Zavolzhsky Plant of Tracked Tractors automated accounting and control using the 1C:ERP Enterprise Management solution

2024: Implementation of "1C:ERP Enterprise Management"

1C:April Soft company on May 7, 2024 announced the implementation of a project to automate accounting and control at the Zavolzhsky Plant of Tracked Tractors.

zzgt.ru

As reported, Zavolzhsky Tracked Tractor Plant JSC (hereinafter ZZGT) is a Soviet the Russian machine-building and enterprise located in the city of Zavolzhye, a manufacturer of tracked floating all-terrain vehicles. As of May 2024, it is a supplier of parts and components for the Gorky Automobile and Zavolzhsky Motor and other plants.

The Zavolzhsky plant of tracked tractors was founded in 1949 as the Mechanical Repair Plant for the repair of construction equipment: bulldozers, tractors, excavators and others. The company specialized in overhaul of various construction equipment.

During the construction of the Gorky hydroelectric power station, the company organized the production of metal structures necessary for construction. During this period, financing made it possible to optimize the production capacity of the enterprise due to the commissioning of additional workshops.

After the construction of the hydroelectric power station in 1956, the company changed its type of activity and began to master the production of high-pressure vessels for the needs of the chemical plant under construction in Dzerzhinsk. During this period, the company received the name Zavolzhsky plant "Himmash" and for almost ten years produced various equipment for the chemical industry.

During the development of the Far North, when the oil and gas complex of the USSR began to develop intensively, floating all-terrain vehicles were required to work in Yakutia and other northern regions. It was necessary in conditions of complete off-road to transport a large number of goods, deliver teams of oil workers to the place of work, transport geologists and patients. In winter, these areas had very low temperatures, and in summer the tundra turned into impassable swamps, which ordinary transport could not pass through, and all-terrain vehicles were required. To solve the problem production of all-terrain vehicles for the conditions of the Far North, by a decree of the CCCH Government in 1967, Khimmash was reorganized into OJSC Zavolzhsky Plant of Tracked Tractors (ZZGT).

At the same time, the company was introduced into the Gorky Automobile Plant (GAZ). The updated specialization required a complete update, the creation of production facilities, structural divisions, retraining of production personnel and the formation of its own design service. Only six years later, an experimental model of the first all-terrain vehicle was made GAZ-71, which was soon put into production. It was followed by the release of the next model, and in total the company mass-produced more than 20 models of all-terrain vehicles.

For more than 50 years, the main specialization of ZZGT has been the production of tracked conveyors. During this time, more than 75,000 units of off-road vehicles were produced. The company introduced automation and mechanization of production processes. High-performance modern equipment. Own Production Implemented a system based on TSP experience to respond quickly to changes in consumer demand.

In April 2021, in order to increase the manageability of the enterprise and reduce labor costs for accounting, an agreement was concluded with 1C: April Soft for the design implementation of the software product "1C:ERP Enterprise Management 2 Rev. 2.5" for two legal entities: ZZGT and PJSC Zavolzhsky Plant of Tracked Tractors.

At the time of the start of the project, the company's ACS included the following software systems: 1C - "1C: Manufacturing Enterprise Management 1.3" (hereinafter referred to as UPP) and the system of own development of warehouse and production accounting at Oracle.

The following objectives were set for the project team:

• Optimization of the system for operational and regulated accounting.
• Obtaining uniform management data from one system.
• Obtain reporting information for the management company.
• Transfer of the current functionality within the framework of regulated accounting in the existing system to an updated platform to improve the stability and reliability of the system.

During the project, 1C: April Soft specialists performed the following works for each stage:

• Stage 1. Section survey for compliance of business process automation schemes.
  • Surveys of accounting processes were carried out at the enterprise. The survey was carried out through an oral survey of employees responsible for the accounting unit of the enterprise. The task is to define tasks for implementing the block.

• Stage 2. Analysis of internal and output reports of the enterprise, in order to determine additional system analytics, determine the rules for storing the necessary analytics for further data generation.
  • Identification of non-conformities between business processes of the Customer's enterprise and algorithms implemented in the program.

• Stage 3. Modeling of processes per section, preparation of interim documentation (LV).
  • Create model by metering area. Model alignment.
  • Create a Non-Conformance Sheet document that records deviations of system implementation requirements from typical configuration and remediation options. This document was sent to the Owner to select a way to eliminate the non-conformity from the proposed options.
  • Study of necessary changes in the system.
  • Creation and approval of the document "List of tasks," which contains a list of system settings, compiled in accordance with the selected implementation option from the document "Non-conformance sheet," with an estimate of the cost and time of work.

• Stage 4. Formalization of the concept by section.
  • Preparation of "Conceptual design" of the system (developed diagram of business process automation).

• Stage 5. Implementation.
  • Development of the system by coding in accordance with the list of tasks developed in stages 2 and 3.

• Stage 6. Data migration.
  • Creation of NSI transfer treatments and initial data.
  • Transfer of directories and initial residues.

• Stage 7. Exchange arrangements with the financial system.
  • Create exchange treatments.

• Stage 8. Training.
  • Training of users according to training schedules.
  • Qualification of users based on training results

• Stage 9. Pilot operation.
  • Works on installation of workplaces, assignment of initial system installations were performed.
  • Provided advice to users to ensure their correct operation in the system.
  • Based on approved system change requests, system modifications are performed.

Features of the integrated implementation project:

• Warehousing:
  • Warehouse accounting was optimized, including in warehouses with a warrant scheme and address storage.
  • To reduce manual labor and minimize errors, the following modifications were made: when creating an item, a package equal to a storage unit is automatically created (a mandatory entity for an address warehouse).
  • A revision was made to automatically reflect the purchase documents of one organization when creating an implementation of another, using a single information base, without using the Intercampani scheme.
  • The scheme of separate accounting of expenses within the framework of the State Defense Order (hereinafter referred to as the State Defense Order) has been introduced.
  • Optimization of MPZ assurance process was performed.
  • Conversion of weight materials in the document "Ordering materials for production" has been implemented to optimize the efficiency of typesetters in address warehouses.

• Production accounting:
  • Multi-stage production scheme implemented;
  • An automated workplace has been created to optimize the reflection of production operations by production employees.
  • Control of the dates and sequence of the production stages has been added to prevent the execution of the stages whose followers were closed in previous periods.
  • A mechanism for calculating labor costs and consumed materials (with selection of batches) was implemented based on the number of products produced.
  • A mechanism has been implemented to select analogues (present on the residues) in the release document in the absence of base material.
  • Schemes of work with tracking the transition of processed parts between workshops are implemented;
  • A scheme for tracking the transition of processed parts between workshops is required, which is implemented on an intermediate issue equal to the nomenclature of real production by stage, therefore, in order to distribute general production costs, it is necessary to separate the same nomenclature remaining in work in progress and the nomenclature of release to the GP warehouse; this division was implemented through the addition of a separate "virtual division," and to optimize the work, a mechanism was implemented for automatically creating release documents from the virtual division to the GP warehouse (general production costs are allocated only to the products of the "virtual division").
  • Reports have been generated to ensure that the production manager correctly reflects production operations by production employees.

• Sales:
  • A mechanism for taking into account analogues of spare parts when placing customer orders has been created. The mechanism allows you to reduce labor costs for finding analogues of the Company's products available for shipment and reduce the time to sell to customers.
  • The mechanism for setting prices for the Company's products has been optimized, based on the calculations of the planning and economic department.

• Treasury:
  • The mechanism of coordination of Requests for spending funds with various types of transactions has been implemented.
  • Creation of a register of payments.
  • A mechanism has been introduced to support the specifics of allocated bank accounts for state defense orders under federal 275-FZ law.
  • Set up Exchange with. bank
  • To maintain records on loans, deposits and loans, the following possibilities were automated:
  • * Entry of initial balances under deposit agreements.
  • * Registration of deposit agreements taking into account the parameters of repayment of loans, accrual of interest and commissions under each agreement.
  • * Calculation of monthly fees and interest under these agreements in the information base.
  • * Entering schedules of deductions and accruals on deposits, analysis of obligations under loan agreements.

• Procurement:
  • Storage of specific information on the unit is provided: division of materials by procurement directions, storage of model, number and suffix of materials, indication of installation code, analysis by product groups, possibility of specification. It also provides for the storage of information on tender procedures.
  • The procurement plan has been completed on the basis of a preliminary production plan with details by suppliers and warehouses. You have set up plan infill rules that take into account the supply schemes of an item for picking up a warehouse and the data on the last delivery of goods for picking up a default supplier.
  • Updated loading of order data from vendors based on supplier units. You have also improved the ability to display quantities in alternative units of materials in orders.
  • Traceability of the materials from the production plan to the procurement and write-off during the execution of the BARS contracts is ensured.
  • Generation of specific reports on low-turnover products, price indexation (BOM indexation), increasing receipt of products, etc.

Regulated accounting is implemented in the standard functionality:

• Record keeping of fixed assets and NMA
• Maintaining settlements with buyers and suppliers
• VAT accounting
• Loading of payroll data from the RM 3 program and its recording in the regulated accounting
• Cost Collection and Allocation
• Accounting for other income and expenses
• Provision accounting
• Formation of regulated reporting
• The possibility of obtaining data on receivables to suppliers by maturity has been improved
• The accountant's AWS was implemented to check warehouse documents (compliance of transfers from production with receipt orders).

As a result of the work performed by employees 1C:April Soft, JSC "Tracked Tractor Plant" got the opportunity to:

• Optimize the efficiency of commercial and logistics services, the accuracy and efficiency of obtaining information in real time.
• Production process optimization.
• All accounting is maintained in one information system.
• The use of calculations in Excel has been significantly reduced.
• The company began to receive regulated reports from the information system (earlier, for many years, reports were formed in Excel).
• Obtaining reliable data on the activities of the enterprise, cost and revenue in the context of the required analysts.
• Build an effective cash management system, transparency of control over the flow of funds.
• Track expenses for each product, including for the needs of state defense orders.
• The main acquisition was the possibility of operational control over the company's processes.

In total, 185 workplaces were automated at the enterprise. According to the results of the comprehensive implementation project, the functional sections of the system "1C:ERP Enterprise Management Rev. 2.5":

• "Sales Management,"
• "Treasury,"
• " Purchasing Management,"
• " Inventory Management" (complies with the requirements of HRT and has been put into commercial operation since 01.06.2023);
• "Product Data Management"
• "Production Accounting"
• "Cost Management"
• "Regulated accounting" (Comply with the requirements of the SPTA and put into commercial operation since 1.01.2024);
• "Sales Management,"
• "Treasury,"
• " Purchasing Management,"
• " Inventory Management,"
• "Product Data Management"
• "Production Accounting"
• "Cost Management"
• "Regulated accounting" (comply with the requirements of PJSC "Zavolzhsky plant of tracked tractors" and put into commercial operation since 01.01.2024)

The system as a whole has been put into commercial operation since 01.01.2024.