KamAZ (BFG iMRP)

2024: Implementation of the system of volume-calendar modeling of production

A large number of factors and the complexity of interaction at PJSC KamAZ led to planning errors, losses and nonsynchronism of support sites and assembly production. Existing local IT solutions did not provide end-to-end assembly planning and connectivity to other departments. To do this, BFG Group implemented a project to introduce a volume-calendar modeling system for the production of BFG iMRP on the main assembly line of KAMAZ PJSC.

Within the framework of the project, the following was achieved:

• Preliminary elaboration of orders in the BFG Group product for loading of equipment and personnel, limitations of supporting industries, MiK availability before transferring orders to work allows to increase the reliability of assembly plans and form an executable plan;
• Assembly sequence is formed, its provision is controlled at every moment of time. Synchronizing the work of the procurement, assembly and support industries department minimizes downtime, costs and reduces production reserves;
• The build assurance forecast, based on process data and current balances in the manufacturing process as well as true constraints, allowed the transition from monthly to weekly planning.

Project results:

• Reducing the planning horizon by 2.5 times, which makes it possible to promise customers faster orders;
• Increase the stability of the set of orders by 50%;
• Reduced assembly downtime due to lack of configuration by 23%;
• Reduction of operating costs;
• Reduction of working capital and WIP volumes;

"Increase the completion rate of build plans on time."

2019: Analysis of the capabilities and limitations of production business processes

At the Foundry of PJSC "KamAZ" there are several production streams for the manufacture of castings from non-ferrous metals (high pressure line, casting line in coke, nickel alloy line, etc.). The peculiarity of production lies in the fact that it was created for large-scale production of a narrow range of products, but in the current realities it works on small-scale production of a wide range of products.

BFG Group carried out a project to analyze the capabilities and limitations of the production business processes of the KAMAZ Foundry based on the use of its own software.

The following works were carried out at the enterprise:

• Stage of collection, verification and validation; data
• A simulation production model has been created;
• Analysis of possibilities and limitations based on modeling was carried out;
• A project for comprehensive reengineering of the enterprise based on a digital model with a return on sales within 9 months has been developed.

In the framework of the reengineering project, algorithms for optimal start-up and a cascade method of operation have been developed, which ensures a lower consumption of energy resources; proposed preservation of part of melting furnaces due to low load of workers; retraining and changing the shift of workers are recommended.

As a result, the BFG Group software demonstrates the following capabilities:

• Reduction of production cycles by 1.5 times;
• Increase labor productivity by 2 times;
• Reducing the deadlines for execution of orders by 2 times;

BFG Group specialists also presented an investment plan to modernize existing foundry technology and equipment, which will attract additional revenues of more than 1 billion rubles.