The plant of the borehole geophysical equipment the Pilot solved a problem of maintaining production orders with the help: PLM

The plant of the borehole geophysical equipment of JSC NPF Geofizika started commercial operation of an automated system of technology preparation of production and maintaining orders on the LOTSMAN:PLM platform. In a new IT system the existing business processes and practices by orders since 2004 are saved, labor regulation on technology elements, formation of the scheduled plan to order and accounting of piece works is implemented. Works on implementation are performed by ASCON-Ufa company, the partner of ASCON.

The Plant of the Borehole Geophysical Equipment (PBGE) is NPF Geofizika branch of JSC (Ufa), one of the leading scientific and production enterprises of Russia for development and production of special and unique means and technologies for geophysical surveys of wells.

Work of technology department of ZSGA has special character: unlike usual business processes in technology divisions here work is aimed at maintaining data on orders for production.

Earlier technologists of the enterprise used the system of own development on the MS Access DBMS platform in which to the middle of 2010 about 4 thousand different orders and 36.5 thousand parts and assembly units (DSE) collected. Features of the accepted software platform imposed a number of restrictions for a possibility of collective work with the general data that began to lead to failures in a database structure and permanent errors at separation of access rights. In parallel there was a need for export of structure of a product from specifications of the KOMPAS-3D system in which designers, in the module of technology preparation of production and maintaining orders worked. As a result the enterprise approached review of the IT system for benefit of the complex approach providing a possibility of the organization of the unified information system with head enterprise JSC NPF Geofizika.

As a new software platform the management system for engineering data of LOTSMAN:PLM of ASCON company was selected, and the ASCON-Ufa company having wide experience of complex automation of machine-building productions became the partner in creation of an automated system of technology preparation of production and maintaining orders. The main stages of works included:

• import of the database from an old system
• creation of a subsystem "Data management about orders"
• creation of a subsystem "Management of piece works"
• creation of a subsystem of formation of a complete packet of technology and production reports on start of the order in production.

The new IT system on the LOTSMAN:PLM platform allows to carry out a number of tasks which differ from classical application of PDM systems in technology preparation of production.

Work begins with creation of the new order for production of products. Further the technologist creates structure of this order. Development of technology process of production of each DSE comes down to a set of the sequence of transactions (drawing up a route) of the predeterminated list.

After filling of the order the technologist transfers him to regulation of labor costs. Date of transfer on regulation is also fixed in a system for an opportunity further to receive data on extent of study of the order.

Unlike traditional approach when technologists create sets of technology documentation (route charts, operational cards), the developed automated system allows to receive such documents as:

• the schedule to order in which DSE, including purchased products and their regulations of production time are listed all;
• bill of materials (limit and intaking card);
• sheets of purchased products and equipment;
• accompanying labels on each DSE with indication of a route of production and required data on DSE (designation, the name, material, quantity and data on the used equipment).

The automated system provides also maintaining data on piece works in production by orders. At the end of every month on each employee in the pofamilny list of the workers occupied in production the price-work dress forms. In it it is specified what DSE, by what orders and in what quantity were executed for the reporting period. Existence of this function exempted norm setters from routine operations on manual filling of price-work dresses that in turn reduced quantity of the errors connected with a human factor.

Summing up the results of the done work, in the report at the bottom of the mechanician with ASCON the leading production engineer of ZSGA Andrey Bredikhin noted: "First, the automated system on a modern software platform, with a high performance and high potential on integration with information space of head office, in particular design department is created and put into commercial operation. Secondly, the first step to ordering and bigger openness of process of regulation and consequently also formations of the final price is taken. Thirdly, premises for payroll simplification (an individual dress) are created that at small upgrade will give the chance to draw interest in real time of accomplishment of each order, necessary for effective work of economical services"