The implementation of the production planning and monitoring system at the Rocket and Space Plant has been completed

2024: Implementation of the Production Planning and Monitoring System 

The implementation of the  Production Planning and Monitoring System (PCM) at the Rocket and Space Plant has been completed . Rightstep announced this on January 22, 2025.

JSC GKNPC named after M.V. Khrunichev is a company in the rocket and space industry.  The holding combines a number of enterprises specializing in the production, launch and maintenance of rocket and space technology.

The goal of the project was to implement an improved methodology for planning and managing production and logistics at the Rocket and Space Plant (RKZ), one of the main production centers within the GKNPC.

Complex production and logistics model of the plant with a large number of workshops, sites, warehouses and a very significant amount of data on all products (millions of parts-workshop-calls). Interphilial cooperation.

Multi-transfer production cycles, sets and production systems, responsible incoming quality control, samples, long and complex final assembly process, selective and periodic tests, etc. Multilevel (20-30 levels) hierarchy of product specifications, fundamental differences in design, process and production compositions, version of DSE versions, management of compositions according to serial (factory) product numbers, process assemblies, complete process passports, cycle schedules of aggregate assembly, etc.

Large total volume of data for all products with the need for daily general rescheduling of the entire volume of orders for all levels and for the entire horizon (several years in advance).

A large number of legacy IT systems, with a significant amount of integration and migration work resulting.

The implementation of the Planning and Monitoring System  (PMS) made it possible to implement the management of the entire production chain, from planning production redistributions and supplying PKIs and materials (to process points and places of consumption, in the required quantity and at the right time), to the final assembly, testing and release of finished products.

The methodological concept of the solution developed by Wrightstep also includes the implementation and constant comparison of two versions of plans - Directive and Calculation - for all levels and components of each product, which provides production managers with the necessary information on plan/fact deviations for making operational management decisions.

The system implemented as a result of the Wrightstep project in the RKZ covers the functional areas:

• Generation of product release invoices, with possibility to predict the release date.
• Maintenance of process and production compositions of products.
• Inter-site cooperative planning and execution management.
• Management of P & IDs and inventory, including the plan/actual/status of expected deliveries, order marking of the availability of DSE and components, targeted storage, accounting and control of precious metals, alcohols, gases, accounting of shelf life and other parameters.
• APS. Synchronized planning and management of the plant production and supply chain in the context of orders, with daily recalculation of current plans for the entire horizon. The following is provided:
  • Consolidate production jobs from one or more invoice orders into a production batch
  • operational batch production planning, start and close dates (production batch includes
  • in the workshop manufacturing route, with all components of the compositions, operations and time characteristics);
  • control of production availability in the context of batches;
  • Calculation of Directive and Calculation Plans, comparison, prioritization.

• MES. Advanced In-House Execution Management:
  • start-up of production (batch and piece), with preservation of end-to-end traceability of each order;
  • management of acquisition of manufactured units and products with materials, purchased products, parts and assembly units;
  • transfer of semi-finished products produced (within the framework of production batches) along the production route,
  • transfer of finished parts, units and finished products to the workshop warehouse;
  • tracking the progress of electronic route sheets and technical specifications. passports (for aggregate shops) for production batches.

• Management monitoring. The Planning and Monitoring System (PIM) provides convenient tools for quick on-line analysis - specialized interactive monitoring forms that provide information indicative (in values ​ ​ and colors):
  • what is happening in production and supply in general;
  • status of orders throughout the hierarchy of product compositions;
  • Gantt diagrams;
  • provision of stocks and manufactured DSE of each production lot and specific product , etc.;
  • analysis in "chess" format;
  • Shop KPI.

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Фото: Wrightstep

All PIM processes and functions configured within the project have been checked for compliance with the agreed requirements for work scenarios (including procurement, detail, assembly and assembly scenarios) during pilot testing with the Customer's team.

The system has been put into full commercial operation.