Chelyabinsk forge and press plant (TRIM)

For the purpose of decrease in product cost the enterprise masters methods of "lean production" for reduction of the losses caused by equipment downtimes, excessive labor input, excessive costs and stocks. In particular, methods 5S are implemented (five steps to purity and an order), SMED (fast readjustment of the equipment), TPM (Total Productive Maintenance) is the hardware maintenance directed to increase in its efficiency with involvement in processes of a MRO of all personnel.

In February, 2008 examination of the enterprise was conducted, the packet of the project documentation became result. At the enterprise the system model with the sample database which is partially containing real information on the plant equipment is installed.

Access to a management system of a MRO is going to be provided to the management of the plant and specialists in its divisions - departments of the chief mechanical engineer and chief power engineer, production workshops (forge, press, wheel), mechanical repair shop, power service, heatpower and electric power economy. Regarding the performed works a system should cover routine maintenance, major, medium, running, abnormal and unscheduled repairs, hardware upgrade, maintenance inspections, checks and inspections, control of technical condition, equipment checkout, checking and calibration of KIP.

With a system the employees directly busy on production, for registration of defects, process parameters, operational statuses, practices should be involved constantly. All these measures are directed to warning of breakdowns, observance of operating conditions, identification and the analysis of the reasons of idle times. Besides, at higher, leading level in a system it will be possible to manage planning, ensuring with resources and accomplishment of repairs, to combine different types of service with an ultimate goal of minimization of idle times in repairs and costs for a MRO at the maximum readiness of the equipment for loading. And at last, automation is intended to reduce dead times on unproductive transactions, such as formation of requests for repairs, introduction of reports on the executed service, accounting of defects and others.

At the first stage it is supposed to automate 36 jobs, at the second stage - to finish number of jobs to 60. Completion of works on the first stage is planned for December, 2008.