As UAZ turns into the digital enterprise

Target IT architecture UAZ of 2019-2020

2018

As UAZ turns into the digital enterprise

The Russian producer of the cars "Ulyanovsk Automobile Plant" (UAP) decided to become the digital enterprise using technologies of the Industry 4.0. How the company moves on this way, in October, 2018 the director of information technology told UAZ Evgeny Stupin.

For a start UAZ booked audit regarding use at the enterprise of technologies of the Industry 4.0. Contrastive analysis with the Russian and foreign automobile plants was carried out.

According to the results of audit 3 main objectives which the enterprise expects to solve using digital technologies were selected. The first - customization of products that they as much as possible met consumer expectations. The second task - quality improvement, and the third - increase in enterprise performance.

In 2018 the document in which expectations UAZ from digitalization are formalized was developed, on each block the road map of projects is developed. The main directions cover the digital product development including transformation of engineering processes, digital production and digital service.

Digital model of the Patriot car

Evgeny Stupin gave examples from the road map of projects. At the initial stage, for example, decrease in volume of non-productive stocks at production of frames of the car due to use of RFID and MES technologies is planned. In projects of this stage also - decrease in operating costs of transport of the company at the expense of a monitoring system based on the system of positioning in real time and Internet of Things.

Example of one more project - providing preset time of operation of assets due to implementation of IoT technologies, analytics and the MRO system.

Further development assumes wider use of technologies of Internet of Things and robotization of production on UAZ. For example, the enterprise is going to apply robotic solutions in processes of welding of frames, putting mastic, transfer of key nodes on a car body, etc.

The IT landscape within transition to the digital enterprise UAZ implements mainly on the platform of 1C. In the current IT landscape of the enterprise all main systems except for sale, managements of industrial equipment, document flow and PLM (product lifecycle management) as of October, 2018 are implemented on this platform. By PLM, in particular, it is created based on software of Siemens.

The key project digital UAZ is creation of PLM in the companies and creation with its help of the digitized product. The Patriot SUV became the first digitized car. Within PLM classical problems are solved: provide interaction of all participants of process, joint development, change management, products cost, quality, service maintenance, etc.

One more system created within transition to digital production to UAZ is MES. Its purpose - to provide the continuity of production, to minimize a downtime of the main pipeline and delivery of the necessary component parts for each specific car, serial accounting. In total 50 points of accounting are implemented, beginning from welding of a body before delivery on a finished goods warehouse, allowing to register production operations.

Separately on the platform of 1C the quality management system working together with MES is implemented. If on any section of production of the car the defect, mismatch to the set standard is registered, this car will not leave section until the service of quality confirms elimination of defect.

Plans for creation of Competence center of the Industry 4.0

On May 24, 2018, on fields of the St. Petersburg International Economic Forum the Ulyanovsk Automobile Plant (UAP), 1C Company and Prof-IT Group company signed the memorandum of cooperation in the development area of technologies and information systems for creation of production factory of the future of the Industry 4.0. The signatures under the document were appended by the Deputy CEO of Ulyanovsk Automobile Plant Zoya Kaika, the director of 1C Boris Nuraliyev and the CEO of Prof-IT Group Evgeny Sudarkin.

According to the memorandum of the party intend to create based on UAZ a polygon for carrying out research and development in the field of development of modern hardware and software systems of planning and management of production processes. Participants are going to develop the concept of development of digital factory based on UAZ and methodical materials for process automation.

Practicians Industrii 4.0 based on 1C: Enterprise can be shown afterwards to the interested industrial enterprises within the joint conferences and scientific and practical actions.

In UAZ calculate that step-by-step connection of the enterprise to technologies of the Industry 4.0. will allow to accelerate significantly process of design-technology preparation of production and also to configure new models and options taking into account opinions and requirements of potential customers. Besides, end-to-end digitalization of physical assets and their integration into a digital ecosystem together with participants and partners of production process will allow to improve the culture of production and to considerably increase product quality, expect in the company.

Premises of conclusion of an agreement in the companies called long-term experience of use UAZ of software products of 1C in the field of preparation and production management and also a number of the successful projects implemented by Prof-IT Group in the field of technologies of the Industry 4.0 at the automobile building plants using solutions on the 1C: Enterprise platform. Prof-IT Group is strategic orchestra seats UAZ on implementing solutions of 1C and some of the leading partners of 1C in the field of complex automation of the automobile building enterprises.

UAZ implements "1C:ERP" for operational production management

2017

Choice of the solution and partner in implementation

Management of Sollers Group which part Ulyanovsk Automobile Plant is stopped the choice on a single technology platform "1C: Enterprise" which completely met all requirements of holding:

• existence on the platform of ready-made solutions for automation of the enterprises of the different industries which are a part of Sollers Group;
• "seamless" integration of industry and functional solutions among themselves;
• scalability, opportunity for work over 1,000 at the same time active users in one base;
• low total cost of ownership;
• minimum implementation time of solutions;
• efficiency of an exit of updates of systems in connection with changes of the Russian legislation;
• existence of a large number of specialists in implementation in labor market.

The Prof-IT Group company became the strategic partner in implementation.

Course of implementation and the first results

One of the most important conditions of further increase in efficiency of activity of holding is improvement of processes of management of production at the shop level. At the moment at Ulyanovsk Automobile Plant the project on development and deployment of the sample solution based on 1C: ERP Enterprise Management 2.0 regarding problems of operational production management is implemented.

Using 1C:ERP the following blocks are already automated:

• management of BOM (Bill of materials);
• maintaining data on routes of production and to the list of transactions of technical processes of parts and assembly units;
• management of standards;
• formation of the podetalny production schedule;
• purchase planning, delivery schedule of component parts and payment schedule to suppliers;
• calculation of normative cost value.

Management of BOM (the specification of cars and assembly units) - one of the most difficult tasks in modern job order automotive industry. Calculation of the podetalny production schedule takes less than 1 hour taking into account complexity of BOM (14 nesting levels, 2000 elements).

Formation of the linear list: "The need for component parts, materials, parts and assembly units - providing/production Terms - a providing Source" allows to plan operation of assembly conveyors according to a set of orders and conditions of their providing with required component parts, materials, parts and assembly units. On the basis of the executed calculation the delivery schedule of component parts, materials and the payment schedule on suppliers forms. Economical divisions of the plant had an opportunity to quickly calculate normative cost value.

The solution based on 1C:ERP is integrated with PDM/PLM the Siemens Teamcenter system.

"Automation of all internal processes of huge holding - very ambitious goal which we began to realize 5 years ago. Professionalism of a command of Prof-IT Group and flexibility of solutions 1C allowed us to implement projects in full in the planned terms and within the set budget. We expect a bigger effectiveness for business which, first of all, we connect with increase in effective management of production from implementation of 1C:ERP" Evgeny Sudarkin, Chief information officer of Sollers Group

Development Plans

Further the car maker is going to develop production management systems at the shop level according to the concept of "lean production" and to replicate project deliverables on all manufacturing enterprises of holding.

The solution on UAZ