Rostec creates more than 20 "smart" workshops for the production of aircraft engines for civil aviation

2023: Plan of merging 23 workshops into a single information system

The United Engine Corporation (UEC) (part of the Rostec State Corporation) is creating a Smart Workshop production management system based on Big Data and the industrial Internet of Things at the UEC-Saturn enterprise in Rybinsk . 23 workshops will be combined into a single information system, the first to be connected to the complex is the competence center that manufactures the blades of gas turbine engines. The project is being implemented as part of the preparation of large-scale production of PD-8 engines for SJ-100 airliners. Rostec announced this on October 12, 2023.

The digitalization of capacities, which takes place in partnership with the Zyfra Group of Companies, will ensure productivity growth by increasing the efficiency of equipment and personnel.

Rostec companies solve large-scale problems in the field of civil aircraft industry. The utilization of enterprises and the volume of production in the near future will grow in multiples, which requires new approaches to production management. The pilot platform for the introduction of the Smart Workshop system was the Rybinsk UEC-Saturn, which by 2030 should produce about 300 power plants PD-8 for the import-replaced SJ-100 liner. The production of blades has already been connected to the platform, in the future all 23 workshops of the enterprise will be connected to it, which will operate in a single digital space. The expected results are an increase in the efficiency of equipment and an increase in productivity, "said Andrey Komarov, director of digital transformation at Rostec State Corporation.

The platform creates a single information space for managers of all levels - from foreman to production director. It allows you to make management decisions based on objective control data and business analytics formed using smart systems.

"Smart Workshop" is a universal comprehensive solution based on domestic products. For this project, we have combined the Dispatcher industrial equipment monitoring system and our flagship production management platform ZIIoT (Zyfra Industrial IoT Platform). It is the base digital layer. To improve the work of production units - this was our task. We solved it at the expense of a whole range of measures: we used the monitoring potential, ensured the integration of information systems and the interpretation of data, - said Sergey Emelchenkov, General Director of Zyfra Group of Companies.

The "smart workshop" stores, structures and analyzes large amounts of production data, controls the availability of the order before launch and the timing of execution. A tool for analyzing the quality of regulatory reference information entering the platform is also actively used. The manager receives an effective management tool in the form of 10 data marts for the main workshop processes, for each of which 7 to 14 analytical panels are formed to develop management decisions.

The implemented project is an important link in building the digital foundation of a high-tech company. The project team made it possible to move from "attentive" production to a data-driven proactive support system. It was possible to exclude the human factor when receiving and processing information from the production resource - machine, materials, personnel, quality. Now, at all levels of management, uncomplicated data is used, without a human filter in real time, "said Evgeny Alekseev, director of digital transformation at UEC-Saturn.

The implementation of the project became possible by attracting grant support from the Russian Information Technology Development Fund. Fundraising is carried out within the framework of the federal project "Digital Technologies" of the national program "Digital Economy of Russia."

2022

Completion of the second stage of implementation of the Smart Workshop digital platform

Rybinsk the enterprise UEC Saturn"" (part of United Engine Corporation Rostec) announced on November 7, 2022 the completion of the second stage of the introduction of the Smart Workshop digital platform software. Ten pieces of metallurgical equipment are connected to, and 60 have also been created. automated workstations

Automated workplaces were created in the workshops of the Center for Production Competencies "Turbine Blades" on personal computers, production terminals and monoblocks based on the modules of AIS "Dispatcher." From them, these enterprises enter the Smart Workshop platform.

All activities of the second stage have been completed. The work carried out allows you to start demonstrating and testing the Smart Workshop digital platform at the third stage. They will go taking into account the receipt of data from various sources, including from automated workplaces "Digital Production" and metallurgical equipment, noted the director of information technology of PJSC "UEC-Saturn ," Evgeny Alekseev.

The platform is configured and configured in a test environment, user and administrator manuals have been developed. The system being implemented will help evaluate the performance indicators of the production unit and make management decisions. The project is being implemented with grant support from the Russian Information Technology Development Fund.

Involvement financings for the comprehensive implementation of the Smart Workshop digital platform is carried out within the framework of the Digital Technologies federal project. national program "Digital Economy of the Russian Federation"

Implementation of the ZIIoT Information and Analytical Platform

The first introduction of the ZIIoT information and analytical platform began at UEC-Saturn. This was reported on January 18, 2022 in the company "Figure."

During the implementation of the comprehensive digitalization plan productions , UEC-Saturn PJSC (part of) United Engine Corporation Rostec launched a pilot project to introduce the Smart Workshop digital platform. The project will allow the company to conduct a multifactorial assessment of production activities to make effective management decisions.

Source: gazeta-rybinsk.ru

The implementation is based on the foundation of the information and analytical platform ZIIoT (Zyfra Industrial Internet of Things platform) and the monitoring system of industrial equipment "Dispatcher" from the company "Digital." With the platform, enterprise management information systems will have access to a wider range of data. Their operation in a single information space allows end-to-end control of business processes at various alterations of the production chain. In turn, the Manager collects an array of data from production equipment, allowing you to select the optimal scenarios for its operation.

PJSC UEC-Saturn, together with the company "Zyfra" , has launched the project "Comprehensive implementation of the Smart Workshop digital platform." The project is implemented with the involvement of grant support, Russian Information Technology Development Fund said Evgeny Alekseev, Information Technology Director of UEC-Saturn PJSC

The comprehensive implementation includes the organization of 60 high-tech automated workplaces at the production site, connecting 10 units of metallurgical equipment to the monitoring system. Thus, at the pilot stage, 70 monitoring objects will be entered into the platform for the formation of analytical reports and user dashboards to the company's management.

"About 500 production machines are already connected to the industrial Internet of Things of the enterprise. The transition to a platform solution is a new stage of digitalization of PJSC UEC-Saturn, which will achieve production efficiency and remain competitive in the long term, noted General Director of Zyfra Group Igor Bogachev

Work on the creation of a digital control system is underway at the Turbine Blades Production Competence Center. The system being created will allow you to move from "manual" control to objective control according to the collected data, thereby ensuring a new stage in the digital transformation of the entire production complex. The efficiency of management will be ensured by means of objective control, automated collection and processing of structured and unstructured data, the implementation of BI-analytics and solutions based on IIoT and BigData and, as a result, the creation of an intelligent assistant to support management decision-making at all levels of management - from master to CEO. Within the framework of the project, algorithms will be formed to increase the efficiency of management in terms of key parameters. A training program for production personnel will also be developed in terms of the use of the implemented digitalization tools and corporate standards for the formation of approaches to data-based management. The solution should become typical for further scaling. The project belongs to the priority support area "Production Process Management Tools (MES): software that should be designed to solve the tasks of synchronization, coordination, analysis and optimization of product production" and is implemented using the funds of a grant from the Russian Information Technology Development Fund, which is part of the group of the state development corporation VEB RF. Financing is carried out within the framework of the federal project "Digital Technologies" of the national program "Digital Economy of the Russian Federation."