Prof-IT Group has implemented an automated control system at the Saryarkaavtoprom automobile plant

2023: Implementation of ACS

Prof-IT Group implemented automated control system at the automobile plant Saryarkaavtoprom"." Prof-IT Group announced this on November 16, 2023.

At the time of the start of the project, the company had only "1C: Accounting for Kazakhstan" and the "Financier" system. All remaining processes were not automated, for example, warehouse logistics management, inventory accounting in warehouses and other areas, a lot of paperwork was carried out.

The implementation of strategic goals for the development of the enterprise and improving the quality of manufactured products required the transition to new digital management tools. The company needed a comprehensive solution that covered all the key processes of the plant: from production planning and equipment management on the conveyor to quality control and the formation of service systems and order processing.

enterprise management systems The solution "" was chosen as the basis for building information, 1C:ERP which meets the key functional requirements of the project and supports integration with other systems in the enterprise. ":" 1CERP became part of the APMS, which included the systems necessary for operational production and, and warehousing MES WMS QLS.

The project was implemented in a short time. Important modules of the ERP system, such as purchasing, sales, warehouse and production accounting, were launched within 12 months. The complex solution covered all the key processes of the plant: from production planning and equipment management on the conveyor to quality control and the formation of service systems and order processing.

The project included the deployment of IT, network, IT service infrastructure, as well as the consistent implementation of a fully functional APMS consisting of several subsystems, including MES, QMS, WMS, regulatory reference information management systems, finished product movements, work with suppliers, dealers, etc.

The special features of the project were the integration of accounting systems with industrial equipment, in particular, the marking of materials using barcodes, inventory management using data collection terminals, and the entry of information into the system at the time of its appearance.

The implemented systems also provide a convenient interface for assembly quality control, product shortage management, automatic determination of the sequence of building production orders.

The geography of the project covered the main production workshops and the head office in Kostanay and Astana.

The project was divided into two phases. As part of the first phase of the project, production planning processes, warehouse and production logistics contours were automated. In particular, technological preparation of production, production and quality management, warehouse management of finished products.

The MES Block provides tracking and planning of the production sequence - the movement of the car and components from one stage of production to another. The whole process is monitored in real time: on specially installed monitors, you can see analytical data in any sections. The QLS quality management system allows you to track the characteristics of manufactured cars and components, analyze warranty claims and, if necessary, issue recommendations for adjusting processes.

The company was interested in moving to a qualitatively different level of planning and management of production facilities based on the use of real data.

Before the start of the project, part of the planning process was carried out in the form of Excel spreadsheets. This approach limited the speed of the production process, increased operating costs and did not allow obtaining operational information about the production progress. Within the framework of the project, the identification of materials is organized through barcoding, an address accounting system at the container site, in warehouses and in the areas of storage of materials.

The process of changing the production program depending on the supply of machine kits has been automated. A separate plan is being carried out in the section of workshops: welding of CKD, painting in the section of brands. Automated collection of information on actually assembled vehicles in the context of inventory accounting in warehouses.

The second stage of the project is devoted to the financial results of production and automation of business processes: electronic document management, treasury, budgeting, accounting and tax accounting, economics, cost calculation, purchase and sales management, repair and maintenance management and salary and personnel management.

The planning and budgeting unit includes the possibility of constructing an annual production plan, an annual budget and a cash flow budget. With the help of the system, procurement specialists can draw up procurement plans taking into account the conditions and specifics of deliveries of the full range of components.

A scalable enterprise resource management system has been built using 1C:ERP Enterprise Management, a platform that supports integration with other systems in the enterprise.

The final result of the project is the formation of balanced production plans that will eliminate downtime at all stages of the plant life cycle. As a result of the implementation, the plant received convenient tools for synchronizing the processes of assembling cars, for managing supply chains and product costs.

The introduction of a comprehensive system allowed:

• Form a single information field of the enterprise.
• Build accounting and production processes in digital format.
• Increase the production volume and turnover of the plant.
• Improve the quality of products and their accounting.
• Organize the process of small assembly of cars (CKD production).
• Expand the line of car brands.
• Increase transparency and efficiency of data exchange between production assets.