a computer. For this purpose, the following design information must be entered into the computer memory: the number of the drawing of the part, the type and grade of the material and its mass, the overall dimensions of the part; type of surfaces - plane, cylinder, hole, thread, jagged surface, ball, curved surface, etc. and their dimensions; surface roughness and processing accuracy and other parameters. All of these parameters must be encoded.
Sorting these parameters (from highest to lowest) makes it possible to create groups of parts similar in design and processing technology, for which it is possible to use standard technological processes that are the basis for the development of specific processes.
The main stages in the development of typical technological processes are defined by GOST 14.303–73*; these include: classification of production objects, their quantitative assessment and analysis of the designs of typical representatives; choice of workpiece and methods of its manufacture; selection of technological bases and type of processing; development of technological route and operations; calculation of accuracy, productivity and economic efficiency of options and design of standard technological processes.
The necessity of each stage, the composition of tasks and the sequence of their solution are determined by the developer of a typical technological process.
A typical process can be operational, reflecting the progressive state of technology at the present time, and promising providing for its further improvement, taking into account the development of science and technology in the field of technology.
A further development of the typification of technological processes is the development of group technology2, which is most effective with small batches of machined parts and frequent changeovers of equipment.
The group technological process is intended for the joint production or repair of a group of products of various configurations.
It should consist of a complex of group technological operations performed at specialized workplaces in the sequence of a technological route for the manufacture of a certain group of products. When developing group technological operations, it is necessary to provide for a sufficient amount of their total labor intensity for work without readjustment of technological equipment (only partial readjustment is allowed).
The basis for the development of a group technological process and the choice of common means of technological equipment is a complex product, which can be one of the products of the group or artificially created (conditional).
Group technological processes and operations are developed for all types of production only at the enterprise level in accordance with the requirements of GOST 14.301–83* and GOST 14.316–75*.
Initial information for the development of group technological processes and operations is determined in accordance with GOST 14.303–73*. Guidance information should additionally include data contained in existing group technological processes and operations, classifiers of products, equipment and tooling. Reference information should be contained in the documentation for the current standard and single technological processes, in the descriptions of advanced processing methods, as well as in the statements of labor intensity of products and other regulatory materials.
The main stages in the development of group technological processes include the analysis of initial data, the grouping of products, the quantitative assessment of groups of objects, and the regulation of the technological process. The remaining stages are similar to the main stages of the development of standard technological processes, defined by GOST 14.303–73*.
The rules for organizing group production are determined by GOST.
The specialized subdivisions of group production may include workshops and sections of group production and group production lines.
Batch technology creates the conditions for the use of serial and large-scale production methods, even with a small number of production of each individual product, which allows you to use all the advantages of serial and large-scale production.
The use of standard and group technological processes allows to increase labor productivity and reduce the cost of production through the use of the most advanced technological equipment, the production process as a whole and tooling. At the same time, the number of various technological routes, labor intensity and duration of technological preparation of production are reduced.
The designed technological processes are recorded in technological documentation: in route, operational and operational and instructional technological maps.
Route maps contain a list of workshops, and inside the workshops, a list of technological operations - indicating equipment, technological equipment, work category and time standards for each operation. They are used in the conditions of single and small-scale production, when there are enough of them for processing parts or performing assembly operations.
Operating cards are used in mass production and contain a list of "transitions" of the operation indicating the equipment for performing the operation, processing modes and technological equipment for each "transition", the category of work, the time norm for individual components and for the operation as a whole.
Operational and instructional cards are used in mass production and contain more detailed instructions for performing a technological operation, including setup sketches, methods of fastening and measuring parts, and workplace organization.
The information generated in the process of creating technological documentation should be suitable for use in automated control systems and in the creation of flexible automated (automatic) systems and industries.
Control operations are established by technologists in accordance with the requirements of the drawings and specifications; they are recorded in technological maps. For complex and responsible operations technical control special maps are developed with an indication of the object of control, the place of its implementation, the method and means of control, and permissible deviations.
When designing technological processes, several options can be developed.
They choose the option of the technological process, which, all other things being equal, makes it possible to manufacture the part at the lowest cost for its production, i.e., at the lowest cost.
The cost of manufacturing a batch of parts Cn, determined during the design of the technological process, is considered as a sum consisting of two types of costs: dependent and independent of the number of parts in the batch:
To the number of processing costs per part p , lot size dependent P, includes the cost of basic materials and the wages of production workers, as well as some other expenses. Among the costs v , independent of the number of parts in the batch, include the costs of preparing the work (operation) and its technological equipment, setting up equipment, instructing, etc. These costs are determined first for the batch as a whole, and then they are given for one part.
The cost of manufacturing one part Sd when starting to process a batch of parts P PCS. is determined by the formula
Sd = p + v / n
1 A batch of parts is usually called the number of parts of the same name n, launched simultaneously into production and processed from one setup.
If the amount of costs incurred per batch is detailed, regardless of its size v = 600 rubles, and the costs incurred for each part, p / n \u003d 0.4 rubles, then with a lot of parts n \u003d 550 pcs. The cost of manufacturing each part is:
SD \u003d 0.4 + 600 / 550 \u003d 1.49 rubles,
and the cost of manufacturing the entire batch:
Cn \u003d 0.4 * 500 + 600 \u003d 820 rubles.
On fig. 2 shows a comparison graph of two variants of the technological process: in the first variant v" = 270 rubles and p" = 1 rub., and in the second variant v" = 600 rubles, p" = 0.4 rubles. The graph shows that with a batch of parts n = 550 pcs. the cost of production for these two options is the same (the cost lines Cd = 1.49 rubles and Cn = 820 rubles intersect at the point corresponding to n = 550 pieces).
Fig.2. Graph of comparison of two variants of technological processes
Comparing two variants of the developed technological process, one of them is chosen, which, for a given batch size, provides the lowest cost.
The designed technological process is recorded in technological maps, on the basis of which material specifications and statements of the required tool and other equipment are compiled.
Technological maps are compiled in the form of: a) route; b) operating rooms; c) instructions.
a) Route maps are used in single and small-scale production with a large range of products. The development of the technological process ends with the preparation of route maps. These maps serve as the basis for inter-shop planning (sales) at enterprises of these types of production.
b) Operating or transitional technological maps, containing all the necessary data on the developed technological process, are compiled at enterprises of large-scale and mass production on the basis of route maps.
c) Instruction cards are compiled mainly in mass production, for the most complex and labor-intensive operations, and are intended for direct use by workers. The instruction card describes in detail not only the content of this operation, modes, equipment, etc., but also the basic methods of work.
Material specifications are compiled in the form of a list of the basic materials required for the manufacture of parts of a specific name, indicating the brand, grade, size and quantity for each size.
Lists of the required tool, as well as material specifications, are compiled on the basis of technological operating cards and serve as the basis for planning the production needs for tools and other equipment.
New technological processes are usually not immediate. are introduced into production, and first they are tested in experimental workshops, after which debugging is carried out in the main workshops. Checking and debugging are carried out during the release of trial series under the direct supervision of technologists. At the same time, not only the designed technological processes are checked and corrected, but also the designs of tools and devices, as well as the planned processing modes, time standards and prices.
Experimentation in the field of technology is aimed at finding, and in the future mastering new, more advanced technological processes for obtaining blanks, mechanical and thermal processing of parts, assembling units and machines, as well as more productive cutting, welding, etc. Experimentation is carried out not only in the order of current technical training, but also according to the research plan.
Process Documentation,
approved by the chief engineer of the plant, is, along with the design documentation, the most important technical document, deviation from which (without appropriate permission) is a violation of technological discipline.
Strict observance of technological discipline is the most important condition for the successful implementation of the state plan task, the speedy development new technology, proper use of means of production, saving time, materials and energy.
At machine-building enterprises, parts are produced that are extremely diverse both in terms of the source material, configuration and dimensions, and in terms of the requirements for accuracy and cleanliness of manufacture. The design and implementation of various technological processes for a large number of parts is a very time-consuming and expensive work. This determines the need to develop standard technological processes.
Typical technological processes are developed on the basis of the classification of parts, according to which all parts manufactured at the factory are divided into classes, classes - into groups, groups - into subgroups according to the following criteria: source material, configuration, dimensions and cleanliness of the machined surfaces of the part. Typification of technological processes has great importance for systematization, generalization and dissemination of advanced high-performance technological processes. Typification of technological processes reduces the complexity of technological preparation by 2-3 times, and technological documentation by 8-10 times. Typical technological processes are widely used mainly for mechanical and heat treatment details in the conditions of small-scale and single productions. It is necessary to expand the use of typification of technological processes of casting, forging and assembly.
Technological preparation of production at the plant is carried out by the service of the chief technologist. At large plants, the technological preparation of production in hot shops is carried out by the department of the chief metallurgist or under his direct supervision. Technological preparation for machine-building plants can be organized according to a centralized, decentralized or mixed system.
With a centralized system, technological preparation is concentrated in the general plant technological department (department of the chief technologist). The centralized system is used in mass and large-scale production. Figure 3 shows exemplary scheme organizational structure technological department of a machine-building enterprise.
A decentralized system involves the dispersal of technological training in the main production shops factory. The technological bureaus of these workshops independently develop technological processes and their equipment. Such a system is used in unit production with a significant range of production of machines, their components and parts, and frequent changes in this range. With a decentralized system, the department of the chief technologist of the plant provides only general methodological guidance to the workshop technology bureaus.
The mixed system of organization of technological preparation is that the development is carried out partly (route technology) in the department of the chief technologist and partly (operational technology) in shop technological bureaus. Such a system is used in serial production.
The composition and organizational structure of the technological department (department of the chief technologist) depends on the scale and nature of its work.
Rice. 3. Scheme of the organizational structure of the technological department of a machine-building enterprise
Development, acceptance and transfer to production of new technological processes in accordance with the requirements of ISO 9000 series standards
The terms of reference compiled by the contractor on the basis of the customer's request are the source document for the development of the technological process.
The parties (persons) involved in the development and implementation of technological documentation may act as a customer, contractor (developer) and consumer.
The customer is the person under the contract with which or according to the application accepted from him, the technological process is being developed. The customer presents the developer with the initial requirements for development; approves the terms of reference for the development; accepts technological processes and determines the scope of their application. The customer is responsible for the feasibility of the initial data for development, for their compliance (norms, indicators, requirements) with the current level of development of science, technology and production. Performer (developer) in accordance with the requirements of the customer, he develops the terms of reference, coordinates it with the customer and other interested enterprises (organizations), develops the necessary documentation, is responsible for the completeness, quality and timing of the transfer of documentation to the customer and exercises architectural supervision during its use.
The development of technological processes is based on two principles: technical and economic. In accordance with technical principle the designed technological process must fully ensure the fulfillment of all the requirements of the working drawing and specifications for the manufacture of a given product. In accordance with the economic principle, the manufacture of the product should be carried out with minimal cost labor and production costs. The technological process of manufacturing products should be carried out with the fullest use of the technical capabilities of the means of production at the lowest cost of time and cost of products.
The constant progress of technological processes is a condition for successful competition enterprises for markets. For purposeful actions on their quality, they are guided by the requirements set out in the ISO 9000 series of standards, ensuring the use of experience foreign firms, which provides for the planning of production operations under controlled conditions, in a certain way and in a certain sequence. Managed conditions include appropriate management of materials, production equipment, processes and procedures, software computers, personnel, supplies, equipment and work environment. Production operations should be defined in sufficient detail in the technological documentation, technological documentation - focus on a complete and accurate description of technological methods (except for fragments that establish what to do, they provide information on how to do it). The formation of the main surfaces of parts and assembly units, defined by the "Classifier of the main surfaces of parts and assembly units, affecting the creation of reserves of technological accuracy (quality reserves) of the product", should be carried out in a standardized
The reserve of technological accuracy (reserve of quality) is understood as a positive difference between the tolerance value and the dispersion field of any parameters of parts (assembly units, products), that is, the margin of the quality reserve (reserve for operation) with which the errors fit within the tolerance field. Thus, with the same technical requirements (standards), the quality of the product will be higher where there are large reserves of technological accuracy. This can be illustrated by the following example. It is known that domestic tolerances and tolerances of the Swedish company SKF for rolling bearings are approximately the same. However, the durability and reliability of SKF bearings is on average higher, since they are produced with large reserves of technological accuracy (for bearings of this company, parts have a more accurate shape and better surface quality , and their dimensions - less dispersion) The same can be said about metal-cutting machine tools, the accuracy standards (technological accuracy reserves) of which are approximately the same, but the operating resources of domestic machine tools and machine tools of the best foreign firms differ significantly. Thus, in the manufacture of machine tools, the accuracy reserves of the best Japanese firms make up 60-70%, i.e., these firms use only 25-40% of the tolerance field in the manufacture of machine tools or with special technological equipment and / or on special machines, as well as machines of the “machining center” type (the classifier is developed by the design department, in addition to kit “working design author's documentation”). In order to create conditions for the controllability of the technological process, the technological documentation clearly defines control operations, control samples, the plan and form of control cards, control of the first and last operation, operations for setting up technological and measuring instruments, change of equipment, etc.; methods and means of maintaining (in acceptable limits) operating conditions environment(temperature, humidity, dust content, etc.). In cases of increased dependence of the product quality on the properties of materials and components, methods and means of their input control are given. Particular attention is paid to product safety operations (electrical safety, noise characteristics, danger due to failures, etc.), as well as the possibility of traceability and documentation of the results of processing (assembly) and control.
The main technological document, in accordance with international standards ISO 9000 series is work instruction(RI). The RI sets out general (of a permanent nature) requirements for the performance of technological operations at a particular workplace, including the actions of working and technological means and safety requirements.
If necessary, in addition to RI, technological instructions (TI) are developed. Variable technological parameters of the technological process (operation) are given in TI - the processing mode and methods for achieving technological accuracy reserves (quality reserves) for a particular workplace.
To control the technological process and visualize the perception of its route, it is recommended to develop a technological scheme. On the diagram, symbols (Table 2.1) indicate: the name and numbers of workshops, sections, jobs; information on the use of STP, RI, TI operating at the enterprise in the developed technological process; operations and activities for the acceptance, storage and transportation of raw materials, materials and components; operations of processing and control during processing; operations of assembly and control during assembly; operations of acceptance (testing); operations of transportation and storage of finished products.
For processes that are already being implemented in production, it is advisable to analyze the designed scheme for compliance with the actual one; if there are differences, they are discussed. The ultimate goal of analysis and discussion is the steady adherence to the technological scheme in real production conditions. The scheme is approved together with the technological documentation for the product.
RI and schemes are performed on sheets of A4 format (GOST 2.301-68) or forms of similar TI (GOST 31105-81); TI-on sheets of À4 format or forms similar to TI (GOST 31105-81) and (or) forms of operational process flow charts (preferably standard ones) of the corresponding type of shaping - cutting, casting, forging and hot stamping, cold stamping, welding, soldering and tinning, paint and varnish and galvanic coatings, plumbing and locksmith and assembly works etc., with the development and execution (if necessary) of sketches of the workpiece (in accordance with the requirements of GOST 3.1105-81). When forming a complete set of the technological process, other forms of ESTD are also used.
When introducing in an organization (at an enterprise) a system for concluding labor agreements with developers of technological documentation on a contract basis, establishing the obligation of a full guarantor of the quality of work performed, metrological control and normative control of documentation is not carried out.
- The production process is the process of converting costs (input) into results (output).
- The production process is a set of labor processes and natural processes necessary for the manufacture of a certain type of product.
- The main products of the enterprise are various kinds of products. There are products of the main and auxiliary production.
- According to the role in the overall process of manufacturing products, there are processes: main, auxiliary, serving.
- The most important principles of the organization of the production process: proportionality, parallelism, continuity, direct flow, rhythm, specialization, automaticity, flexibility, consistency, optimality.
- The production cycle is a calendar period of time during which the object of labor goes through all stages of the production process.
- The production cycle consists of two parts: the working period and the break time.
- The production cycle is determined by the nature of the products, the technological process, the level of technology and the organization of production.
- In the production process, there are three types of movement of objects of labor: sequential, parallel, parallel-sequential.
- The type of production is determined by the specialization, volume and constancy of the product range, as well as the form of movement of products in the workplace.
- The main indicator characterizing the type of production is the coefficient of consolidation of operations. It shows the ratio of the number of different technological operations to be performed within a month to the number of jobs.
- There are three types of production: serial - a limited range of products is manufactured in batches (series) with a wide specialization; mass - continuous production of a limited nomenclature at highly specialized workplaces; single - production of a wide range in single quantities, repeating at indefinite intervals or not at all repeating, at workplaces that do not have a specific specialization.
- According to the prevailing type of production, the type of site, workshop, plant is also determined.
- Technological preparation is a set of measures that ensure the manufacturability of production and is based on unified system technological preparation of production (ESTPP).
- Technological preparation solves the following tasks: ensuring the manufacturability of the design, development of technological processes and control methods, design and manufacture of technological equipment, organization and management of the TPP process.
- Design documentation includes: technical proposal, draft design, technical design.
- The achievement of unified technical requirements for products is carried out on the basis of product certification and the quality system of its production. Certification may be mandatory or optional.
- Initial information for the development of technological processes includes: basic, guidance, reference.
- The main stages of the development of technological processes: analysis of the initial data, selection of an existing standard project or similar, selection of the initial workpiece and methods for its manufacture, selection of technological bases, preparation of a technological processing route, development of technological operations, standardization of the technological process, determination of safety requirements, calculation of economic efficiency technological process, design of technological processes.
- The designed technological processes are recorded in the technological documentation: in route, operational, operational and instructional cards.
- The economic feasibility of the selected variant of the technological process is determined by the minimum cost of manufacturing parts from several.
- Technological preparation of production is carried out by the service of the chief technologist.
Questions, tests, tasks
- The production process, its essence and composition.
- The content of the main production processes.
- The content of auxiliary production processes.
- Partial production process, its definition and varieties of its constituent operations.
- The structure of production processes.
- Basic principles of organization of production processes.
- The production cycle, its structure and ways of reduction.
- Sequential movement.
- Parallel movement.
- Parallel-sequential type of movement.
- Characteristics of the types of movement of production processes in time.
- Mass production, its characteristics.
- Serial production, its characteristics.
- Single production, its characteristics.
- The main stages of technological preparation.
- Initial data and technical documentation for the development of technological processes.
- Economic feasibility of the selected process option.
- Organization of management of technological preparation of production.
- A method of transferring parts in which processing is performed in batches, and the transition from operation to operation only after processing the entire batch:
- parallel;
- consistent;
- mixed;
- there is no correct answer.
- In single and small-scale production, they usually use:
- sequential type of movement;
- parallel;
- consistent and mixed;
- there is no correct answer.
- The main software is divided into the following functions:
- procurement, processing and assembly;
- procuring, processing and selling;
- procurement and transport;
- there is no correct answer.
- The equipment sections are arranged in the order of TP:
- consistency;
- direct flow;
- rhythm;
- there is no correct answer.
- The duration of the production cycle is:
- the time during which the processed products are in production;
- the time interval between the processing of two parts;
- the time interval between successive releases of an equal number of products;
- there is no correct answer.
- Parallel-sequential type of movement:
- parts are transferred from operation to operation individually or in small batches;
- parts are transferred from operation to operation only in the entire batch;
- individual parts in a batch are partially processed simultaneously in two or more operations;
- there is no correct answer.
- The parallel type of movement is used:
- only in serial production;
- in single and mass production;
- in large-scale and mass production;
- no correct answer
- The production process takes place:
- only in time;
- in time and space;
- only in space;
d) there is no correct answer.
- Completed part of the TP, performed at one workplace:
- technological transition;
- technological operation;
- auxiliary transition;
- no correct answer
- The main PP is:
- the process of manufacturing products that will be used within the enterprise;
- the process by which raw materials and materials are converted into products;
- a set of production tools necessary for the implementation of TP;
- there is no correct answer.
- The technological process is:
- a process that changes the shape, size, properties of the product;
- a process that does not lead to a change in the shape, dimensions, and properties of the product;
- completed part of technological transition;
- there is no correct answer.
- According to the formula: T \u003d S t pcs i + /n - 1 / x / S t pcs b - S t pcs m / the duration of batch processing is determined at:
- parallel;
- parallel-serial;
- sequential;
- there is no correct answer.
- The process of labor, as a result of which no product is created, is:
- auxiliary software;
- main software;
- serving PP;
- no correct answer
- The non-technical process is:
- a process that leads to a change in the shape, size and properties of the product;
- a set of useful actions for the sale of finished products;
- a process that does not lead to a change in the shape, size and properties of the product;
- there is no correct answer.
- The product is:
- completed part of the technological process, performed at one workplace;
- any object of labor to be manufactured in production;
- the main structural unit of PP;
- there is no correct answer.
- The duration of the production cycle is determined by the formula:
- TC \u003d T main + T obs + T lane
- TC \u003d T main + T aux + T pcs.
- Tp \u003d T obs + T pz
- there is no correct answer.
- Proportionality is:
- compliance with the determined proportions between the main, auxiliary and service processes;
- periodically systematically repeating PP;
- coordination among themselves of the dates for the start and completion of work in adjacent areas;
- there is no correct answer.
- Simultaneous execution in time of different parts of a single complex software program is:
- Parallelism.
- Consistency.
- Proportionality.
- There is no correct answer
- 19. The production process is:
- A set of interrelated labor processes, as a result of which raw materials are converted into finished products.
- Part of the technological process, which includes work to change the state of the product.
- A set of useful actions for the production and sale of finished products.
- There is no correct answer.
- Creates conditions for uniform output throughout the entire planning period:
- Rhythm.
- Parallelism.
- Proportionality.
- There is no correct answer.
- New technology in the process of creation goes through the following stages:
- Scientific research, technical development, material development.
- Scientific research, design and technical development, production development.
- Scientific research, design and technical development, organizational training.
- There is no correct answer.
- The development of the technological process is carried out:
- After testing the design for manufacturability.
- Before working out ----² ----.
- There is no correct answer.
- The degree of detail of the design depends on:
- Detail type.
- Production type.
- There is no correct answer.
- The coefficient of useful use of the material is calculated by the formula:
- Kim = Mz / Md
- Kim \u003d Md / Mz * 100
- Kim = Md / Mo
- There is no correct answer.
- Debugging of technical processes in general and design documentation completes:
- Design training.
- Technological preparation.
- technical training.
- There is no correct answer.
- The initial stage of product design is the development of:
- Technical task.
- Sketch project.
- Technical project.
- There is no correct answer.
- Indicators of production manufacturability can be:
- Direct and indirect.
- absolute and relative.
- There is no correct answer.
- The process of experimentation applies to:
- mass production.
- serial production.
- Single production.
- Mass and serial production.
- There is no correct answer.
- Costs dependent on the method of processing are called:
- technological cost.
- Planned cost.
- There is no correct answer.
- The purpose of the product, scope, operational, technical and economic requirements determine:
- Technical task.
- Technical project.
- Preliminary design.
- There is no correct answer.
- The general view of the product, its main idea determines:
- Technical task.
- Technical project.
- Preliminary design.
- Working project.
- There is no correct answer.
- Calculation of geometric shapes and dimensions of parts, the choice of materials and workpieces is determined when compiling:
- Technical task.
- Technical project.
- Sketch project.
- There is no correct answer.
Determine the duration of the production cycle for processing a batch of parts consisting of 6 pcs. with sequential, parallel and parallel-sequential types of movement, if the complexity of processing for operations is: 005-4 min., 010-2 min., 015-5 min., 020-4 min. Transfer of parts piece by piece. Build graphs for all types of movement and draw conclusions about the effectiveness of these types of movement.
For the manufacture of the part, 2 variants of the technological process have been developed: cutting and stamping. Determine which option is more economically feasible with an annual program of 900 pcs. based on the following data.
Determine the critical program and establish how many parts per year it is advisable to process them on a four-spindle machine instead of a turret machine with the following data:
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When processing |
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On a revolver |
on four spans automatic |
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Salary of a machine operator, kop./pc. Operating cost kop./pc. Tool Depreciation of the machine, kop./pc. The cost of setting up and operating equipment, rubles / year |
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