Prof-It Group has introduced a digital platform for production management at the Ural automobile plant

2023: Implementation of a digital production management platform

Prof-It Group has introduced a digital platform for production management at the Ural automobile plant. Representatives of the company reported this on December 22, 2023. According to them, this is the first project in the country on the 1C platform to introduce an operational management system for assembly production for an enterprise producing heavy trucks.

In 2020, the project on the digital transformation of AZ Ural was launched, in connection with the geopolitical situation, the plant decided to abandon the foreign information system, which partially performs the functions of production management, and switch to Russian software.

To digitalize production, the Prof-It Group system integrator with experience in implementing such projects on the 1C: Enterprise platform in the automotive industry was chosen. The basis for building a new production management information system was the PROF-IT MES solution on 1C: Enterprise platform created by Prof-It Group.

As part of the project, MES and QMS functional blocks were implemented. The MES Block guarantees the traceability of production, allows you to synchronize the work of services throughout the process cycle, automatically issue tasks to subassemblies according to the extracting method, supports the execution of the process plan, automated control of the execution of key operations and online control of the work of the pipeline with visualization and notification according to the specified parameters and conditions.

Among the main features of the implementation of the MES unit, it is possible to provide the function of controlling the production of each car and its main components in a mode close to real time. MES allows you to quickly respond to various situations arising during the production of complex equipment along the entire manufacturing chain, from frames and bridges to a completely finished car, taking into account its modification and configuration.

The QMS unit provides reliable information on the quality level of products online, blocks products of inappropriate quality, registers critical and system defects, automatically collects data from diagnostic devices and stands and provides continuous quality control of products, including the process of auditing the finished product.

The QMS Block is integrated with the MES in terms of order checkpoint registration and associated process control logic. In the overwhelming case, all workplaces of QCD controllers are equipped with mobile tablets.

As part of the project implementation, workplaces are set up on assembly conveyors, in the areas of welding, painting, subassembly of the main units and production of auto components, including the manufacture of frames, bridges, gearboxes, platform and suspension trolleys. Dispatching of the main assembly conveyor, painting, frame manufacturing, bridges and welding of cabins on all main streams and conveyors, and the related integration of MES data with the ERP system of the enterprise, is provided. The quality processes for recording defects, performing inspections, audits and obtaining reports, planning quality measures have been digitized.

With the help of the MES system, it was possible to build end-to-end production control not only at the stage of assembling cars, but also during the assembly of key components. The idea of ​ ​ traceability of components to installation on a car is fully implemented - while preserving the history of the quality of each product. To achieve the greatest efficiency, MES and QMS are integrated with the main systems that support the management and production processes: 1C:ERP and WMS.

"As a result of the project, a single independent infrastructure was created, the cost of software ownership was reduced by reducing the number of platforms used, and the time for approval of the design change was reduced. It is very important that we use only domestic software. The introduction of PLM, ERP and MES allow us to go further into the "workshop," continuing and improving the digitalization of the plant, "said Eldar Gumurzakov, head of the information technology department of URAL.

"The task of our project team is to create a basis for the effective activities of all services and departments of the plant: production, front and back office. This is a step to build a transparent digital production. Thanks to traceability, the plant was able not only to control the quality of products, timely eliminating production errors, but also to keep statistics on the quality of components and production efficiency. As an integrator, we are always ready to support the digitalization of Russian enterprises in the mechanical engineering industry, and we are pleased with the trust shown by AZ URAL, - said Evgeny Sudarkin, General Director of PROF-IT GROUP.

In the future, it is planned to functionally expand and develop the project on the basis of the implemented platform: the creation of the ANDON system, integration with a smart tool and diagnostic stands, replication of the created solution for new industries. Work continues to automate quality control in production. We are considering the implementation of a global quality management system throughout the life cycle of QMS Professional products.