Gorky Automobile Plant completed the second stage of introducing a digital production management system

2024: Completion of the second phase of implementation of the digital production management system

Gorky Automobile Plant has completed the second stage of introducing a digital production management system. This figure was reported on June 2, 2024.

source = Zyfra

The project includes the introduction of a digital platform for monitoring production equipment and process control. As part of the project, all numerical control machines at four key sites of the automobile plant for the production of cars and auto components are combined into a single digital system. This allows real-time analysis of production performance information.

In June 2024, the implementation of the second stage was completed - the equipment monitoring system was put into operation at four sites of the automobile plant, "MDC Manager" testing of the Dispatcher operational internal planning system was completed at the pilot site. MES The machines have been equipped with special sensors that are monitored by the operator from electronic, tablet which allows you to transmit and analyze information production information online.

177 pieces of equipment are connected to monitoring: processing centers, robotic complexes, conveyor lines, turning and milling machines, lasers.

The increase in equipment productivity after the implementation of the project amounted to 15%.

2023

Completing the First Phase of the Manager Implementation

The Gorky Automobile Plant, together with the Zyfra Group of Companies, completed the first stage of the project to implement the Dispatcher complex at the pilot site of the Nizhny Novgorod Motors enterprise (it specializes in the production of gearboxes for the model line). The Russian Fund for the Development of Information Technologies (RFRIT) announced this on October 20, 2023.

At the server GAZ facilities, the specialists of the Tsifa Group of Zyfra deployed the Dispatcher industrial equipment monitoring system, as well as the Manufacturing MES Execution System, an independent product included in the Dispatcher complex. Software solutions allow you to manage production on a data real-time basis: assess free capacity and effectively redistribute equipment utilization, help you identify problems in a timely manner and make the necessary management decisions. Thanks to the system, company managers receive objective data on the operation of machine tools and can quickly manage it.

At the next stages, it is planned to adapt the "MES Dispatcher" to other GAZ production facilities. This system, as well as the "MDC Manager" (Machine Data Collection) - a system for monitoring industrial equipment that performs continuous data collection, is planned to be gradually implemented at 8 production sites. In total, 190 units of a wide variety of equipment will be connected to the Dispatcher: processing centers, robotic complexes, conveyors, lasers, turning and milling machines. According to the experience of the implementation of the complex, it is possible to predict an increase in the real load of equipment connected to the system up to 15%.

For the first time in the automotive industry, the MES Dispatcher module will be used to implement end-to-end automation of production processes - from operational planning of production activities and dispatching of production work to monitoring the state of production operations at workplaces, - said Sergey Emelchenkov, General Director of Zyfra Group of Companies.

This work is carried out within the framework of the project of the Gorky Automobile Plant to create an integrated system for managing the product lifecycle and technological processes. The total investment in the project is 513 million rubles, of which 379.7 million rubles. is a grant from the Russian Information Technology Development Fund (RFRIT).

The implementation of the project will create IT solutions that can be scaled up to domestic automotive enterprises as an alternative to the solutions of Western companies. The result of the project will be a reduction in the time for the development and launch of new products on the market, an increase in the efficiency of production processes. The developed solution is planned to be gradually put into commercial operation at GAZ enterprises in 2025, - explained Elena Smirnova, director of the Center for IT Solutions for Business.

The project, implemented with the support of RFRIT, is included in the list of especially significant and included in the roadmap "New Industrial Software," approved by the Government Commission for Digital Development, the use of information technologies to improve the quality of life and business conditions.

We see a special perspective in projects that combine industry expertise industries and competencies IT-. industries As a result of their implementation, IT solutions will work not only for local tasks of a specific enterprise, but also be replicated according to the industry principle, - said the General Director of RFRIT. Alexander Pavlov

Implementation of "Dispatcher" industrial equipment and personnel monitoring system

Gorky Automobile Plant, Russian producer commercial, cars began the implementation IT of the project using the software solution for industrial production control "" Dispatcher from GC "." Zyfra Technology It is aimed at increasing the efficiency of processes due to the introduction of digital control of production and at analysts all its stages. The system will significantly reduce time the receipt information of about efficiency factors and about the actual execution of tasks from several hours to several minutes.

The project is being implemented with support. Russian Information Technology Development Fund (RFRIT) The total amount of the grant, part of which will be used to develop the solutions of the Zyfra Group of Companies in accordance with the specifics, automobile building industries is 379.7 million - rubles this is more than 70% of the total budget of 513 million rubles for the project "Elimination of gaps, completeness data of the product at various stages of the life cycle and the introduction of a system for monitoring production equipment at GAZ production sites."

The project is scheduled to be completed in 2025.

The project will allow the introduction of digital solutions that will become an alternative to the products of Western companies, as well as increase the efficiency of processes by introducing digital production control. Subsequently, these solutions can be scaled to other enterprises in the automotive industry.

The main goals are to increase the efficiency of the use of industrial equipment, the work of production personnel and to create tools for accounting for orders, to assess the rhythm of production and production of products on time, in the required amount and of appropriate quality.

The "Dispatcher" complex closes these needs, since its implementation makes it possible to further improve the following processes:

• Time and attendance;
• Increase the efficiency of equipment utilization by analyzing production chains
• increased efficiency of production organization as a result of prompt decision-making;
• optimization of the production process through centralized storage and transfer of control programs for equipment to machines;
• increased efficiency of evaluation of operation of the entire fleet of CNC machines;
• reduction of production costs due to improvement of equipment operation quality.

The project provides for the launch of two classes of Manager products - MDC and MES. The first is used to monitor industrial equipment and production analytics and continuously collect data. The MES Dispatcher is an operational planning and production control system at the shop level. The technology helps to identify problems in real time and make the necessary management decisions.

The peculiarity of the project consists in the possibility of combining a large fleet of various equipment within one system, such as turning, milling machines, machining centers, lasers, pipe benches, conveyors, etc. At the same time, for the Digital Group of Zyfra, it is of particular interest, as it contributes to the development of the MES Dispatcher functionality in accordance with the needs of the automotive industry.

The GAZ project is based on the extensive experience of GAZ engineering and IT divisions in creating competitive products and digitalizing engineering and production processes. The solution developed as part of the project is planned to be put into commercial operation at enterprises in 2025. In addition to creating the possibility of working on domestic IT solutions, the result of the project will be a reduction in the development time, technological preparation of production and launch of other products on the market, an increase in the efficiency of using production equipment at automotive enterprises, noted the head of the Center for Information Technologies of GAZ Elena Smirnova.

The introduction of Russian digital solutions at GAZ enterprises is caused by the urgent need for import substitution and increased production efficiency due to digital transformation, which is rapidly gaining momentum. The development of the Dispatcher for the needs of the automotive industry, envisaged within the framework of the project, will contribute to the further improvement of Russian digital products for industry, their adaptation to the needs of specific industries, told the general director of the GC "Figure " Sergey Emelchenkov.