Preparation of a project for a new product and new technologies - technical preparation of production - is a complex of scientific, design, technological, production and economic work on the creation and development of new products and the introduction of new technologies. In the "science - technology - production - consumption" system, technical training plays the role of a link, as it combines individual research, design, experimental and organizational and technical work, as a result of which the products of science turn into products production.
Depending on the industry affiliation of the enterprise, its scale, production profile, the structure and volumes of technical preparation of production can change significantly, and therefore the duration of technical training and the amount of resources used for these purposes change. There are the following forms of technical preparation of production:
full form, which is used to organize the preparation of the release of new or modernized products of a technically complex profile of mass and large-scale production and includes a full cycle of work on the system "science - technology - production - consumption";
small form, which is widely used in organizing and preparing the release of products that are simple in design and technology, when introducing standard equipment and carrying out other organizational and technical measures;
technological form, which is used in preparation for the introduction of complex equipment, production lines, control systems.
There are no clear boundaries between these forms of technical training. All types of work on the technical preparation of production consist of the following stages:
scientific research, design and experimental work on the creation and development of samples new products(design preparation);
technological preparation, including the development of technology, the design of equipment placement, production flows, the design and manufacture of special equipment, tools, equipment, their testing, equipment adjustment, etc.;
putting products into production.
Note that some authors call the technical preparation of production scientific and technological preparation of production, design and technological preparation of production, etc., putting the same meaning into their content. Technical training production is carried out in the production of new products, as well as re-equipment, reconstruction and expansion of the enterprise or its individual production sites. Thus, design and technological preparation, as well as measures for putting products into production, are the basis of the scientific and technical organization of production at the enterprise.
The process of technical preparation of production is regulated by relevant norms, rules, requirements and standards.
Currently, about 27 systems of intersectoral documentation are used, designed in the form of standards:
State Standardization System (TSS);
Unified system for design documentation (ESKD);
Unified system of technological documentation (ESTD);
Unified system of technological preparation of production (ESTPP);
State System for Ensuring the Uniformity of Measurements (SSI);
System of labor safety standards (SSBT);
System for the development and production of products (SRPP);
State Product Testing System (SGIP), etc.
All of the above standards together create the conditions for ensuring the technical preparation of production at high level, capable of guaranteeing the competitiveness and quality of manufactured products and their sale not only in the domestic but also in the international market.
The level of technical preparation of production depends on many factors (technical, economic, organizational and social). Technical factors include the development and implementation of standard and standard technological processes, the use of standardized and unified technological equipment. Economic factors include stage-by-stage advanced financing of work on the technical preparation of production, the provision of soft loans, the creation of a fund to stimulate the development (putting into production) of new products.
Organizational factors include the development and deepening of the specialization of production, certification of the quality of technological processes and technological equipment, non-standard equipment based on the results of assessing the quality of a prototype or the first industrial batch of products of the main production, improving the organization of auxiliary production.
Social factors are advanced training of performers, mechanization and automation of production and auxiliary operations in order to improve working conditions, development social sphere, improving the psychological atmosphere in the team. All stages of technical training are interconnected.
Stage 1. Product design (design preparation). The standard stages of product design include the following sequential work:
development of a preliminary design;
production of a prototype;
prototype testing;
development of a technical project;
working draft development;
production of an experimental batch or prototype of a product;
testing of products of an experimental batch;
refinement of samples according to test results;
clarification of the working draft and its execution;
transfer of the working draft to the bodies of technological preparation of production.
The starting point for the design of a new product is the technical (design) task, which is drawn up by the customer of the project or (under the contract) scientific or design organization. The project assignment contains detailed requirements for a new product, providing for technical parameters that determine the novelty and necessary consumer properties of products, the cost of cost elements (calculation items), economic efficiency compared with the old replaced equipment, the volume of production, the main consumers of the product and suppliers of raw materials, materials, components.
Stage 2. Design of production technology (technological preparation). When mastering the production of new products, technology design is a continuation of the product design stage. At the stage of product design, it is determined what a new (upgraded) product should be, and at the stage of technological preparation - in what way, with what technical means and methods it should be manufactured, and the cost of the product and its effectiveness are finally determined. The purpose of technological design and preparation of production is the development of a project for the technological process (technology) for manufacturing a product and the implementation of this project in the specific conditions of the enterprise.
Production technology is the methods technical means and a system of interrelated ways of producing a product or performing a specified type of work (for example, transportation). The technology includes the entire list of sequential operations for the transformation of the source material into the finished product, indicating the type and nature of the equipment, tools and devices that the worker uses at each stage of production.
Technological preparation consists of the following stages:
development of a route technology, which contains a project for placing the sequence of technological operations (from the first to the last) along the route of the passage of units and parts of the product through the shops and sections of the enterprise, up to the receipt of the finished product;
development of standard production technologies that provide for limiting the number of projects and applied technological operations, establishing the uniformity of the method of processing the same type of products and the technological equipment used;
the manufacture and adjustment of special technological equipment, machine tools, technological equipment necessary for the production of a new (modernized) product is the most time-consuming and expensive stage of technological preparation at enterprises of large-scale and mass production producing technologically advanced products. In this regard, in these industries, the transition to the manufacture of a new product, as a rule, is combined with the reconstruction and technical re-equipment of enterprises.
The results of the design of production technology are documented in special documentation. In many industries (including mechanical engineering), such documents are technological maps, which provide a complete description of the technological process - from the receipt of raw materials and components to the warehouse of the enterprise to the release of the finished product and its transfer to the sales department.
Project management of technical preparation of production includes the following steps:
project development planning;
control over the implementation of the plan;
adjustment of the plan and operational regulation of work.
The initial data for planning are:
1) volume and duration general plan technical development of the enterprise;
2) design norms and standards for determining the scope and scope of design work for all stages of technical preparation;
3) the amount of funding.
Both industry-wide and special standards are being developed for projects of technical preparation of production. Based on the standards, typical stages and a list of types of work for each stage, a schedule for the technical preparation of production is drawn up, which sequentially establishes:
stages of preparation;
performers by stages;
start and end dates for each stage of work.
In the absence of design standards, analogues are used for the performed engineering and commissioning works of a similar profile. The introduction of standards makes it possible to systematize the execution of design and technological documentation in accordance with the requirements of ESKD and ESTD and provide a single approach for each enterprise to the selection and application of methods of technological preparation of production in accordance with the Unified System of Technological Preparation of Production (UTPP).
With the successful completion of functional testing of a new product, many firms produce market tests (trial marketing). The problem of conducting market trials of new products depends on many factors, the main of which are the following:
- goals and resources of the company;
- type of product, expected volume of production and type of market;
- degree of reliability marketing information and research;
- the degree of firm confidence in the competitive success of a new product in the market;
- the company's policy in relation to risk;
- assessment of the time delay of the full range of work on the creation and development of a new product.
Deciding whether (or not) conducting market tests, as well as deciding which design documentation (prototype, serial production) and in which production (experimental or serial) will be used to produce a pilot batch of a new product for trial marketing and whether to suspend or continue pre-production work before the results of market tests, depends on the specific operating conditions of the firm, its goals, resources, methods of work and policies.
Purpose of Market Tests- testing the product in real-life conditions, identifying the opinions, comments of consumers and salespeople about the features of its use and sales problems, as well as determining the size of the market and the overall sales forecast, i.e. production program.
Tests in market conditions provide management with information to make a final decision on the feasibility of releasing a new product. If the company starts to deploy commercial production, it will face large expenses for the completion of pre-production, the cost of capital construction and the development of production, the cost of distribution channels and promotion of the sale of a new product. At the same time, it must solve the following main questions - when, where, to whom and how to sell new product.
WHEN. The first decision is made on the timeliness of the release of a new product on the market. If the new product undermines the sales of other similar products of the firm, or further improvements can be made to its design, then the introduction of the new product to the market is likely to be delayed.
WHERE. A decision is made to sell the product in certain geographic markets or on a national or international scale. In the absence of sufficient confidence in success, the necessary funds and opportunities to enter the national market with a new product, a time schedule is set for the consistent development of markets.
TO WHOM. The most profitable markets in the group of developed ones are selected, and sales promotion efforts are concentrated to develop them.
HOW. An action plan is being developed to consistently bring a new product to the markets (marketing plan).
The answers to these questions, simple in form, but extremely complex in their essence, have an impact on the further course of preparation for production and industrial development of new products, since they determine:
- production capacity firms;
- type of production;
- production structure;
- production schedule by years.
Design preparation of production at the plant is the final part of the checkpoint. The purpose of the design preparation of mass production is to adapt the design documentation of the R&D to the conditions of a specific mass production of the manufacturer. As a rule, R&D design documentation already takes into account the production and technological capabilities of manufacturers, but the conditions for pilot and serial production have significant differences, which leads to the need for partial or even complete processing of R&D design documentation.
The gearbox is produced by the department of the chief designer of the serial plant (OGK) or the serial department of the research institute, special design bureau, design bureau in accordance with the rules " unified system design documentation" (ESKD).
In the CPT process, designers, to the maximum allowable limits, must take into account the specific production conditions of the manufacturer:
- the presence of unified, standard parts and assembly units manufactured by the enterprise or related enterprises;
- available means of technological equipment and control;
- available technological and non-standard equipment, vehicles, etc.
Scope of works of design preparation of production of the manufacturer:
1. Obtaining design documentation from the developer.
2. Checking the documentation for completeness.
3. Making changes in accordance with the characteristics of the manufacturer.
4. Making changes based on the results of testing the design for manufacturability.
5. Making changes based on the results of technological preparation of production.
6. Technical support for the manufacture of an experimental batch of products.
7. Making changes to the design documentation based on the results of the production of an experimental batch.
8. Assignment of documentation letter O 2 for the manufacture of the installation series.
9. Technical support for the production of the installation series.
10. Translation of documentation into the letter A for the established mass production.
11. Issue of repair, export and other documentation.
12. Technical support for mass production.
Currently, methods of computer-aided design and the creation of design documents (CAD) are becoming increasingly important in the work of the CPD.
The task of the CCI is to ensure the complete technological readiness of the company for the production of new products with specified technical and economic indicators (high technical level, workmanship, as well as with minimal labor and material costs at a specific technical level of the enterprise and planned production volumes).
The following main tasks are solved in the CCI process:
- development of the product for manufacturability;
- development of technological routes and processes;
- development of special technological equipment;
- technological equipment of production;
- technical support for the production of an experimental batch, an installation series and an established serial production.
The initial data for the CCI are:
1) a complete set of design documentation for a new product;
2) the maximum annual volume of output with the full development of production, taking into account the manufacture of spare parts and supplies through cooperation;
3) the expected period of production of products and the volume of production by years, taking into account seasonality;
4) the planned mode of operation of the enterprise (number of shifts, duration working week);
5) the planned load factor for the equipment of the main production and the repair strategy of the enterprise;
6) planned cooperative deliveries to the enterprise of parts, units of semi-finished products and supplier enterprises;
7) planned supplies to the enterprise of standard products and supplying enterprises;
8) estimated market prices of new products based on the pricing strategy of the enterprise and its objectives;
9) adopted strategy in relation to risk (in terms of availability of redundant equipment);
10) the policy of the sociology of labor of the enterprise.
Technological preparation of production is regulated by the standards of the "Unified System of Technological Preparation of Production" (ESTPP).
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Chamber of Commerce Planning |
Forecasting, planning and modeling of Chamber of Commerce and Industry |
Production Planning Department (OPPP) |
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Development of the design for manufacturability |
Development of product design, assembly units for manufacturability Participation in the production of a prototype |
Departments chief specialists(OGT, OGS, OGMet, etc.), OGK |
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Distribution of the nomenclature of parts and assemblies between workshops and divisions of the enterprise |
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Development of technological routes for the movement of production facilities |
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Development of technical processes for the manufacture and control of parts, assembly and testing and other technological documentation |
Departments of chief specialists (OGT, OGS, OGMet, etc.) |
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Typification of technological processes, development of basic and group processes |
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Feasibility study of technological processes |
Departments of chief specialists, economic department |
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Equipment selection |
Selection and justification of universal, special, modular and non-standard equipment Issuance of assignments for the design of this equipment, as well as for the design of flexible automatic, automated, robotic lines and complexes, conveyors, vehicles, etc. |
Departments of chief specialists |
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Selection and technological design of tooling |
Selection of the necessary special, universal and unified equipment Design (technological design) tooling |
Technological and design departments of chief specialists |
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Feasibility studies for the selection and use of tooling |
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Rationing |
Establishment of operational technical standards time of all technological processes. |
Department of labor and wages (OT and Z). |
Development of products for manufacturability
Technological rationality is characterized by:
- the complexity of manufacturing;
- specific material consumption;
- material utilization factor;
- technological cost;
- specific energy consumption of the product manufacturing;
- specific labor intensity of preparing the product for operation;
- coefficient of applicability of materials;
- coefficient of application of group and standard technological processes, etc.
1) applicability factor
K pr \u003d (m - m op) / m,
where m is the total number of standard sizes (names) of parts (elements, microcircuits, etc.); m op - the number of original parts;
2) repeatability factor
where m about - the total number of parts;
3) unification factor
where m y is the number of unified standard and borrowed parts produced by industry enterprises;
4) standardization coefficient
where m st is the number of standard parts.
The coefficients K pr, K p, K y, K st are more correctly calculated using the labor input of the product elements.
Choice the best option technological process
In various variants of technological processes for the manufacture of new products, a variety of workpieces, equipment, technological equipment, etc. can be used, which leads to different labor intensity, productivity and the use of workers of different qualifications. The main criteria for choosing the optimal technological process are cost and productivity. To simplify the calculations, the technological cost is used, which is part of the total cost and takes into account the costs that depend on the variant of the technological process:
,
where Z t - technological cost; - conditionally variable costs for one detail (product); - semi-fixed costs for the annual program; Q - annual release program.
To select the optimal variant of the technical process, i.e. for a comparative assessment, there is no need to perform an element-by-element calculation of all cost items included in the cost, but it is enough to analyze only the costs that change when the technological process changes. It makes no sense to calculate and include in the cost price the costs that do not change when the process option is changed, since when determining the absolute value of the savings achieved by using a more profitable option, the same cost components cancel each other out.
Comparison of options for the technological process at cost is as follows.
The technological cost for option 1 is equal to
,
and for option 2 is
.
Graphically, options 1 and 2 can be represented by straight lines (Fig. 28).
Rice. 28. Graph comparative evaluation two variants of the technological process
The point A of the intersection of these lines determines the critical amount of detail Q cr, at which both options will be equivalent, i.e.
If the output volume is less than the critical one, option 1 will be more economical, and if the number of products is more than the critical one, option 2 will be more economical.
The choice of the most economical option for the implementation of the technological process from the set possible ways in the general case, production should be carried out at the minimum of reduced costs, which are taken as an optimality criterion. However, in order to compare variants of technological processes, in many cases it is sufficient to confine ourselves to calculating the technological cost of production.
Therefore, in what follows, not the full reduced costs are used as the price function, but the minimum amount
where is the technological cost of the annual output according to the manufacturing option; E n - coefficient of efficiency; K i - capital investments that change when changing the variant of the technological process.
Let's consider a technical and economic assessment of possible options using the example of manufacturing semiconductor microcircuits.
A typical enlarged sequence of the technological process for manufacturing semiconductor microcircuits includes nine main operations (chemical processing, oxidation, photolithography, diffusion, separation of wafers into crystals, mounting a crystal in a package, connecting leads, sealing and testing), each of which can be carried out in 3 to 7 ways .
Even combining processes into groups of operations gives an idea of the multivariance of the technological process of manufacturing microcircuits. In addition to the methods for implementing each operation in real conditions of development and production, one has to take into account and choose: methods of isolating circuit components, technology methods, the degree of integration of the device, as well as solving many other design and technological issues.
The implementation of each method at a particular operation involves different costs for basic materials and components M ij , for the main wages L ij , depreciation allowances A ij , capital costs K ij and leads to the achievement different levels yield coefficient of suitable products P ij .
It is convenient to present the listed initial data by groups of operations in the form of a matrix of operational indicators.
Due to the complexity of the analysis, the entire set of operations of the technological process is divided into three large stages, namely: processing, assembly and testing of products.
The number of possible ways to perform each stage is also limited to three. As a result, an enlarged matrix of indicators of the stages of the manufacturing process of products is obtained, presented in Table. 9.2.
The calculation is reduced to the fact that from a given set of possible ways to perform the stages of the process, choose a rational option for carrying out the entire technological process that satisfies the minimum of a given objective function.
The search for a rational variant of the technological process is carried out on computers using specialized software.
Table 9.2
Matrix of indicators of the stages of the technological process
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Options for performing a group of operations |
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Treatment |
M 11 L 11 P 11 |
M 12 L 12 P 12 |
M 13 L 13 P 13 |
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M 21 L 21 P 21 |
M 22 L 22 P 22 |
M 23 L 23 P 23 |
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Tests (measurements) |
M 31 L 31 P 31 |
M 32 L 32 P 32 |
M 33 L 33 P 33 |
Functions of organizational preparation of production:
1) planned (including pre-production calculations of the progress of production, equipment loading, movement material flows, release at the development stage);
2) providing (personnel, equipment, materials, semi-finished products, financial resources);
3) design (designing sites and workshops, planning the location of equipment).
In the process of organizational preparation of production, design, technological documentation and data are used for conducting technological preparation of production (Section 9.3). The main stages of the EPP, their content and performers are given in Table. 9.3.
Table 9.3
Stages of the PPP and their content
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Stages and content of the work of the RPP |
Performers |
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Planning and Modeling ERP Processes |
Production Planning Department (OPPP) |
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Production of special technological and control equipment |
Department of tool economy (OIKh) Tool shops |
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Quantity and nomenclature calculations additional equipment, drawing up applications and placing orders for equipment |
OGT (capacity bureau) OKS (or OMTS) |
Calculations of the movement of parts and the course of future production; calculations production lines; loading jobs; calculations of operational and planning standards, cycles, batch sizes, backlogs |
Planning and dispatching department (PDO) Departments of chief specialists (OGT, OGS, OGMet, etc.) |
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Planning the work of auxiliary shops and services, as well as service units |
OIKh, department of the chief mechanic (OGM), department of the chief power engineer (OGE), transportation Department, warehousing department |
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Calculations and design of layouts of equipment and workplaces, formation of production sites |
Departments of chief specialists (OGT, OGS, OGMet, etc.); OOT&Z |
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Design and selection of interoperational transport, containers, office equipment and auxiliary equipment; making requests and placing orders |
Department of non-standard equipment (ONO) or department of mechanization and automation (OMA) Departments of chief specialists (OGT, OGS, OGMet, etc.), OMTS |
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Manufacture of vehicles, containers, office equipment and other auxiliary equipment |
Auxiliary production workshops, OMA |
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Acceptance, assembly and placement of the main, auxiliary equipment, means of transport and office equipment at workplaces |
OGM, OGE, OMA, auxiliary production workshops |
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Provision of materials, blanks, parts and assemblies obtained through cooperation |
OMTS, department of external cooperation (OVK), department of a complete set (OKP) |
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Training and staffing |
Personnel department (OK), personnel training department (OPK), OOT and Z |
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Organization of production of experimental and pilot batches; curtailing the production of old products and expanding the production of new products |
Production shops, departments of chief specialists |
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Determining the cost and price of products |
PEO, marketing department |
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Preparation of product distribution, distribution of new products and sales promotion |
Marketing department |
The initial stage of mastering the production of new products is characterized by increased costs. The reason for this can be explained by the following factors:
- a small volume of output of products, on which the semi-fixed costs associated with the development are distributed;
- increased labor intensity and machine-tool intensity of manufacturing (due to the gradual debugging of equipment, incomplete equipment of technical processes with special equipment and tooling, insufficient experience of workers and engineers);
- a large number of equipment changeovers;
- increased marriage;
- the cost of staff training;
- additional payments up to the average level of salary during the development period, etc.
As the volume of new products is increased, costs decrease. Possible ways to improve production efficiency at the development stage are shown in fig. 29.
Rice. 29. The main directions of obtaining an economic effect in the process of developing new products
Minimization of losses is closely related to the characteristic of increasing output, which in turn depends on the reduction in the labor intensity of the product in the process of development. For each specific enterprise, which is characterized by the release of a specific type of product, a certain level of technology, organization, it is possible to establish a correlation between the total volume of output and its labor intensity based on statistical data on the development of the production of similar products. A similar relationship can be established for the total output and cost:
where Z i - cost or labor intensity Q i -th product since the start of production; Z 1 (a) - the cost or labor intensity of manufacturing the first product, from which the beginning of development is considered; Q i (x) - the serial number of the product from the beginning of production; b - indicator characterizing the steepness of the development curve (0.05-0.75) for a given enterprise.
The indicator b and the coefficient of development K os are interconnected by the dependence
b=log K oc /log 2.
Practice shows that for instrument-making enterprises K os lies within 0.7¸0.9. The values of K os and the indicator b depend on factors:
- technical (constructive, testing thoroughness, etc.);
- technological;
- material and technical;
- organizational;
- subjective.
On fig. Figure 30 shows the development curves corresponding to the coefficients K os =0.9, K os =0.8, K os =0.7 for conditionally variable costs. The smaller K os (and, accordingly, the greater the indicator b), the greater the losses incurred by the enterprise at the stage of development.
Rice. 30. Change in costs per unit of output in the process of development
As can be seen from the previous sections, pre-production is a complex process consisting of many stages and stages. The decisions made at each of these stages affect the subsequent stages and the overall effectiveness of R&D. All this makes end-to-end intra-company planning expedient. life cycle products. Preparation of production - that stage of the life cycle of the product, when these circumstances become decisive. In sec. 8.5 emphasized the critical importance of reducing R&D and preproduction times. One of the methods to achieve this is the maximum parallelization of the development and pre-production processes. One embodiment of this is shown in Table. 9.4. Of course, for specific ROCs, such combinations require appropriate adjustments.
Table 9.4
Distribution of work on checkpoints, chambers of commerce and PP at various stages of R & D (approximate)
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checkpoint |
CCI |
OPP |
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TK for R&D |
Drawing up a set of documents necessary for development |
Determination of basic indicators of manufacturability. |
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Technical Proposal |
Preliminary calculations and clarification of the requirements of the TOR |
Metrological support of development and production. |
Development of a draft integrated schedule of pre-production activities (CSMP). |
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Development of a set of documents |
Development of the design for manufacturability with the participation of the manufacturer. |
Coordination of KSMP. |
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Technical project |
Development of design documentation for special equipment, technological equipment, means of control and testing of a prototype. |
Determination of the nomenclature of technological processes to be developed in relation to the conditions of mass production. |
KSMP approval. |
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Working design, manufacturing and testing of a prototype |
Development of a set of documents. |
Development of the design for manufacturability. |
Placement of orders for materials and components. |
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Development of documentation based on the test results of a prototype |
A set of used documents |
Refinement of the set of technological documentation for mass production conditions |
Development of consumption standards and preparation of standard and planned cost estimates for the product |
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Pre-production |
Technical assistance to the manufacturer by the developer in the preparation of production. |
Work on the development of new technical processes |
Production of tooling in volumes of serial production. |
Pre-production in a serial manufacturing plant is the final part of the innovation process, especially if the launch of the product is prepared by trial marketing. Almost all departments of the plant are involved in the preparation of production. input information for such preparation is the availability of a complete set of design documentation and marketing evaluation of the production program for a new product. Further, the preparation of production goes through the following stages:
- completion of design preparation of production;
- technological preparation of production;
- organizational preparation of production.
These stages are largely carried out in parallel in the following main areas (prior to the production of an experimental batch at an existing enterprise):
- provision of design documentation;
- development of the production program;
- development of technological documentation;
- Equipping shops with special gear and equipment;
- calculation of prices and conclusion of contracts;
- provision of materials and purchased products;
- metrological support of production;
- operational and production planning;
- Provision of workforce.
An exemplary simplified network graph (not a schedule!) of pre-production is given in Appendix 1.
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Material provided by the site ( E-library economic and business literature)
– Organization of information support for the pre-production process;
– Organization of scientific research, invention, rationalization and patent work;
– organization of design work;
– implementation of work on standardization and unification;
– organization of technological preparation of production;
– organization of mastering the production of new equipment.
Organization technical preparation of production covers works on design and technological preparation of production.
Main task design training production is the creation of a set of drawing documentation for the manufacture and testing of mock-ups, prototypes (pilot batch), installation series and documentation for the established serial or mass production of new products using the results of applied research and development work, as well as in accordance with the requirements of the terms of reference.
Technical task is the source document on the basis of which all work on the design of a new product is carried out. It is developed for the design of a new product either by an enterprise (manufacturer of products) and is agreed with the customer (main consumer) or the customer.
In the terms of reference, the purpose of the future product is determined, its technical and operational parameters and characteristics are carefully substantiated. It also contains: information on the nature of production, conditions of transportation, storage and repair, recommendations on the implementation of the necessary stages of development of design documentation, the composition of the documentation, a feasibility study and other requirements.
The development of the terms of reference is based on the performed research and development work, the results of the study of patent information and marketing research, analysis of existing similar models and their operating conditions.
Technical Proposal is developed in the event that the technical task for the developer of a new product is issued by the customer. This document contains a thorough analysis of the terms of reference and feasibility study of the proposed technical solutions, analysis of patent materials.
The procedure for agreeing and approving the technical proposal is the same as for the technical specifications. The technical proposal is the basis for the development of a preliminary design. The latter is developed if it is provided for by the terms of reference or technical proposal, the composition and scope of work is also determined there.
Preliminary design consists of a graphic part and an explanatory note.
A draft design is developed on the basis of a technical proposal (task) and is carried out in three stages: development of a draft design itself; production and testing of layouts; consideration and approval of the project.
The graphic part of the project gives an initial idea of the design of the future machine, including drawings general view, the kinematics of the units, structural diagrams of the most important units.
In brief explanatory note contains the calculation of the main parameters of the product, a description of the operational features and establishes an approximate schedule for the technical preparation of production.
Modeling is used in a number of cases to obtain a more successful arrangement of individual parts of the machine, ergonomic and aesthetic solutions. Models are made of plaster, wood, polystyrene for small samples - in full size, for large machines - in scale.
The draft design goes through the same stages of approval and approval as the terms of reference.
Technical project is developed on the basis of the approved preliminary design. It provides for the implementation of a full scope of work on graphic and settlement part. Once again, the technical and economic indicators of the product being created are specified. The graphic part of the technical project contains drawings of a general view of the designed product, assemblies in the assembly and main parts. Drawings must be coordinated with technologists. All details of the layout design must be kept until the machine is taken out of production.
The explanatory note contains a description of the main assembly units and basic parts of the product, the calculation of their parameters, a description of the principles of its operation, the rationale for the choice of materials and types of protective coatings, as well as all schemes and technical and economic calculations.
The technical project goes through all the same stages of approval and approval as the terms of reference.
working draft is a further development and concretization of the technical project. This stage of the checkpoint is divided into three levels: a) development of working documentation for an experimental batch (prototype); b) development of working documentation for the installation series; c) development of working documentation for an established serial or mass production.
First level detailed design is carried out in three, and sometimes in five stages.
On the first stage develop design documentation for the production of an experimental batch. At the same time, the possibility of obtaining some components from suppliers is determined. All documentation is transferred to the experimental workshop for the manufacture of an experimental batch (prototype) on it.
On the second stage carry out the manufacture and factory testing of an experimental batch (laboratory of type tests).
On the third stage technical documentation is being adjusted based on the results of factory testing of prototypes.
Fourth stage necessary if the product passes state tests, during which the parameters and performance of the product in real operating conditions are specified, all shortcomings are identified, which are subsequently eliminated.
On the fifth stage the documentation is corrected based on the results of state tests and a number of issues are agreed with the technologists.
Second level
On the first stage in the main workshops of the plant, an installation series of products is manufactured, which then undergoes lengthy tests in real operating conditions, where they specify the durability and durability of individual parts and components of the product, and outline ways to improve them. The launch of the installation series is preceded, as a rule, by the technological preparation of production.
On the second stage carry out adjustment of design documentation based on the results of manufacturing, testing and equipping technological processes for manufacturing products with special equipment. At the same time, technological documentation is being adjusted.
Third level detailed design is carried out in two stages.
On the first stage manufacture and test the head or control series of products, on the basis of which they finally work out and align technological processes and technological equipment, adjust technological documentation, drawings of fixtures, dies, molds, as well as standards for the consumption of materials and working hours.
On the second stage final revision of the design documentation.
This, at first glance, cumbersome procedure for the implementation of design preparation for mass production gives a great economic effect, ensures maximum manufacturability and maintainability in operation.
In other types of production, the number of stages and stages can be reduced by combining them.
Throughout the entire period of design work, it is necessary to ensure the cooperation of designers with technologists for two reasons: firstly, this allows you to create technological structures with the lowest labor costs in the conditions of this particular enterprise; secondly, it provides a reduction in the pre-production cycle due to the parallel and coordinated execution of design and technological work.
The main form of participation of technologists in the design preparation of production is the technological analysis and control of drawings performed at the stages of technical and especially detailed design, as well as in the process of manufacturing a prototype. Technological analysis and control of drawings is required. Drawings can be transferred to production only with a visa of technologists. A special addition to technological control is the normalization control, carried out by the employees of the standardization department (bureau) and consisting in checking and stimulating the implementation of standards.
Technological preparation of production is carried out in accordance with the requirements of the Unified System for Technological Preparation of Production (USTPP) standards and includes an extensive range of works. Depending on the scale and type of production, the complexity of products and the requirements for them, these works are carried out with varying degrees of detail.
Prior to the start of work on the technological preparation of production, technological control of the drawings must be carried out. It is necessary for the analysis and verification of designed products for the manufacturability of their design, the correct assignment of processing accuracy classes, the rationality of assembly schemes, etc.
First stage technological preparation of production - development t technological processes obtaining blanks, their thermal, mechanical and other types of processing, as well as the assembly of individual assembly units and the entire machine as a whole.
This work is preceded drawing up interdepartmental technological route (casing). It determines the phased movement of parts, assemblies, machines in the manufacturing process. At the same time, they proceed from the possibility of minimizing the path of movement and the possibility of its direct-flow organization.
Second phase - the design of equipment and non-standard means of mechanization and automation is carried out in parallel with the first and organically merges with it.
Third stage work consists in the manufacture of equipment and non-standard tools. This work, along with design, is the most time-consuming part of the entire work on the technological preparation of production (up to 70% of its total volume). In this regard, such work is carried out gradually (equipment of the first stage, and then an increase in the degree of equipment) to the maximum economically justified limits.
Fourth stage work on the technological preparation of production - alignment, debugging and implementation of the developed technology and equipment. At the same time, the suitability and rationality of the designed technology and equipment are checked.
Fifth stage (final) - organization of the development of planned output. At this stage, adjustments, changes, improvements are made to the technological documentation, allowing to reach the design output.
The performance of all the listed works is concentrated in the department of the chief technologist and in the technological bureaus of the workshops. At factories with developed procurement industries (casting, forging and pressing, welding, etc.), the corresponding technological preparation is carried out in the department of the chief metallurgist. Both departments have approximately the same organizational structure.
Workshop technological bureaus continue the work of the department of the chief technologist, mainly engaged in the introduction of technology launched by the workshops, instructing workers in its development, helping them to improve the methods and methods of work, identifying the degree of economic feasibility of the equipment used, etc. One of the most important functions of workshop technological bureaus is to control the observance of technological discipline.
The distribution of work on the technological preparation of production between the department of the chief technologist and shop technological bureaus depends, first of all, on the type of production and the structure of production management.
At factories of single and small-scale production, technological preparation of production is decentralized, i.e. all work is entrusted to the technological bureaus of the workshops, and the departments of the chief technologist (metallurgist) provide general methodological guidance.
At enterprises of large-scale and mass production, all work is centralized in the departments of the chief technologist and metallurgist, and shop technological bureaus are engaged in the implementation of the designed processes, their adjustment and subsequent rationalization.
However, in factories with serial production of products with different volumes, one can also meet mixed system organization of technological preparation of production, in which for objects of a stable nomenclature it is carried out in a centralized manner, and for frequently changing products - decentralized, in workshops.
The main document that completes the development of the designed process is routing : a route in single and small-scale production and an operating room in large-scale and mass production. For especially critical and complex operations in mass production, a cross-sectional instruction card is additionally compiled.
The company strives to create only the most Required documents and provide only relevant information. The list of documents used in the technological preparation of production is determined by the ECTPP standards.
Of the methods available to the technologist for the effective manufacture of products, he must choose the optimal one. Such a choice is made on the basis of comparative calculations of the technological cost for each of the compared options and the establishment of such an annual production volume, which serves as the boundary of their economic feasibility.
The problem of mastering new, more progressive and highly efficient products that are competitive on the market is directly related to the organization and improvement of the technical preparation of production. It covers a complex of consistently linked scientific, design, technological, production and economic work on the creation, development and implementation of new equipment and technology.
The entire area of technical preparation of production is regulated by standards.
Technical preparation of production includes technological preparation. It is carried out in accordance with the technical training plan available at the enterprise.
The activity of the enterprise for the development of its material and technical base, labor and management is the technical preparation of production. It includes:
- performing applied research;
- design of new products and modernization of previously produced ones;
- development of the technological process of manufacturing products;
- purchase of special equipment, tools and equipment from outside;
- material and technical support of production;
- training and advanced training of personnel;
- development of technical norms and standards;
- organization information support.
Technical training is carried out in order to effectively master the production of a new product, introduce new machines and equipment, and new technological methods for organizing production.
The task of technical preparation of production includes the creation of technical, organizational and economic conditions, fully guaranteeing the translation production process to a higher technical and technological level based on the achievements of science and technology.
Technical preparation of production consists of design and technological preparation.
At enterprises of different types, scales and profiles, different stages of production preparation can be represented with different completeness; however, in any case, a significant part of the work on the organization of production is within the competence of the enterprise.
Planning for technical training
The technical preparation of production is an object of internal planning and represents, to a certain extent, the detailing and concretization of technical and technical plans. organizational development production.
Technical training plan
The development of a plan for the technical preparation of production is an organic part of long-term and medium-term planning. The long-term plan defines the main directions and stages of technical training, the timing of its start and end, broken down by type of work, specific contractors, sources and objects of funding. The annual plans include those stages and types of work that must be carried out during the planned year.
The initial data for planning the technical preparation of production are: tasks of the plan for the technical development of the enterprise; standards for determining the composition and scope of work, their duration for all stages of technical preparation.
Planning Methods
In the organization of planning the technical preparation of production, an essential role is played by standards for technical preparation of production.
Among the standards, it is necessary to distinguish: volumetric production standards, standards for the amount of work on preparing production in physical terms, and standards for the labor intensity of these works.
These standards are local in nature, since for their development it is necessary to analyze and summarize the reporting data on the development of new products at a particular enterprise, taking into account the specifics of its functioning and economic condition.
Volumetric standards give grounds to calculate in physical terms the amount of work on technical preparation. These calculations are based on indicators such as the number of technological operations, the volume of drawing and technical documentation, the number of original parts and their complexity in manufacturing.
The labor intensity standards for the technical preparation of production are determined according to the standards that reflect the experience of designing products and designing technological processes not only at a given enterprise, but also in the industry, at allied enterprises, and at competing enterprises.
In the planning process, tasks are often set to reduce the time for technical training in order to accelerate the implementation of the achievements of science and technology in production, reduce the cost of technical training and improve the quality of work.
In practice, in order to reduce the preparation time, method of parallel and parallel-sequential work. In this case, work, for example, of the second stage begins earlier than the first one ends, and the work of the third stage - earlier than the second one ends, etc. As a result of combining different design stages, the overall preparation cycle is drastically reduced.
In the organization of work on the creation and development of new equipment and technology, an important place is occupied by the use of visual graphic images - network charts. They consist of two elements: works and events. Events represent the beginning or end of each type of work, which can be clearly recorded in their initial and final stages. The initial event is the moment of the beginning of the first work related to the preparation and implementation of the planned event.
On the chart, events are indicated by circles with the numbers indicated in them, works - by an arrow connecting sequentially related events. The duration of the work is indicated not by the length of the arrow, but by the number of units of time that is indicated above the arrow (usually this is the number of days or months). At the bottom, under the arrow, the costs of the work are indicated (rubles, man-days). A complete path in a network diagram is a continuous sequence of interrelated activities and events leading from a start event to an end event.
The network schedule allows you to most rationally build the progress of work, establish a strict sequence and priority in the performance of all necessary operations and actions. With the help of a network diagram, it is possible to determine with sufficient accuracy the timing of the completion of each event and, consequently, the deadline for achieving the results of the final event. In addition, using a network schedule, you can optimize the timing of the final event, identify and determine the influence of various factors on reducing the time of each event, organize control, monitoring and management of the actions of individual performers.
In the process of planning the technical preparation of production, the use of norms, rules and requirements established by the systems of relevant standards. The use of standards creates favorable conditions to ensure the scientific and technical preparation of production at a high level, capable of guaranteeing the competitive quality of manufactured products.
The tasks of the Chamber of Commerce and Industry of prototypes and single products are:
Working off in working conditions determining technological and organizational decisions for the manufacture of the product;
Ensuring the technological readiness of production for manufacturing for acceptance testing of prototypes, single and other products subject to industrial development.
The organizer and responsible executor of the CCI of prototypes and single products is their manufacturer, co-executors - the developer and, if scientific, technical and economic feasibility - specialized technological organizations.
To conduct CCI of prototypes and single products, the developer transfers to the manufacturer:
Working design documentation for a prototype (without a letter or with the letter "O" in accordance with GOST 2.103) or for a single product of one-time production (with the letter "I" in accordance with GOST 2.103) as it is ready or complete for the product as a whole. To reduce the terms of the TPP, the manufacturer, in agreement with the developer, can start the TPP according to the design documentation of the technological (draft) project;
Documentation (including directive) containing defining technological and organizational decisions for the production of the product.
The manufacturer, together with co-executors, on the basis of the documentation received from the developer, taking into account the fundamental decisions on the organization of the CCI taken during the design of the product, develops a plan (schedule) of the CCI of prototypes and single products in the form of an independent document or as part of a plan (schedule) for the manufacture of these products.
The Chamber of Commerce and Industry of prototypes and single products provides for the execution of the following main works:
Development of working design documentation for prototypes and single products, taking into account the manufacturability of the solutions incorporated in it:
Completion of research and development work in the field of technology, materials science and production organization;
Development using information arrays of descriptions of design and technological solutions:
a) technological processes for the manufacture of prototypes and single products in accordance with state standards ESTD;
b) special means of technological equipment in accordance with state standards of ESKD and technological processes for their manufacture in accordance with state standards ESTD. The priority for pilot production conditions is the use of high-precision universal or reconfigurable equipment, simplified and reconfigurable tooling;
c) control programs for automated process equipment:
Organization of the manufacture of special means of technological equipment for prototypes and single products;
Formation of plans (programs) for the development of fundamentally new, previously undeveloped and most critical technological processes and technological equipment within the framework of plans (programs) for ensuring the quality and reliability of the product, taking into account the requirements of mass production;
Development of technological processes and means of technological equipment in accordance with the plans (programs) of development;
Clarification (adjustment) of documentation containing defining technological and organizational decisions for the production of a product, as well as working documentation for technological processes and technological equipment - based on the results of manufacturing and testing prototypes and single products;
Ensuring the requirements of resource saving, ecology and labor protection in the manufacture and testing of prototypes and single products.
With the aim of ensuring the technological readiness of production to the manufacture of quality products for acceptance testing, the manufacturer performs, within the framework of the TTPP, measures to organize:
Timely provision of production under contracts and cooperation relations with the necessary materials, parts, assembly units, components, technological equipment, as well as input quality control;
Metrological support of production;
Technical control and defect-free manufacturing;
Certification of technological processes, workplaces of performers and technological equipment before its primary use;
Training of production personnel in connection with the development of new technologies and materials.
The criterion for the completion of the Chamber of Commerce and Industry of prototypes and single products - actual performance of work provided by the plan, confirmed by an assessment of the technological readiness of production for the manufacture of products for acceptance tests, which is performed by the manufacturer with the involvement (if necessary) of independent experts from specialized technological organizations, if they do not participate in the CCI.
When assessing technological readiness, special attention is paid to checking:
The ability of technological processes and other elements of production to ensure the manufacture of products in accordance with the requirements of the documentation and within the specified time;
Controllability of technological processes and other elements of production, i.e. the possibility of their control and bringing (if necessary) to the required state.
The evaluation procedure is established by the expert and the manufacturer by mutual agreement.
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