"The Lomonosov experimental plant" uses system "1S:TOIR" for accomplishment of the purposes of "lean production"

2020: System implementation "1S:TOIR"

On May 25, 2020 the Desnol Soft company reported that at the end of 2018 the Lomonosov experimental plant began to rebuild management of production assets, the 1C system was implemented and brought into operation : The MRO 2 2020th plant CORPB led the first results of implementation.

Economic results from implementation 1S:TOIR 2 CORP:

• Acceleration of obtaining the management reporting — 50%
• Cutting of costs for the maintenance of the equipment — 12%
• Cutting of costs for repair of the equipment — 4%
• Reduction of time of repairs of the equipment — 2.5%
• Decrease in level of breakdowns — 3.8%
• Increase in availability quotient of the equipment — 3.8%
• Reduction of production costs — 3.8%

At the end of 2018 as a result of production audits at the Lomonosov experimental plant the factors which are slowing down achievement of key levels on the purposes of Road map for the program of "lean production" were revealed:

• Report generation in the MS Excel, collecting and introduction of data manually.
• Informing service of operation and repair on the arisen fault of the equipment manually by transfer of the paper form.
• Paper document flow with services of economic directorate regarding management of inventory items and also with department of work and the salary regarding a time recording of staff of repair service.

The analysis of the existing reporting showed that these factors reduced effectiveness and reliability of work planning. Optimization of activity of division and review of a part of processes was required. From quality IT- the solution which will allow to rebuild process of management of production assets according to the concept of "lean production", it was selected information system "1C: TMAR Technology maintenance and repairs of equipment 2 CORP".

Project Objectives:

1. to Optimize process management of a MRO and contents of the normative reference information of the enterprise by creation of uniform base of the equipment.
2. to Provide accomplishment of target indicators on management of production assets within the program of "lean production" by formation of analytics on the purposes of Road map (a technique of TRM — Total Productive Maintenance).
3. to Provide transparency of the movement of inventory items by optimization of document flow between production and financial and economic services.

With assistance of specialists Desnol Soft the staff of the plant as of May, 2020 entered to 1S:TOIR 2 information CORP on 386 items of equipment separated into 1525 objects of repair. Among them 42 software-controlled machines, capital technology equipment and ancillary equipment. A system is used by 50 employees of the enterprise:

• specialists of service of operation and repairs;
• staff of service of the chief mechanical engineer;
• staff of service of the chief power engineer;
• masters;
• heads of divisions of the enterprise;
• specialists of planning department;
• accountant officers.

In August, 2019 integration 1S:TOIR 2KORP since 1C: Manufacturing Enterprise Management regarding consumption of the inventory items (II) is configured. In January, 2020 the plant transferred enterprise resource planning from 1C: Manufacturing Enterprise Management to 1C:ERP, all data from old are transferred to the created system. Between 1C:ERP and 1C: The MRO 2 CORP configured exchange of the reference books and documents reflecting material consumption and receiving services. For this purpose specialists Desnol Soft finished detailing of data necessary for the enterprise in 1S:TOIR 2 CORP. Integration between 1S:TOIR 2 CORP and a monitoring system of industrial equipment of the AIS "Manager" is in the long term planned.

1S:TOIR 2 CORP on Lomonosov experimental plant it is used as means of achievement of target indicators of Road map by the TRM method (Total Productive Maintenance) and allows to fulfill the requirements of "lean production" regarding management of production assets. Active users of a system are both specialists of service of operation and repairs, and employees of production. For them it is finished 1 standard and 2 additional automated workplaces are created:

1. the automated workplace "Technical specialist" is finished on the basis of standard taking into account real processes at the enterprise which include an obligatory stage of preliminary diagnostics. When the request from production comes to service of operation and repairs, the specialist of service defines a type of necessary works: repair or an action within maintenance.
2. the automated workplace "Master" is developed especially for needs of the plant as the non-standard scheme of registration of requests for repair was required. For descriptive reasons status monitoring of repairs to the automated workplace is added:

• color indication,
• icons,
• form of confirmation of repair work,
• additional details,
• additional reports,
• an opportunity to change equipment state-of-health data.

1. the automated workplace for maintaining working schedules of the equipment. It allows in a convenient type to create working schedules for different items of equipment taking into account subordination of nodes. Need for such automated workplace is explained by the mobile working schedule of production: depending on plans, works can be conducted in 1, 2 or 3 changes.

Standard functionality 1S:TOIR 2 CORP does not contain reports which are used for assessment of levels of Road map therefore were developed and included in the system of 11 additional reports. For their formation standard business processes in a system are corrected. Process of information exchange between employees of production and repair service about existence of fault of the equipment and the status of repair is organized in electronic form. The special reporting for the program of "lean production":

1. Allocation base of material costs. The report allows to see what costs (materials, labor costs) on each item of equipment are made what materials are spent, what material cost and labor costs. There is an opportunity to analyze what models of machines are most expensive in service.
2. the Analysis of failures on the CNC. The report is intended for collection of information on key indicators of the equipment with program numerical control, the most expensive and technological.
3. Analysis of breakdowns and losses. The report allows to determine types of losses by each item of equipment for the reporting period, to make the analysis and to develop actions plans.
4. Accomplishment of the plan of the Party of Pensioners of Russia. The report allows to analyze percent of accomplishment of scheduled preventive maintenance.
5. Share of distribution of material costs to service and repair. The report allows to define a share of costs for repairs from the general implementation of the enterprise and to compare to a planned target.
6. Register of carrying out abnormal repairs. The report allows to analyze the registered defects: types, elimination time, emergence frequency.
7. Calculation of key indicators of reliability. The report allows to analyze key indicators of operation of the equipment, MTTR, MTBF.
8. Comparison of level of breakdowns. The report allows to analyze level variation of breakdowns of the equipment for the reporting period.
9. Average time of repair. The report displays the average time of repair on all equipment.
10. Average level of breakdowns. The report allows to see the percentage of the general operating time of the equipment and a downtime during repair.
11. Level of breakdowns. The report allows to reveal 20 items of equipment which have the highest rate of level of breakdowns.

" noted we see serious progress in preparation of the management reporting. It was required up to 3 days earlier to collect and compare information from paper magazines. According to the results of the project information is accumulated systematically, day behind day, and the report is under construction automatically. It is important that not the head, but several operators of the equipment is engaged in introduction of data. It at the same time increases information processing rate, reduces quantity of possible errors and releases time of leading employees for the main work. The enterprise has an opportunity to really save, increase quality of information on a status of fixed assets, to quicker achieve effective objectives",

Project Results:

• The problems of the enterprise which are slowing down achievement of target indicators of Road map by the TRM method (Total Productive Maintenance) for the program of "lean production" are solved:
• Management of a MRO due to creation of uniform base of the equipment and the normative reference documentation is optimized.
• Tools for the specialized reporting and analytics are created.
• The transparency of the movement of inventory items, including their expense and planning is reached.
• The high level of preparation for production audits is provided: data from 1S:TOIR 2 CORP are estimated as reliable.