UKVZ of S.M. Kirov created schedule system for production management and deliveries of products

On July 12, 2018 the Raytstep company announced project completion for the Ust-Katavsky Car-building Plant (UKCBP) on setting and start of schedule system and monitoring (SPM) for production management and deliveries of civil products.

Prerequisites of the Project

Accomplishment of difficult projects, both on a scientific and technical component, and on terms and responsibility for their accomplishment, and in tough terms, for UKVZ is "regulation of life". The UKVZ civil direction is known production of trams (since 1901). UKVZ performs a full stroke of production of trams, including all main repartitions: procurement, machining, "subassembly" workshops and final assembly. Also "internal cooperators" - workshops of special production of UKVZ (for example, a foundry) and also external cooperators participate in a supply chain. Different modifications of trams taking into account requirements of customers are made, options of execution differ from each other both on a complete set and in other aspects. All this is studied in own CB.

Project Tasks

Before Raytstep the task to implement SPM (Schedule system and Monitoring) for production management and deliveries of civil products was set. "The fast project" was the condition set by the customer. SPM was necessary not so much as the production automation equipment how many as a system:

1. Supporting the "correct" ideology of management,
2. the Management tool by means of which the release of batches (new) trams should be provided.

Course and results of the project

The Raytstep company suggested to use a standard configuration, with ready methodology of management and the customized SPM system (Lean ERP SCMo), suitable for many machine-building productions working on the type "development-…", "production-…", "assembly-under-order".

Assigned tasks were carried out by a joint project team of UKVZ and Raytstep.

During the project the following processes were delivered and smoothly running:

1. Management of the technology structure of a product (TSP)
   • the production and logistic model of the enterprise (PLM) in the form of departments of supply and a complete set, production sites, the assembly conveyor detailed to jobs/posts Is defined.
   • TSI with detailing "the expanded specification" Is created: the specification + "shop-to-shop routing" ("shop-to-shop routing" to the UZ level (Uchastkozakhod)), for assembly shops / sections of UZ is an assembly step in a workplace, for purchased – duration and stages of purchases.
   • Management of TSI taking into account serial restrictions for automatic formation of job order structure of the specific tram.
   • storage and viewing in all workplaces of contractors of relevant drawings of DSE Is provided.
   • It is organized, in the form of regulations and procedures, the interaction of constructs, technologists, production and supply for correct formation of TSI excluding errors.

2. Job order planning
   • Maintaining orders of finished product output, where each "order" the separate tram with the directive issue date and serial number.
   • Synchronous planning, on all production - a logistics chain of deliveries with determination for each made and purchased position of a priority, date of start and release.
   • Each tram of the order are controlled in production separately, on the structure determined No. of the order and specific serial number.
   • Planning and production management is exercised "without stocks", the WIP is conducted in a system in the form of interlocal deliveries.

3. Production management
   • Formation of the interlocal nomenclature plan of start/release prioritized and synchronized with product output.
   • Management of start of DSE in production:
     • Start of a batch of DSE and formation of accompanying documents of a batch type Technical. Passport and detachable coupon;
     • Formation of group start of a batch of different DSE, but with the same route, identical material;
     • Formation and fixing at the section stand of "The plan of section" for the started positions.

   • Registration of interlocal deliveries of a batch of DSE to SPM, on the basis of the completed detachable coupon of a batch of DSE.
   • procedures of autoclosing and autowrite-off Are developed for simplification of accounting "not of critical" DSE.
   • Automatic recalculation of plans, taking into account the start/release fact - formation of "settlement" (rather "directive") version of the plan.
   • Automatic redistribution of the fact of deliveries on the set algorithms in case of change in a route of production or change of the specification to drawings of DSE.
   • Formation of dresses on a piece-work pay of SPM, printing on the set report form for transfer to accounting.

4. Management of warehouses and MTS
   • Automatic formation of nomenclature requirements plans of production in the purchased materials and component parts according to the diagram of product output and consumption rates of TSI by orders, suppliers.
   • purchase Process control:
     • Formation of the supplier order (SO);
     • Management of procurement cycles.

   • Management of replacements (alternatives).
   • B to the SPM system conducts the following main warehouse transactions of MTS, with formation of primary accounting documents:
     • Arrival on ZP;
     • Issue of Inventories in production;
     • Movement of Inventories between warehouses (write-off orders form);
     • Return of Inventories from production.

5. Monitoring (execution control)
   • Readiness of orders (on each product), on settlement and directive terms;
   • Synchronism, rather assembly production, work of all sections suppliers and MTS, with control of the WIP in terms of timeliness of its formation.

The project on complex setting and commissioning of SPM UKVZ was executed in 8 months.

In Raytstep noted that it was succeeded to implement the fast project thanks to not just ready IT tools, but also:

• the methodology of management put in the SPM system machine-building production;
• to accurate following to the worked and approved strategy of project implementation and start of a system offered Raytstep in productive operation;
• to harmonious work of a joint project team of UKVZ and Raytstep and to coaching of the project from heads of both companies.