Approbation and branding

Refinement and insertion of stones (jewelry section)

Hanging and attaching labels

Package

Finished products warehouse

Scheme of the technological process of production

jewelry

The beginning of the formation of the concept of a new organization. The merger of two interacting firms (one - manufacturing, the other - trading) will significantly reduce taxation and streamline the management system. Since Firm X will be staffed for the most part by former employees firm Z, the question arises of the maximum formalization of relations at the very initial stage of work on the creation of a new organization. Using the concept of types of organizational paradigms (systems) by L. Konstantin, the desired system was defined by management as closed, based on strong leadership, with formal and subject to general rules of communication.

At the first stage of work on structuring the organization, a diagram of the technological process of jewelry production was drawn up, which made it possible to identify the main structural divisions with their specialization, a system of direct subordination, and communication links between divisions.

The next step is the development of an optimal management structure based on the analysis of the process flow diagram. The following structural subdivisions were identified: raw material warehouse, finished product warehouse, chemical laboratory, procurement section, melting section, bulk casting section, special casting section in graphite molds, jewelry assembly, weighing, packaging, engraving sections, accounting department, personnel department, secretariat .

The subdivisions related to the main production are directly subordinate to the head of production, the subdivisions of auxiliary production are directly subordinate to the general director. The engraving section, which is both part of the main production and performing auxiliary functions, reports to the head of production and works at the direction of the marketing department of an adjacent company.

It should be noted that the production structure described above, due to some objective reasons, cannot be completely created immediately. But this is exactly the model of organization that we want to achieve by following a series of successive steps.

As already noted, the desired system was defined by management as closed, based on strong leadership, with formal and rule-based communications. The principle underlying the division of labor is functional. Managers, specialists and performers were identified.

Supervisor organizations - the CEO who manages the resources of the organization.

Specialists - chief accountant, production manager, warehouse manager, personnel manager - do not have administrative power, but are experts in a certain area and assist the manager in the decision-making process.

CEO

Technical Secretary

Accounting

Production director

HR manager

harvesting area

Chemical laboratory

Melting section

Special casting area

Volumetric casting area

Warehouse Manager

Jewelry assembly area

Raw material warehouse

Stock finished products

Hanging site

Packing area

Tracking the material from the part to the finished product is a task that is especially relevant for machine-building enterprises. Obviously, without the use of information systems, it will be extremely difficult to solve such a problem, therefore, the corresponding requirement is one of the first in a series of those that are presented by machine builders to IT solution providers. Nevertheless, many expect from information systems, if not a miracle, then certainly a magic red button that will remove all problems.

In this article, we have attempted to understand what Information system is really able to decide, and what should remain the responsibility of a person: what decisions he should make, what actions to perform and what data to supply the information system in order to achieve the desired result from it.

Without pretending to a comprehensive coverage of the issue, let us focus on its most important component - consider the first steps, on which, however, the fundamental possibility of solving the entire problem will depend. Moreover, we will consider these steps using the example of a solution for an enterprise whose industry affiliation dictates the most stringent requirements for traceability: for each product, or rather an instance (serial number) of the product, it is necessary to have information about the specific characteristics of the material from which all its components were made.

Under such conditions, it is important to properly organize the information support of processes at the initial stages of production, that is, at the material warehouse and then at the procurement site.

This article will focus on the project being implemented at CJSC Energotex (Kurchatov). As a process automation tool production accounting the TechnologiCS system (www.technologics.ru) is used.

Note that traditionally such tasks are solved by warehouse accounting methods, usually implemented within the framework of the functionality of accounting (accounting) systems. Traditionally, the solution to the problem using such systems is as follows:

• accounting primary documents(waybills and invoices) received from material suppliers;
• distribution of material by batches of arrival with individual (primarily price) characteristics;
• issuance of material to production (write-off from the warehouse according to the invoice);
• receipt of blanks from the production (procurement) site to the appropriate warehouse.

However, upon closer examination, it turns out that at each of these steps one has to solve a much more complex problem, and the greatest difficulties arise already at the first stage of its solution.

Let's explain what has been said:

1. From the point of view of an accountant, the material is what is recorded in the position of the accounting document, and this document was created by a third-party organization (supplier), which does not think too much about the rules for recording the name adopted by the consumer enterprise.
2. From the point of view of the designer, the material is what is written in the title block of the drawing (usually it is the grade of the material). Additional requirements to the material can be given in specifications, but it's just text.
3. From the point of view of the technologist, the material is already a blank. This means that the record of the material grade should be supplemented with information on the assortment, standard size and other similar data.

The production worker is even more demanding on the record of the material. He, in addition to all the information already mentioned, needs data on the individual characteristics of a particular batch of material, up to the actual geometric dimensions, heat number, chemical composition and physical properties material within this lot.

Then we will try to figure out where this information comes from. Obviously, there are two sources, and at a certain stage, the information that arises in each of them meets and must be combined. An explanation is given in fig. one.

It can be seen from the explanation that the main and inevitable collision occurs already at the first stage of production accounting - this is the problem of identifying the material received from the supplier and the material of the workpiece specified in the design and technological documentation of the manufacturer.

The solution to this problem is based on the use of special functionality of the TechnologiCS system - settlement and accounting documents, as well as on the mechanism of their interaction.

Unlike the classical warehouse system TechnologiCS, which works only with accounting documents, on the basis of which accounting objects move around the warehouse and, as a result, their balances change, TechnologiCS also operates with so-called settlement documents.

A settlement document is a special object of the system, which also has a specification, operates with quantities and other attributes characteristic of a warehouse document, but does not directly affect the movement of accounting objects. It can be, in particular, the basis for a number of accounting documents, and the content of the accounting document (specification) will be generated automatically using the corresponding specification of the base document.

Now it is time to specify the steps to be taken in production system to solve the problem of end-to-end tracking of the material within the harvesting area. Recall that the solution of this problem will be the foundation for the implementation of tracing this chain up to the finished product.

So, we need:

1. Obtain information about the receipt of goods at the central warehouse.
2. Identify the received material and the workpiece material specified in the documentation (contained in the TechnologiCS database).
3. Clarify and record information about the geometric dimensions of the material, determine the list of additional tests.
4. Issue the material to the cutting section (with the transfer of the material to the "Blank" state).
5. Carry out the cutting of the material at the cutting site.
6. Form the so-called a dki (with a dka - a group of blanks simultaneously subjected to heat treatment).
7. Carry out hardness testing of specimens after heat treatment.
8. Record test results.
9. Move the blanks to the pantry of the harvesting area.

Rice. 2 explains the first two steps of the above sequence. The features of the procedures that are performed at these stages imply the adoption of decisions that require appropriate qualifications from the specialists who make them. Obviously, the storekeeper cannot be required to solve the problem of identifying the material, and the functions performed by the storekeeper should be as mechanical as possible - thereby eliminating inaccuracies and errors in subsequent steps.

RD - settlement document TechnologiCS
UD - accounting document TechnologiCS

It is important to pay attention to the key point here: the supplier's invoice, before falling into the hands of a warehouse worker (storekeeper), undergoes preliminary processing in the logistics service (OMTS).

The OMTS employee, having information about the chain of documents that generated the invoice (own application, the supplier's invoice and the invoice itself), gets the opportunity to decide on the compliance of the delivered material with the position of the TechnologiCS materials directory. In addition, the specification of the application, being formed on the basis of production needs calculated in the same system, increases the chances that the supplier's invoice will contain the same items - this is a significant help to the OMTS employee in making a decision.

The result of processing the supplier's invoice in the OMTS is the settlement document "Incoming OMTS" (Fig. 3).

The positions of the specification of the settlement document are already links to the corresponding TechnologiCS reference book, and this gives the storekeeper the opportunity, when creating an accounting document - an incoming invoice - not to think about the content of the specification, but simply create a document "based on".

It should be noted that in the process of creating a settlement document, the OMTS employee uses specially designed macros and input forms that help him, already at the stage of initial processing, supply the specification positions with the maximum possible set of information characterizing the incoming material, which greatly facilitates the work of services that use this information on subsequent stages of material movement (Fig. 4).

After the settlement document has been created and the OMTS employee has entered all the necessary information about the received material into it, you can post the material to the warehouse.

The action is performed by the storekeeper, while he does not create an incoming invoice manually, but uses a special macro function that generates an invoice based on the settlement document. Thus, the possibility of any errors at this stage is practically reduced to zero.

The result of the storekeeper's work is the completed accounting document (Fig. 5).

Posting an accounting document caused the movement of material in the warehouse and a change in its balances (Fig. 6).

Please note: the credited material was distributed among the index cards in such a way that each card corresponds to a material with the same properties, for example, a certificate and a heat number.

Each batch of material received its own serial number, which will subsequently be traced in blanks and further in parts and products.

The next stage is the so-called transition of the material into the workpiece. This action requires a special decision, and therefore is of particular importance. Service Representative technical control, having full information about the rest of the material in the warehouse, as well as a comprehensive description of each batch of material, decides which specific blanks can be made from each batch.

During the decision-making process, additional testing of material samples by the laboratory may be required.

The decision on the need for such tests is recorded in the settlement document "Work Order" (Fig. 7).

Rice. 7. Creation of work orders for additional tests

A special card is filled out for each settlement document “Work order”, where specific types of tests that need to be carried out in the laboratory are noted (Fig. 8).

Please note: the full list of tests is predetermined. When making a decision, the employee only notes those that are necessary in this case.

On the basis of the created settlement document, a test task is automatically generated (Fig. 9).

When a decision is made to manufacture blanks from specific batches of material, it becomes possible to link metal cutting charts to each batch, which, in turn, make up the contents of the corresponding TechnologiCS reference book (Fig. 10). Each card in TechnologiCS has a specification containing specific blanks that are obtained by performing a nesting procedure.

Rice. 10. Binding of metal cutting charts to serial numbers of material batches

The result of this action is the automatic generation of the "Demand" document, which is the official basis for receiving material from the warehouse (Fig. 11).

In order not to overload the article with technical details, we deliberately omitted a number of actions preceding the formation this document and those who follow him. Let us draw the attention of readers only to the fact that the actions that make up the procedure for transferring material to production are as automated as possible and boil down to the sequential launch of a number of macro functions that form a chain of settlement and accounting documents one on the basis of another.

In none of the cases, the employee does not need to manually fill in the content of the document (specification), he only has to add the necessary Additional information to the relevant positions and post the accounting document, thereby confirming the fact of the movement of the material.

Let us dwell in more detail on one more key moment of the process. We already know which batches (serial numbers) of the material are in stock, a decision has been made to manufacture specific blanks from these batches, nesting charts are attached to the batches. In order to transfer the material to the material cutting section, the procuring section wizard launches the “Material to workpiece transition” macro, having previously selected the necessary lines in the “Invoice receipt” accounting document specification corresponding to the materials transferred for cutting (Fig. 12). In this case, an expense accounting document is created, as well as a settlement document "Requirement" (Fig. 13).

The algorithm for compiling the specification of the settlement document "Requirement" is as follows:

• each position of the specification of the accounting document "Acceptance by waybill" must be associated with the parameter "Nesting chart";
• if this parameter exists, then the “Quantity” value for the same item from the specifications of all nesting plans will be added up and, together with the name of this item, will be written into the specification of the settlement document “Requirement”;
• if the parameter for the specification item is not specified, the system will prompt you to enter the number of blanks for each such item of the accounting document "Invoice receipt".

Upon the issuance of the material to the cutting section, the accounting document is received by the storekeeper, thereby removing the material from the remains of the warehouse and moving it to the material responsible person cutting area (Fig. 14).

Let us draw the reader's attention to the fact that the settlement document shown in Fig. 13 links a batch of material with certain individual characteristics to a specific workpiece. This makes it possible to automate the further sequence of actions performed by the macro (Fig. 15):

• for the cutting section, create an incoming accounting document “To work on the site”;
• for each nomenclature item specified in the specification for the cutting chart, create as many accounting cards for blanks as indicated in the “Quantity” column of the “Requirement” settlement document (see Fig. 13);
• assign a unique serial number to each workpiece corresponding to a specific heat and position from the nesting chart specification;
• post the document.

Having illustrated in detail the main points that make it possible to organize end-to-end information tracking of the movement of material in the process of its transformation into a workpiece, we note that the functions of the procurement site include a number of actions that precede the transfer of workpieces for further processing:

• heat treatment of blanks with automated formation of cages;
• sampling from each cage;
• carrying out hardness tests, entering the results of the tests;
• moving blanks to the pantry of the harvesting area.

These actions are performed according to algorithms that are fundamentally no different from those given above. They are based on the automated formation of chains of settlement and accounting documents one on the basis of the other. The result of these actions is the appearance of additional data that individually characterize the workpieces from each batch (Fig. 16).

In conclusion, let us once again formulate the basic principles underlying the solution of the problem of tracing material from receipt to the warehouse to specific blanks:

• in the process of organizing information support for the movement of material, it is necessary to make a number of fundamental decisions;
• such decisions can be made by an employee with appropriate competence;
• the information support system of the process should provide this employee with the necessary information for making a decision and record the result;
• the system should automate as much as possible routine functions related to warehouse accounting, while excluding manual input the content of the documents;
• the system must also unambiguously predetermine the sequence of actions performed by employees.

Note that in our case, the information system correctly separates the processes: the decision on the initial identification of the material is made by the OMTS employee, the storekeeper only fixes this decision with an incoming document; the decision to conduct additional tests is made by the STK employee, the site foreman uses this decision when writing off specific batches of material for production, etc.

The system automates routine functions and unambiguously determines the sequence of their execution: a warehouse employee (storekeeper) runs macros that perform related chains of necessary actions and generate documents, and the storekeeper only records the fact of material movement by posting documents. This eliminates the errors that inevitably arise when manual processing documents.

As a result, each blank with a unique serial number that appears in the warehouse carries comprehensive information about the material from which it was made. The workpiece automatically inherits it along the chain of documents accompanying the processing processes.

It is easy to understand that, using similar algorithms, it is possible to trace the path of the workpiece to the finished product, and this task is purely technical in nature. At the same time, the foundation, which is the basis for its solution, is laid precisely at the first steps of accounting for the material and processing it at the procurement site.

Dmitry Dokuchaev

Director of Engineering Consulting Department, CSoft.

Evgeny Troshchinsky

General Director, CSoft Ukraine.

Andrey Kurochkin

Head of Engineering Systems Department, CSoft Ukraine.

The purpose of the lesson: the study of the basic operations and equipment of forging and blanking production in the production of packages, disks, shafts, compressors.

Marking of steel blanks

Metal coming from metallurgical plants has its own factory marking. On each rental, blooms, square, there is a release on the end side. On this rebound is the steel grade and melt number. There is also an accompanying document - a certificate.

Marking of steel blanks after cutting

After the steel blanks are cut at the blank section, all metal (rolled stock, blooms, square) is marked with paint according to the marking table:

Table 1.

Procurement area equipment

Round saw cutting machine 8G662 - designed for cutting ferrous metals with segment saws of round, square sections. Saw length - 1430 mm, diameter - 710 mm.

Combined scissors - used for cutting rolled products with a diameter of 10-36 mm, a channel - with a diameter of 6.5 mm, 8 mm, 10 mm, a hexagon - with a diameter of 10-36 mm.

Saw sharpening machine

Wire drawing machine - designed for cold drawing wire from a large diameter to a smaller one using dies. (For example, from 6 mm to 5.5 mm).

cutting blanks

1) Abrasive wheels (vulcanite).

Cutting blanks on press scissors. Used for cutting sheet metal.

2) Flame cutting

There are two types of gas cutting machines: semi-automatic and automatic. In the KKZ workshop there is an ASSh2 automatic machine (stationary-articulated automatic machine). It works with oxygen and gas. Cuts workpieces with sheet thickness from 6 to 60 mm. Cut off the parts according to the copier template.

Plasma cutting

AVPR403 - water-plasma cutting machine. Used for cutting non-ferrous metals: brass, copper, of stainless steel thickness from 6 to 60 mm. Operates with an electric compressed DC arc and is cooled by water.

6.5.1 Heating of blanks before forging

Before forging, the workpieces are heated in a furnace to the following temperature:

Table 2.

6.5.2 Heating ovens, loading and unloading heated billets

Heating gas furnaces are a metal frame lined with a fold of refractory bricks that form the working chamber of the furnace. Serves for gas supply of smoke channels and working windows, for loading and unloading of metal, covered by lifting doors. The fuel used is gas. An overhead crane and a blacksmith's shovel are used to load blanks into the furnace. Small blanks are thrown manually. Heated blanks from the furnace are unloaded from the furnace using a forge poker. Temperature control is performed by a pyrometer device or visually - by color. (see table 1)