Manufacturing change. Organization of production

Manufacturing process is a set of purposeful actions of the personnel of the enterprise for the transformation of raw materials and materials into finished products.

The main components of the production process that determine the nature of production are professionally trained personnel; means of labor (machines, equipment, buildings, structures, etc.); objects of labor (raw materials, materials, semi-finished products); energy (electrical, thermal, mechanical, light, muscle); information (scientific and technical, commercial, operational and production, legal, socio-political).

The professionally controlled interaction of these components forms a specific production process and constitutes its content.

The production process is the basis of any enterprise. The content of the production process has a decisive influence on the construction of the enterprise and its production units.

The main part of the production process is technological process. During the implementation of the technological process, the geometric shapes, sizes and physical and chemical properties of the objects of labor change.

According to their significance and role in production, production processes are divided into: main, auxiliary and service.

The main are called production processes, during which the production of the main products manufactured by the enterprise is carried out.

Auxiliary processes include processes that ensure the uninterrupted flow of the main processes. Their result is the products used in the enterprise itself. Auxiliary are the processes for the repair of equipment, the manufacture of equipment, the generation of steam, compressed air, etc.

Service processes are called those, during the implementation of which the services necessary for the normal functioning of both the main and auxiliary processes are performed. These are the processes of transportation, warehousing, picking parts, cleaning rooms, etc.

The production process consists of many different operations, which are respectively divided into main (technological) and auxiliary.

A technological operation is a part of the production process performed at one workplace on one production object (part, assembly, product) by one or more workers.

According to the type and purpose of products, the degree of technical equipment, operations are classified into manual, machine-manual, machine and hardware.

Manual operations are performed manually using simple tools (sometimes mechanized), such as manual painting, assembly, product packaging, etc.

Machine-manual operations are carried out with the help of machines and mechanisms with the obligatory participation of a worker, for example, the transportation of goods on electric cars, the processing of parts on machine tools with manual filing.

Machine operations are completely performed by the machine with minimal participation of workers in the technological process, for example, installing parts in the machining zone and removing them after processing is completed, monitoring the operation of machines, i.e. workers do not participate in technological operations, but only control them.

Hardware operations take place in special units (vessels, baths, furnaces, etc.). The worker monitors the serviceability of the equipment and instrument readings and, as necessary, makes adjustments to the operating modes of the units in accordance with the requirements of the technology. Hardware operations are widespread in food, chemical, metallurgical and other industries.

The organization of the production process consists in combining people, tools and objects of labor into a single process for the production of material goods, as well as in ensuring a rational combination in space and time of the main, auxiliary and service processes.

The economic efficiency of the rational organization of the production process is expressed in reducing the duration of the production cycle of products, in reducing the costs of production, improving the use of basic production assets and increase the turnover of working capital.

The type of production is determined by a complex characteristic of technical, organizational and economic features production, due to the breadth of the nomenclature, regularity, stability and volume of output. The main indicator characterizing the type of production is the coefficient of consolidation of operations Kz. The coefficient of consolidation of operations for a group of jobs is defined as the ratio of the number of all different technological operations performed or to be performed during the month to the number of jobs:

	Kz =	To opi
		K r. m.

where Kopi is the number of operations performed on i-th worker place; Kr.m - the number of jobs on the site or in the shop.

There are three types of production: single, serial, mass.

Single production is characterized by a small volume of production of identical products, re-manufacturing and repair of which, as a rule, are not provided. The pinning ratio for a single production is usually higher than 40.

Serial production is characterized by the manufacture or repair of products in periodically repeating batches. Depending on the number of products in a batch or series and the value of the coefficient of consolidation of operations, small-scale, medium-scale and large-scale production is distinguished.

For small-scale production, the coefficient of consolidation of operations is from 21 to 40 (inclusive), for medium-scale production - from 11 to 20 (inclusive), for large-scale production - from 1 to 10 (inclusive).

Mass production is characterized by a large volume of output of products that are continuously manufactured or repaired for a long time, during which most workplaces perform one work operation. The coefficient of fixing operations for mass production is assumed to be 1.

Consider the technical and economic characteristics of each type of production.

Single and small-scale production close to it are characterized by the manufacture of parts of a large range at workplaces that do not have a specific specialization. This production must be sufficiently flexible and adapted to the execution of various production orders.

Technological processes in the conditions of unit production are developed on an enlarged basis in the form of route maps for the processing of parts for each order; sections are equipped with universal equipment and tooling, which ensures the manufacture of a wide range of parts. The wide variety of jobs that many workers have to perform requires them to have different professional skills, so highly skilled general workers are used in operations. In many areas, especially in pilot production, a combination of professions is practiced.

The organization of production in the conditions of unit production has its own characteristics. Due to the variety of parts, the order and methods of their processing, production sites are built according to the technological principle with the arrangement of equipment into homogeneous groups. With this organization of production, the parts in the manufacturing process pass through various sections. Therefore, when transferring them to each subsequent operation (section), it is necessary to carefully consider the issues of quality control of processing, transportation, and determining jobs for the next operation. Features of operational planning and management are the timely picking and execution of orders, monitoring the progress of each detail in operations,

ensuring the systematic loading of sites and jobs. Great difficulties arise in the organization of material and technical supply. A wide range of manufactured products, the use of enlarged consumption rates of materials create difficulties in uninterrupted supply, which is why enterprises accumulate large stocks of materials, and this, in turn, leads to the deadening of working capital.

Features of the organization of unit production affect economic performance. For enterprises with a predominance of a single type of production, relatively high labor intensity of products and a large volume of work in progress due to the long periods of storage of parts between operations are typical. The cost structure of products is characterized by a high share of costs for wages. This share is usually 20-25%.

The main possibilities for improving the technical and economic indicators of a single production are associated with its approximation in terms of technical and organizational level to the serial one. The use of serial production methods is possible with a narrowing of the range of manufactured parts for general machine-building applications, unification of parts and assemblies, which makes it possible to proceed to the organization of subject areas; expansion of constructive continuity to increase the batches of launch parts; grouping parts that are similar in design and manufacturing order to reduce the time for preparation of production and improve the use of equipment.

Serial production is characterized by the production of a limited range of parts in batches, repeated at regular intervals. This allows you to use along with the universal special equipment. When designing technological processes, they provide for the order of execution and equipment for each operation.

The following features are typical for the organization of serial production. Shops, as a rule, have in their composition subject-closed areas, equipment on which is placed in the course of a typical technological process. As a result, relatively simple connections between workplaces arise and prerequisites are created for organizing the direct-flow movement of parts in the process of their manufacture.

The subject specialization of the sections makes it expedient to process a batch of parts in parallel on several machines that perform successive operations. As soon as the previous operation finishes processing the first few parts, they are transferred to the next operation before the end of the processing of the entire batch. Thus, in the conditions of mass production, it becomes possible to organize the production process in parallel and sequentially. This is his distinguishing feature.

The use of one or another form of organization in the conditions of mass production depends on the labor intensity and volume of output of the products assigned to the site. Thus, large, labor-intensive parts manufactured in

in large quantities and having a similar technological process, they are assigned to one site with the organization of variable-flow production on it. Parts of medium size, multi-operational and less labor-intensive are combined in batches. If their launch into production is regularly repeated, batch processing areas are organized. Small, low-labor parts, such as normalized studs, bolts, are fixed to one specialized section. In this case, the organization of direct-flow production is possible.

Serial production enterprises are characterized by significantly lower labor intensity and cost of manufacturing products than in a single one. In serial production, compared to single-piece production, products are processed with fewer interruptions, which reduces the volume of work in progress.

From the point of view of the organization, the main reserve for increasing labor productivity in mass production is the introduction of mass production methods.

Mass production is the most specialized and is characterized by the production of a limited range of parts in large quantities. Mass production workshops are equipped with the most advanced equipment, which allows almost complete automation of the manufacture of parts. Automatic production lines are widely used here.

Technological processes of machining are developed more carefully, by transitions. Each machine is assigned a relatively small number of operations, which ensures the most complete loading of jobs. The equipment is located in a chain along the technological process of individual parts. Workers specialize in performing one or two operations. Details are transferred from operation to operation piece by piece. In the conditions of mass production, the importance of organizing interoperational transportation increases, Maintenance work places. Constant monitoring of the state of the cutting tool, fixtures, equipment is one of the conditions for ensuring the continuity of the production process, without which the rhythm of work on sites and in workshops is inevitably disturbed. The need to maintain a given rhythm in all stages of production is becoming a distinctive feature of the organization of processes in mass production.

Mass production provides the most complete use of equipment, a high overall level of labor productivity, and the lowest cost of manufacturing products. In table. 1.1 presents data on the comparative characteristics of various types of production.

Table 1.1 Comparative characteristics various types of production

Compared				Type of production
signs		singular			serial		massive
Nomenclature		unlimited					limited
output volume		nomenclature		nomenclature			nomenclature
		manufactured according to		manufactured			manufactured in
				parties
							quantities
Repeatability		missing		periodical			constant
Applicability		universal		partly special				mostly
equipment							special
Anchoring		missing		limited			one, two	operations
operations				operation-detail			on the machine
machines
Location
equipment		homogeneous machines		processing			technological
				constructively			process	processing
				technologically
				homogeneous parts
Transfer of items		consistent		parallel			parallel
labor from operation				parallel
for surgery
Form of organization		technological		subject			rectilinear
production
process

1.4. Organization of the production process

v space and time

Building a rational production structure enterprises are carried out in the following order:

- the composition of the enterprise's workshops, their capacity in sizes that ensure a given output of products are established;

- the areas for each workshop and warehouse are calculated, their spatial arrangements are determined in the master plan of the enterprise;

- all transport links within the enterprise are planned, their interaction with national (external for the enterprise) routes;

- the shortest routes of intershop movement of objects of labor in the course of the production process are outlined.

The production units include workshops, sections, laboratories in which the main products (manufactured by the enterprise), components (purchased from outside), materials and

semi-finished products, spare parts for product maintenance and repair during operation; various types of energy are produced for technological purposes, etc.

TO subdivisions serving employees include housing and communal departments, their services, kitchen factories, canteens, canteens, kindergartens and nurseries, sanatoriums, boarding houses, rest houses, dispensaries, medical units, voluntary sports societies, departments of technical training and schools involved in improving production qualifications, the cultural level of workers, engineering and technical workers, employees.

The main structural production unit of an enterprise (except for enterprises with a non-shop management structure) is a workshop - an administratively separate link that performs a certain part of the overall production process (production stage).

Workshops are full-fledged subdivisions; they carry out their activities on the principles of cost accounting. In mechanical engineering, workshops are usually divided into four groups: main, auxiliary, secondary and auxiliary. In the main workshops, operations are carried out for the manufacture of products intended for sale. The main workshops are divided into procurement, processing and assembly.

TO blanks include foundries, forging and stamping, forging and pressing, sometimes workshops for welded structures; to processing

- machining, woodworking, thermal, electroplating, protective and decorative coatings of parts, assembly shops - aggregate and final assembly of products, their painting, completing with spare parts and removable equipment.

Auxiliary workshops - tool, non-standard equipment, model, repair, energy, transport.

By-products - shops for recycling and processing of metal waste by casting and pressing chips into briquettes, shops for consumer goods. Ancillary - workshops that manufacture containers for product packaging, sawn timber, perform conservation of products, package them, load them and send them to the consumer.

In addition to these workshops, almost every machine-building plant has production workshops, services and departments serving non-industrial facilities (municipal, cultural and household, housing, etc.).

A certain place in the structure of all machine-building plants is occupied by warehousing, sanitary facilities and communications (electricity networks, gas and air pipelines, heating, ventilation, well-maintained roads for rail and trackless transport, etc.).

A special role in the production structure of the association (enterprise) is played by design, technological divisions,

research institutes and laboratories. They develop drawings, technological processes, carry out experimental work, bring product designs to full compliance with the requirements of GOST, specifications, experimental and experimental design work is being carried out. In these subdivisions, the integration of science with production is manifested with particular force.

The workshops include main and auxiliary production sites.

The main production sites are created according to the technological or subject principle. In areas organized according to the principle of technological specialization, technological operations of a certain type are performed. In a foundry, for example, sections can be organized in the following technological areas: land preparation, production of rods, casting molds, processing of finished castings, etc., in a forging shop - sections for the manufacture of forged blanks on hammers and presses, heat treatment, etc., in the mechanical - turning, turret, milling, grinding, metalwork and other sections, in the assembly - sections of the nodal and final assembly of products, testing their parts and systems, control and testing station, painting, etc.

In areas organized according to the principle of subject specialization, not individual types of operations are carried out, but technological processes as a whole, as a result, finished products for this area are obtained.

The auxiliary ones include the sections of the chief mechanic and the chief power engineer for the current repair and maintenance of machining and power equipment; a tool and distribution pantry with a grinding workshop, a transport service, a workshop for the repair and maintenance of technological equipment, etc.

At centralized system service organizations and current repair at the enterprise, auxiliary sections in the shops are not created.

Auxiliary shops and sections are organized according to the same criteria as the shops and sections of the main production.

The constant appeal of the company's managers to the factors external environment allows you to change the management structure in a timely manner in order to contribute to the stability of the enterprise and its flexible response to market fluctuations in the market environment. That is why the organization of production management (territorial, transport, resource, technological, and other factors) should be considered as a system of actions that guides the development of an enterprise.

The production structure is influenced by a number of factors:

Industry affiliation of the enterprise - the range of products, its design features, materials used, methods of obtaining and processing blanks; simplicity of design and manufacturability of the product; the level of requirements for product quality; type of production, level of its specialization and cooperation;

composition of equipment and technological equipment (universal, special, non-standard equipment, conveyor or automatic lines):

- centralized or decentralized organization of equipment maintenance, its current repair and technological equipment;

- the ability of production to quickly and without large losses be reorganized to produce new products in a modified product range;

- the nature of the production process in the main, auxiliary, secondary and auxiliary shops.

Production structure of the enterprise various industries has its own characteristics arising from the nature of the main production.

At textile factories, in most cases, a technological structure operates with the simultaneous specialization of individual sections for certain yarn numbers and rough articles. The largest number of factories has all stages of fabric production: spinning, weaving, finishing. Some factories specialize in one or two stages.

At metallurgical plants, the technological structure prevails. Pilot, blast-furnace, steel and rolling shops are being set up.

General in the production structure of enterprises in various industries

- organization of auxiliary and service farms. Shops of the chief power engineer and chief mechanic, transport and storage facilities are available at the enterprise of any industry. At the machine-building plant there is always a tool shop, at the textile factory there are felling and shuttle workshops that manufacture tools for textile production.

The question of choosing and improving the production structure of an enterprise (association) should be addressed both in the construction of new enterprises and in the reconstruction of existing ones.

The main ways to improve the production structure:

- enlargement of enterprises and workshops;

- search and implementation of a more perfect principle of building workshops

and manufacturing enterprises;

- observance of a rational ratio between the main, auxiliary and service shops;

- constant work to rationalize the planning of enterprises;

- integration of individual enterprises, creation of powerful industrial and research and production associations based on the concentration of production;

- ensuring proportionality between all parts of the enterprise;

- change in the production profile, i.e. nature of output, specialization and cooperation; development of combined production; achievement constructive and technological homogeneity

products due to wide unification and standardization; creation of a non-workshop enterprise management structure. The enlargement of enterprises and workshops makes it possible to introduce new high-performance machinery on a larger scale, constantly improve technology, and improve the organization of production.

Identification and implementation of reserves for improving the structure of shops and production sites are factors in the continuous improvement of the production structure, increasing production efficiency.

Compliance with a rational ratio between the main, auxiliary and service shops and sections should be aimed at increasing the share of the main shops in terms of the number of employed workers, the cost of fixed assets, and the size of the occupied areas.

Rationalization of planning implies the improvement of the master plan of the enterprise.

The quality of the use of available opportunities, resources and a favorable market environment is associated at the enterprise with the mechanism of production planning. Construction of the optimal in terms of possible change the market situation of the plan is the key to the implementation of the internal stability of the enterprise in the external economic environment. That is why you should pay special attention to the production planning material.

The master plan is one of the most important parts of the project of an industrial enterprise, containing a comprehensive solution to the issues of planning and landscaping, placement of buildings, structures, transport communications, engineering networks, organization of household and consumer services systems, as well as the location of the enterprise in an industrial area (node).

The master plan is subject to high requirements, the main of which are:

1) location of production units strictly in the course of the technological process - warehouses of raw materials, materials and semi-finished products, procurement, processing, assembly shops, warehouses finished products;

2) placement of auxiliary sites, farms near the main production shops that they serve;

3) rational arrangement of railway tracks within the enterprise. They should be connected both to the premises of warehouses for raw materials, materials and semi-finished products, and to the warehouse of finished products, where products are completed with removable equipment, spare parts, conservation, packaging, capping, loading, sending products to the consumer;

4) the greatest straightness and the shortest ways of transportation of raw materials, materials, semi-finished products and finished products;

5) exclusion of counter and return flows both indoors and outdoors;

6) the most appropriate options for the location of external communications of the enterprise and their connection to engineering networks, highways, railways, etc.

7) placement in blocks of workshops of laboratories (measuring, chemical, X-ray control, ultrasound, etc.), serving them, as well as shops for heat treatment and protective coatings of parts, finished products.

At large enterprises, it is advisable to combine workshops into buildings. When designing enterprises, care must be taken

building compactness. Depending on the nature of the product, its design features, it is possible to build multi-storey buildings. Choose rational distances between shops, blocks of shops and buildings, observing sanitary and technical conditions, safety and fire safety requirements.

The master plan should also provide for the possibility further development enterprises and provide such a production structure in which the highest production results can be achieved at the lowest cost; create conditions for maximum satisfaction of the interests of all employees of the enterprise.

Placement of the main, auxiliary, secondary, auxiliary workshops

and sites serving farms, governments, transport routes on the territory of the enterprise has a huge impact on the organization of production, its economy;

determines the direction of cargo flows, the length of rail tracks

and trackless tracks, as well as the efficiency of the use of production areas.

The compactness of the building, its rational density and number of storeys make it possible to save capital investments, reduce the volume construction works and intra-factory transportation, reduce the length of communications, shorten the duration of the production cycle, implement on a wider scale comprehensive mechanization and automation of production and auxiliary processes, reduce the time spent by finished products in the warehouse, increase labor productivity, improve product quality, and reduce its cost.

The task of employees of design institutes, engineering and technical workers and production workers of industrial enterprises is the constant improvement of the production structure, the location of workshops and production sites. Particularly serious attention to this issue must be paid during the period of reconstruction, technical re-equipment, expansion of the enterprise and new construction. Improvement of the master plan of the plant is a manifestation of concern for increasing production efficiency, improving the quality of products and working conditions.

Analysis of information on the dynamics of the internal support of the production of the enterprise and the demand for its products on the market is a condition qualitative assessment its sustainability. At the same time, paying attention to the maintenance of production in the enterprise can reveal the factors of the ability or inability of the enterprise and sustainable development in the future. At the same time, the mechanism of such an analysis can be fixing the relationship between the properties of service and the goals of providing general characteristics production service at the enterprise.

The form of organization of production is a certain combination in time and space of the elements of the production process with an appropriate level of its integration, expressed by a system of stable relationships.

Various temporal and spatial structural constructions form a set of basic forms of organization of production. The temporary structure of the organization of production is determined by the composition of the elements of the production process and the order of their interaction in time. According to the type of temporary structure, forms of organization are distinguished with sequential, parallel and parallel-sequential transfer of objects of labor in production.

The form of organization of production with the sequential transfer of objects of labor is such a combination of elements of the production process, which ensures the movement of processed products in all production areas in batches of arbitrary size. The objects of labor for each subsequent operation are transferred only after the completion of the processing of the entire batch at the previous operation. This form is the most flexible in relation to changes that occur in the production program, allows you to fully use the equipment, which makes it possible to reduce the cost of its purchase. The disadvantage of this form of organization of production lies in the relatively long duration of the production cycle, since each part, before performing the next operation, lies in anticipation of processing the entire batch.

The form of organization of production with the parallel transfer of objects of labor is based on such a combination of elements of the production process that allows you to start, process and transfer objects of labor from operation to operation piece by piece and without waiting. This organization of the production process leads to a reduction in the number of parts being processed, a reduction in the need for space required for warehousing and aisles. Its disadvantage is the possible downtime of equipment (jobs) due to differences in the duration of operations.

The form of organization of production with parallel-sequential transfer of objects of labor is intermediate between

serial and parallel forms and partially eliminates their inherent disadvantages. Products from operation to operation are transferred by transport parties. This ensures the continuity of use of equipment and work force, partially parallel passage of a batch of parts through the operations of the technological process is possible.

The spatial structure of the organization of production is determined by the amount of technological equipment concentrated on the work site (the number of jobs) and its location relative to the direction of movement of objects of labor in the surrounding space. Depending on the number of technological equipment (jobs), a single-link production system and the corresponding structure of a separate workplace and a multi-link system with a workshop, linear or cellular structure are distinguished. Possible options for the spatial structure of the organization of production are presented in fig. 1.2. The workshop structure is characterized by the creation of sites where the equipment (jobs) is located parallel to the flow of workpieces, which implies their specialization on the basis of technological homogeneity. In this case, a batch of parts arriving at the site is sent to one of the free workplaces, where the necessary processing cycle goes through, after which it is transferred to another site (to the workshop).

Rice. 1.2. Variants of the spatial structure of the production process

On a site with a linear spatial structure, equipment (jobs) is located along the technological process and a batch of parts processed on the site is transferred from one job to another sequentially.

The cellular structure of the organization of production combines the features of a linear and shop floor. The combination of spatial and temporal structures of the production process at a certain level of integration of partial processes determines various forms of organization of production: technological, subject, direct-flow, point, integrated (Fig. 1.3). Consider the characteristic features of each of them.

Rice. 1.3. Forms of organization of production

The technological form of the organization of the production process is characterized by a shop structure with a consistent transfer of objects of labor. This form of organization is widespread in machine-building plants, because it provides maximum equipment utilization in small-scale production and is adapted to frequent changes in the technological process. At the same time, the use of a technological form of organization of the production process has a number of negative consequences. A large number of parts and their repeated movement during processing lead to an increase in the volume of work in progress and an increase in the number of intermediate storage points. A significant part of the production cycle is the loss of time due to complex inter-sectional communication.

The subject form of the organization of production has a cellular structure with a parallel-sequential (sequential) transfer of objects of labor in production. On the subject area, as a rule, all the equipment necessary for processing a group of parts from the beginning to the end of the technological process is installed. If the technological processing cycle is closed within the area, it is called subject-closed.

The subject construction of sections ensures straightness and reduces the duration of the production cycle for the manufacture of parts. In comparison with the technological form, the subject one allows to reduce the total cost of transporting parts, the need for production areas per unit of production. However, this form of organization of production also has disadvantages. The main one is that when determining the composition of the equipment installed on the site, the need for certain types processing parts, which does not always provide a full load of equipment.

In addition, the expansion of the range of manufactured products, its renewal require periodic redevelopment of production sites, changes in the structure of the equipment fleet. The direct-flow form of production organization is characterized by a linear structure with a piece-by-piece transfer of objects of labor. This form ensures the implementation of a number of organization principles: specialization, direct flow, continuity, parallelism. Its application leads to a reduction in the duration of the production cycle, more efficient use of labor due to greater specialization of labor, and a decrease in the volume of work in progress.

With a point form of organization of production, work is completely performed at one workplace. The product is manufactured where its main part is located. An example is the assembly of a product with the worker moving around it. The organization of point production has a number of advantages: it provides the possibility of frequent changes in the design of products and the sequence of processing, the manufacture of products of various nomenclature in the quantity determined by the needs of production; costs associated with changing the location of equipment are reduced, production flexibility is increased.

An integrated form of production organization involves the combination of main and auxiliary operations into a single integrated production process with a cellular or linear structure with sequential, parallel or parallel-sequential transfer of objects of labor in production. In contrast to the existing practice of separate design of the processes of warehousing, transportation, management, processing in areas with an integrated form of organization, it is required to link these partial processes into a single production process. This is achieved by combining all jobs with the help of an automatic transport and storage complex, which is a set of interconnected, automatic and storage devices, computer equipment designed to organize the storage and movement of objects of labor between individual jobs.

The management of the production process here is carried out using a computer, which ensures the functioning of all elements of the production process at the site according to the following scheme: search

the necessary workpiece in the warehouse - transportation of the workpiece to the machine - processing - return of the part to the warehouse. To compensate for deviations in time during transportation and processing of parts, buffer warehouses of inter-operational and insurance reserves are created at individual workplaces. The creation of integrated production sites is associated with relatively high one-time costs caused by the integration and automation of the production process.

The economic effect in the transition to an integrated form of production organization is achieved by reducing the duration of the production cycle for manufacturing parts, increasing the loading time of machine tools, and improving the regulation and control of production processes. On fig. 1.4 shows the layout of equipment in areas with various form organization of production.

Rice. 1.4. Layouts of equipment (workplaces) at sites with various forms of production organization:

a) technological; b) subject; c) straight-through; d) point (for the case of assembly); e) integrated

The basis of the production and economic activity of the enterprise is the production process. The manufacturing process is purposeful processes activities of employees (technology) of a particular enterprise, which, using a variety of tools, turn raw materials, objects of labor into products ready for consumption or further processing (processing).

The objects of labor and tools of labor are deciphered through the means of production. At the same time, the objects of labor are part of the means of production. Materials that people act on with the help of tools: a variety of raw materials, materials and semi-finished products, they also include purchased products as components. Tools of labor are another part of the means of production, with the help of which or through which a person acts on objects, objects of labor. In accordance with GOST 2.101-68, a product is any item or set of production items to be manufactured at the enterprise. The use of the term “product” is common in the defense industries, as well as in mechanical engineering, wherever design documentation is actively used. As a synonym for the term "product", the term "product" is often used in practice. On fig. 3.1 illustrates the use of the above concepts.

The process of production of each individual type of product of the enterprise is called a private production process. At the same time, the production process at the enterprise as a whole can be divided into partial production processes (for example,

Purposeful activity of the worker with the help of tools

Rice. 3.1. An illustration to the concepts through which the production process is determined, the manufacture of individual components of the product or the implementation of a certain stage in the process of creating the product).

Technological processes are called complexes of works on extraction, processing, processing, transportation, warehousing, storage, which are the main integral part production process (i.e. partial production processes).

To select production processes for use in specific conditions of the enterprise, they are classified.

The classification of private and partial production processes can be based on the following criteria:

• roles in the overall production process;
• the nature of the object of production (product);
• the method of obtaining end products;
• degree of continuity;
• the way the labor force is used;
• the level of mechanization and automation;
• the form of impact on the objects of labor;
• the scale of production of homogeneous products;
• the nature of the impact on the object of labor;
• form of resource use;
• work packages.

In the following, we will use the concept of "production process" realizing that the same can be said about private and partial production processes. The choice is always determined by the specific situation.

According to their role in the overall production process, private and partial production processes are divided into:

• the main ones are technological processes that specify changes in the physical and chemical properties, geometric shapes and sizes of products to obtain the characteristics of a future product. These include preparatory, procurement, processing, assembly and finishing, picking, natural processes and finishing;
• processes (including technological ones), which are aimed at assisting in the manufacture and ensuring the continuous flow of the main technological processes. For example: production and repair of equipment and tools; annealing, hardening of parts, electroplating, painting, etching, etc.; repair, construction and installation processes, energy production processes;
• service - these are the processes associated with the maintenance of both the main and auxiliary processes; while the products are not created. These include processes such as storage of parts, assemblies, finished products, their transportation, technical control and others, including transport and support, energy supply, logistics; repair of equipment, buildings and structures, recreation, sanatoriums and hygiene;
• managerial - these are the processes associated with the management of the main, auxiliary and service processes. At present, these processes are computerized due to computerization. These include: forecasting and planning, control, accounting and analysis, organization, regulation and coordination, creation of design and technological support, etc.

By the nature of the object of production of the product, production processes are divided into complex and simple. The former are used in the manufacture of complex products, as well as products created from a large number of components. For the manufacture of the latter, one or a small number of components are used, the corresponding production process is called simple. The division into simple and complex processes is of great importance in the organization of production at the enterprise.

According to the method of obtaining final products, production processes are divided into direct, analytical and synthetic. In a direct process, from one type of raw material (material) one type of semi-finished products or finished product is obtained. Processes, as a result of which several types of products are obtained from one type of raw material, are called analytical. At the same time, the process in which one type of finished product is obtained from several types of raw materials is called synthetic.

An example of a direct process is coal mining, which is a finished product. As a rule, direct processes are used in small-scale industries with a small number of stages in the processing of feedstock. An example of analytical processes is production, where complex raw materials are separated: ore, oil, milk, from which various products are obtained. Analytical processes are used in the refinery and chemical industry. Synthetic processes are widely used in mechanical engineering.

According to the degree of continuity, production processes are divided into continuous and discontinuous (discrete). V continuous processes there are no interruptions in the transfer of objects of labor from one workplace to another. Production maintenance operations are carried out simultaneously or in parallel with the main operations. In contrast, in discontinuous or discrete processes, the execution of basic and maintenance operations occurs sequentially, for this reason the main production process is interrupted in time.

According to the way the labor force is used, production processes are divided into hardware (closed) and open (local). The instrumental technological process provides a change in the physical and chemical properties of the object of labor under the influence chemical reactions, thermal energy, various kinds of radiation, biological objects. Hardware processes take place in devices of various design forms - furnaces, chambers, baths, vessels, etc. In these processes, the function of the worker is to manage and maintain the corresponding equipment indirectly, the predominance of this function is a classifying feature of the hardware process. Such a product may differ from raw materials in chemical composition, structure and state of aggregation. These processes prevail in the chemical, metallurgical, food, microbiological industries. V open processes the worker processes the objects of labor using a set of tools and mechanisms directly.

According to the level of mechanization and automation, partial production processes are divided into five levels: manual, machine-manual, machine, automated, complex-automated. In particular, manual processes are performed without the use of machines, mechanisms and mechanized tools. For this reason, the process of processing objects of labor is long, and the number of products produced in this way is insignificant. The consequence of this is the high cost of such a product, which is basically determined by the cost of a man-hour.

Machine-manual and machine processes proceed with the use of machines, machine tools and mechanisms. The difference arises in the degree of direct participation of the worker: the share of manual labor is large in machine-manual processes, it is also preserved in machine processes, but on a limited scale.

In automated processes, work is done by automatic machines, and the function of the worker is to control and manage the progress of production, in other words, the creation of the product occurs with the indirect participation of the worker.

If in automated process to carry out automatic operational control, then such a process is called complex-automated.

For better memorization, the levels of mechanization and automation are shown in Fig. 3.2. Technological progress changes the system of levels, reducing the share of manual labor everywhere, which changes the structure of the distribution of production processes in economies

Rice. 3.2.

countries towards increasing the share of automated and complex-automated production processes.

According to the form of impact on the objects of labor, production processes are divided into: mechanical, physicochemical, biological, assembly and disassembly (mounting and dismantling), conservation (for example: lubrication, painting, packaging, placement in an inert environment, etc.) . The use of these forms of influence on objects of labor in order to obtain products requires a different composition of equipment, maintenance methods, and spatial planning. The difference is significant. This determines the usefulness of using the classification on this basis in practice.

According to the scale of production of homogeneous products, production processes are divided into mass, serial and individual (single). The mass production process is characterized by the constant release of a strictly limited range of products with a low level of diversity in large quantities. Mass production process is applied in auto industry, footwear industry, computer industry. The serial production process is characterized by the constancy of the release of a wide range of products in batches with a set frequency. The size of batches (series) from enterprise to enterprise can vary significantly (change). The serial production process is widely used in mechanical engineering, machine tool building, furniture industry, etc. The individual (single) production process is characterized by piece production of products with unique properties. In this case, a lot of manual labor of generalists is used. Widely used in heavy machinery, space industry, manufacturing jewelry and in a number of other areas. In pilot production, individual production processes are used to a large extent.

According to the nature of the impact on the object of labor, production processes are divided into technological and natural. Natural processes differ from technological ones in that in them the physical state of the objects of labor changes due to the forces of nature, while in technological processes the change occurs due to the use of living and materialized labor. Natural production processes are sometimes considered as necessary technological breaks between operations (for example: cooling, drying, aging, etc.).

The presence of natural processes in production is due to the low cost of these processes, but the need to increase the output of products in a shortened time continuously reduces the share of natural production processes in industry. Natural processes can be part of technological processes, then they are called natural technological processes.

According to the form of resource use, production processes are divided into pull and push. A pull process is an on-demand process where a customer pulls a product and/or service that they want from a company. The production process in these cases serves the flow of single orders. Accordingly, this order of the consumer "pulls" the minimum amount of resources required for the execution of this particular order from suppliers, thereby generating minimal costs. It is important that real consumer demand "stretches" through the entire system. In the environment of "pull" production, the tendency of overproduction is controlled. The absence of overproduction on the same equipment makes it possible to serve more orders than before, while at the same time rationalizing the cost of the "pull" system or reducing redundant equipment. An example is the production system of a company Toyota (just in time).

In the traditional push production process (pych system) the system encourages each resource to be used in production to the maximum extent possible, thus "pushing" products through the system. Attention is focused on maintaining the necessary stock, its decrease is immediately compensated. This creates redundant inventory in warehouses and additional costs for work in progress. The "push" mentality based on the traditional predictive production-distribution approach will increasingly become a thing of the past thanks to today's information technology. Markets are so dynamic today that last year's demand is weakly related to what will happen this year, and historical forecasts in this context lose their appeal. At the forefront is the monitoring of actual consumer demand.

According to the complexes of works, production processes are divided into phases (synonymous - stages). Phase (stage) is a set of works, the performance of which characterizes the completion of a certain part of the technological process, and is associated with the transition of the object of labor from one qualitative state to another. In mechanical engineering and instrumentation, technological processes are mainly divided into three phases: procurement, processing and assembly. The procurement phase includes the processes for obtaining blanks. These may include methods of casting, stamping, upsetting, pressing, cutting materials, etc. The processing phase covers the processes of converting blanks into finished parts. For example: stamping, mechanical, chemical, thermal and plasma treatments, galvanic and paint coatings, welding, etc. The assembly phase includes the creation of assembly units, kits and complexes, as well as their adjustment, adjustment and testing.

The sequence of changing the phases of the technological process is shown in fig. 3.3.

Production processes in enterprises are detailed in content through not only classified production processes, but also by classifying operations and actions. Therefore, each production process can be represented as a series of more fractional technological actions - operations, sequentially performed on a given object of labor. In this case, an operation is understood as a part of the production process performed at one workplace (machine, stand, unit, etc.) and consisting of a series of actions on each object of labor or a group of jointly processed objects. Operations, as a rule, are technologically homogeneous parts of production

Rice. 3.3. Change of phases of the technological process of the process, while the production process itself is almost always heterogeneous.

Operations that do not lead to a change in the physicochemical, biological properties of objects of labor, geometric shapes, sizes are called non-technological operations (for example: transport, handling, control, testing, picking, and others).

All other operations, as well as production processes, are divided into main and auxiliary. The main operations change the properties of the objects of labor, their shapes and sizes, while the auxiliary operations do not.

Depending on the type of product and its purpose, the level of technology and industry affiliation, operations, as well as production processes, are divided into manual, machine-manual, machine, and automated operations. Manual operations are carried out without the use of machines and mechanisms, using a simple tool, such as manual loading of raw materials, manual painting of a product, manual work on setting up and adjusting machines. In manual operations, machines and mechanisms are used, but with the obligatory continuous participation of workers, while part of the labor is manual. Working on simple machines, such as milling, drilling, turning, combined with manual labor is an example of this type of operation. Machine operations occur with limited participation of workers. Workers mainly monitor the progress of the machine process, exercising its control, and also install, fix, start and stop the machine, unfasten and remove the part. Automated operations are mainly performed on automated lines and automatic equipment. The combination of machine and automated operations in special units, such as furnaces, installations, baths, etc., gives rise to the concept of "hardware operations".

The same operation can be performed by different sets of actions. This means that when describing operations in terms of actions, it is fundamentally impossible to do this unambiguously. Therefore, there is always a choice and this must be remembered.

Thus, any production process can be described in the following terms - production processes, classified production processes, classified operations and actions (Fig. 3.4).

Descriptions of production processes at the level of their classification are of a generalized nature and are widely used in industrial relations. Descriptions at the level of operations are mainly used by a narrower circle of specialists for the purpose of training, organizing and reorganizing production processes in practice.

Rice. 3.4.

tick. The classification of operations according to various characteristics is much more extensive than the classification according to characteristics for the production process. The activity (element) level is used by process engineers to change operations, create new operations, develop new methods for analyzing and managing production processes. The classification of actions is also very extensive.

An example of using the concept of "action" to create a new approach in describing the production process is the method developed by Shigeo Shingo for controlling the rate of changeover of equipment. (SMED - Single-Minute Exchange of Die) , which is applicable to almost any equipment and process in production. Method SMED makes it possible in 15 minutes to reconfigure the whole plant from the production of one product model to another, including the change of not only tools and fixtures, but also computer programs, document forms, auxiliary materials, etc. It allows you to reduce the inventory of work in progress by 90%. The method has been developed and distributed in the world for more than 25 years. The general conclusion is: modern industry Apparently, there is no equipment that would require a changeover stop for more than 10 minutes, in most difficult cases 3 minutes will be enough. Simple cases do not require time at all.

For the first time this method was applied in the production process of the company Toyota (TPS). V TPS production is carried out to order, i.e. Implemented a pull production process. This led to a one-off flow, requiring frequent changeovers of equipment that took from a few minutes to several hours. The reduction of these breaks in work to a few minutes was facilitated by the method SMED or the Shinto method. Its essence consists in dividing the actions for the readjustment of equipment into internal and external and converting internal actions into external ones, with the subsequent simplification of all selected actions. Internal actions are called personnel actions when the equipment does not stop, external actions are actions when it is necessary to stop the line or equipment in operation. This approach radically restructures the entire production process at the enterprise.

The importance of the Shingo method can be illustrated by data from a study by the company InforAG in 2002 among 400 enterprises in Germany and other European countries, which showed insufficient control over costs and delays in production processes. Manufacturing companies in the middle sector of the market have large reserves of capacity that are not used in production processes: almost 2 / 3 companies use less than 85% of production capacity. According to company representatives, the main disadvantages are insufficient control over costs (71% of respondents) and delays in production processes (69%). That is why the optimization of production processes is among the tasks with a "high" or "very high" priority in the business plans of 53% of companies.

• Shingo S. The study of the Toyota production system from the point of view of the organization of production / Per. from English. M.: Institute of complex strategic research, 2006.

The production process consists of partial processes, which can be divided into groups according to the following criteria:

According to the method of execution: manual, mechanized, automated.

By purpose and role in production: main, auxiliary, serving

The main production processes are those processes that are directly related to the transformation of the object of labor into finished products. For example, in mechanical engineering, the result of the main processes is the production of machines, apparatus and instruments that make up the production program of the enterprise and correspond to its specialization, as well as the manufacture of spare parts for them for delivery to the consumer. The totality of such partial processes constitutes the main production.

Ancillary manufacturing processes are processes that create the necessary conditions to create finished products, or create finished products, which are then consumed in the main production at the enterprise itself. Auxiliary are the processes for the repair of equipment, the manufacture of tools, fixtures, spare parts, mechanization and automation. own production, production of all types of energy. The totality of such partial processes constitute auxiliary production.

Servicing production processes - during the implementation of such processes, products are not produced, but services necessary for the implementation of the main and auxiliary processes are performed. For example, transportation, warehousing, issuance of all types of raw materials and materials, control of the accuracy of instruments, selection and assembly of parts, technical control of product quality, etc. The totality of such processes constitutes service production.

Helper process. A process that contributes to the normal flow of the main process of transforming the object of labor and is associated with the provision of the main process with equipment, fixtures, cutting and measuring tools, fuel and energy resources.

service process. A process that is not specifically related to this subject of labor, ensuring the normal flow of the main and auxiliary processes by providing transport services, logistics services at the "input" and "output" of the organization.

The main production processes take place in the following stages: procurement, processing, assembly and testing stages.

The procurement stage is intended for the production of blank parts. A feature of the development of technological processes at this stage is the approximation of blanks to the shapes and sizes of finished parts. It is characterized by a variety of production methods. For example, cutting or cutting blanks of parts from a material, manufacturing blanks by casting, stamping, forging, etc.

The processing stage is the second in the course of the production process. The subject of labor here is the blank parts. The tools of labor at this stage are mainly metal-cutting machines, furnaces for heat treatment, and apparatus for chemical processing. As a result of this stage, the parts are given dimensions corresponding to the specified accuracy class.

The assembly stage is a part of the production process, as a result of which assembly units or finished products are obtained. The subject of labor at this stage are components and parts of our own production, as well as those received from outside (component products). Assembly processes are characterized by a significant volume handmade Therefore, the main task of the technological process is their mechanization and automation.

The testing stage is the final stage of the production process, the purpose of which is to obtain the necessary parameters of the finished product. The subject of labor here are finished products that have passed all the previous stages.

The constituent elements of the stages of the production process are technological operations.

A production operation is an elementary action (work) aimed at transforming the object of labor and obtaining a given result. The production operation is a separate part of the production process. Usually it is performed at one workplace without readjustment of equipment and is performed using a set of the same tools.

Production is the central link of the enterprise, where the final product is created, which has the specified consumer properties. Production is the creation of material goods necessary for the existence and development of society. The content of production determines labor activity, which includes the following points:

Purposeful work or work itself;

The subject of labor, i.e., everything that a person’s labor is aimed at;

Means (tools) of labor - machines, equipment, tools with which a person transforms the objects of labor.

The result of material production is the creation final product, which has given consumer properties. A product is any object or set of objects of labor to be manufactured at an enterprise.

The production process is a set of all actions of people and means of production aimed at manufacturing products. The production process consists of the following processes:

The main ones are technological processes during which changes in the geometric shapes, sizes and physical and chemical properties of products occur;

Auxiliary - these are processes that ensure the uninterrupted flow of the main processes (manufacturing and repair of tools and equipment; repair of equipment; provision of all types of energy (electric, thermal, steam, water, compressed air, etc.);

Servicing - these are processes associated with the maintenance of both main and auxiliary processes, but as a result of which products are not created (storage, transportation, technical control, etc.).

In the conditions of automated, automatic and flexible integrated production, auxiliary and service processes are to some extent combined with the main ones and become an integral part of the production processes.

Technological processes, in turn, are divided into phases. Phase - a set of works, the performance of which characterizes the completion of a certain part of the technological process and is associated with the transition of the object of labor from one qualitative state to another. The technological process consists of technological actions, operations, sequentially performed on a given object of labor. An operation is a part of a technological process performed at one workplace (machine, bench, unit, etc.), consisting of a series of actions on each object of labor or a group of jointly processed objects. Operations that do not lead to a change in the geometric shapes, sizes, physical and chemical properties of objects of labor are non-technological operations (transport, loading and unloading, control, testing, picking, etc.).

Operations also differ depending on the means of labor used:

• manual - performed without the use of machines, mechanisms and mechanized tools;
• machine-manual - performed with the help of machines or hand tool with the continuous participation of the worker;
• machine - performed on machines, installations, units with limited participation of the worker (for example, installation, fixing, starting and stopping the machine, unfastening and removing the part, etc.);
• automated - performed on automatic equipment or automatic lines.

The organization of production is a set of methods that ensure the most appropriate connection and use in time and space of the means of labor, objects of labor and labor itself in order to effectively conduct production processes and business activities in general.

The nature and structure of production depend on the characteristics of the products being manufactured, the type of production, the tools and objects of labor used, and technological processes.

Production structure of the enterprise

The production structure of an enterprise is the composition and relationship between its production units. The production structure characterizes the division of labor between the divisions of the enterprise and their cooperation. It influences technical economic indicators production, enterprise management structure, organization of operational and accounting.

The production structure consists of four stages: production, workshop, production site, workplace.

Main production determines the profile this enterprise. This is the part of the enterprise where the production of the main products takes place, it covers all the processes associated with the transformation of raw materials into finished products. The results of the activity of the entire enterprise depend on the organization of the work of the main production.

Ancillary production consists of the processes of material and technical maintenance of the main production. To workshops auxiliary production include instrumental, repair, energy. The number of auxiliary workshops and their size depend on the scale of production and the composition of the main workshops.

Service production ensures the uninterrupted operation of the main production (warehouse, transport facilities).

Side production produces products from the waste of the main production.

On the basis of the production structure, a general plan of the enterprise is developed, i.e., the spatial arrangement of all shops and services, as well as routes and communications on the territory of the plant. In this case, the direct flow of material flows should be ensured. Workshop and must be located in the sequence of the production process.

The workshop is the main structural unit of the enterprise. It is endowed with a certain production and economic independence, is a separate organizational, technical and administrative production unit and performs the tasks assigned to it. production functions. Each workshop receives a single plan task that regulates the amount of work performed, quality indicators and marginal costs for the planned amount of work.

The workshop and sections are created according to the principle of specialization:

• technological;
• subject;
• subject-closed;
• mixed.

Technological specialization is based on the unity of applied technological processes. At the same time, a high loading of equipment is ensured, but operational and production planning becomes more difficult, the production cycle is lengthened due to increased transport operations. Technological specialization is used mainly in single and small-scale production.

Subject specialization is based on the concentration of the activities of shops (sections) on the production of homogeneous products. This allows you to concentrate the production of a part or product within a workshop (site), which creates the prerequisites for organizing direct-flow production, simplifies planning and accounting, and shortens the production cycle. Subject specialization is typical for large-scale and mass production.

If a complete cycle of manufacturing a part or product is carried out within a workshop or site, this unit is called subject-closed.

The workshop and (sections) organized according to the subject-closed principle of specialization have significant economic advantages, since this reduces the duration of the production cycle as a result of the complete or partial elimination of oncoming or return movements, reduces the loss of time for equipment changeover, simplifies the planning system and operational management of production.

A production site is a subdivision that unites a number of jobs grouped according to certain characteristics, which carries out part of the production process for the manufacture of products or maintenance of the production process. The production areas connected with each other are specialized in detail and technologically.

The workplace is a link in the production process, served by one or more workers. The workplace is designed to perform a specific production or service operation and is equipped with appropriate equipment and organizational and technical means.

Production types

The type of organization of production is understood as a complex characteristic of the characteristics of the organization and technical level industrial production. The type of production has a great influence on the scale of the enterprise, the formation of its structure, conditions, requirements and criteria for the rational organization of production. Type of production - a set of its organizational, technical and economic features. The type of production is determined by the following factors:

• the range of manufactured products;
• release volume;
• the degree of constancy of the range of manufactured products;
• the nature of the workload.

There are three main types of production - single, serial, mass. Single production provides for the piece production of products of a diverse and non-permanent nomenclature of limited consumption.

The most important features of this type of production are as follows:

• versatility of manufactured products, often non-repeating;
• organization of jobs for technological specialization;
• use of universal equipment and technological equipment;
• the presence of a large amount of manual operations;
• a large proportion of highly skilled general workers employed in the production process;
• significant duration of the production cycle;
• a significant amount of work in progress;
• decentralization of operational and production planning and production management;
• a relatively high proportion of production waste;
• relatively high labor costs.

Serial production involves the simultaneous production of a wide range of homogeneous products in series, the release of which is repeated for a long time. In mass production, products are produced in batches.

A production batch is a group of products of the same name and size, launched into production within a certain time interval with the same preparatory and final time for the operation. Operational batch - a production batch or part of it that enters the workplace to perform a technological operation.

Key Features:

• the constancy of a relatively large range of repetitive products manufactured in significant quantities;
• specialization of jobs to perform several fixed operations;
• the frequency of manufacturing products in series, processing parts in batches;
• the predominance of special and specialized equipment and technical equipment, etc.

Depending on the number of simultaneously manufactured products in a series, small-, medium- and large-scale production is distinguished.

Mass production is characterized by continuity and a relatively long period of production of a limited range of homogeneous products in large quantities. Enterprises with mass production include, for example, watch factories, sewing and knitting factories, etc.

Mass production - highest form specialization of production, which makes it possible to concentrate on the enterprise the production of one or several standard sizes of products of the same name. An indispensable condition for mass production is the level of standardization and unification of parts of assemblies and assemblies.

The main features of mass production:

• strictly established release of a small nomenclature in large quantities;
• specialization of workplaces to perform, as a rule, one fixed operation;
• location of jobs in the order of operations;
• a large share of special and specialized equipment and technological equipment;
• a large share of complex-mechanized, automated technological processes, etc.

Enterprises, sites and individual jobs are classified according to the types of production. The type of production of an enterprise is determined by the type of production of the leading workshop, and the type of production of the workshop is determined by the characteristics of the site where the most critical operations are performed and the bulk of the production assets are concentrated.

The assignment of a plant to a particular type of production is conditional, since a combination of different types of production can take place at the enterprise and even in individual workshops.

The type of production has a decisive influence on the features of the organization of production, its economic indicators, the cost structure (in single production, the share of human labor is high, and in mass production, the cost of repair and maintenance needs and maintenance of equipment), different levels of equipment.

The production cycle is a calendar period of time during which a material, workpiece or other processed item goes through all the operations of the production process or a certain part of it and turns into a finished product (or into a finished part of it). It is expressed in calendar days or (in case of low labor intensity of the product) in hours.

Distinguish between simple and complex production cycles. A simple production cycle is a part manufacturing cycle. A complex production cycle is a product manufacturing cycle. The duration of the production cycle to a large extent depends on the method of transferring the part (product) from operation to operation. There are three types of movement of a part (product) in the process of its manufacture:

• consistent;
• parallel;
• parallel-serial.

The most cost-effective form of organization of the production process is in-line production, the features of which are:

• assigning one or a limited number of product names to a specific group of jobs;
• rhythmic repetition of technological and auxiliary operations coordinated in time;
• job specialization;
• location of equipment and workplaces along the technological process;
• application of special Vehicle for interoperational transfer of products.

In mass production, the following principles are implemented:

• specializations;
• parallelism;
• proportionality;
• straightness;
• continuity;
• rhythm.

In-line production ensures the highest labor productivity, low cost of production, and the shortest production cycle. The production line is the basis (primary link) of in-line production.

When designing and organizing production lines, calculations are made of indicators that determine the line operation schedule and methods for performing technological operations.

The production line cycle is the time interval between the release of products (parts, assembly units) from the last operation or their launch for the first operation of the production line.

Rhythm is the number of products produced by a production line per unit of time, or the reciprocal of tact. A backlog is a production stock of materials, blanks or constituent parts products to ensure the uninterrupted flow of production processes on production lines.

There are the following types of backlogs:

• technological;
• transport;
• reserve (insurance);
• negotiable interoperational.

Synchronization is the process of equalizing the duration of a process operation according to the cycle of the production line. The operation execution time must be equal to the line cycle or a multiple of it. Synchronization methods:

• differentiation of operations;
• concentration of operations;
• installation of additional equipment;
• intensification of equipment operation (increase in processing modes);
• the use of progressive tools and equipment;
• improving the organization of workplace services, etc.

The highest form of in-line production is automated production, which combines the main features of in-line production with its automation. In automated production, the operation of equipment, assemblies, apparatus, installations occurs automatically according to a given program, and the worker controls their work, eliminates deviations from the given process, and adjusts the automated equipment. Distinguish between partial and complex automation.

With partial automation, the worker is completely released from work related to the implementation of technological processes. In transport, control operations during maintenance of equipment, during the installation process, manual labor is completely or partially reduced.

In conditions of complex automated production the technological process of manufacturing products, the management of this process, the transportation of products, control operations, the removal of production waste are carried out without human intervention, but the maintenance of the equipment is manual.

The main element of automated production are automatic production lines (APL). Automatic production line - a complex of automatic equipment located in the technological sequence of operations, connected by an automatic transport system and a system automatic control and providing automatic transformation of raw materials (blanks) into ready product(for this line). When working on a nuclear submarine, the worker performs the functions of setting up and monitoring the operation of equipment, as well as the function and loading of the line with blanks. The main features of the nuclear submarine:

Automatic execution of technological operations (without human intervention);

Automatic movement of the product between the individual units of the line.

Automatic complexes with a closed cycle of product production - a number of interconnected automatic transport and handling devices automatic lines.

Automated sections (workshops) include automatic production lines, autonomous automatic complexes, automatic transport systems, automatic storage systems; automatic quality control systems, automatic control systems, etc.

In the conditions of a constantly changing unstable market (especially multi-product production), an important task is to increase the flexibility (versatility) of automated production in order to meet the requirements, needs and demands of consumers as much as possible, to master the production of new products faster and at minimal cost.

Automatic production lines are especially effective in mass production. Rapid product changeover and requirements for its low cost high quality(say, in terms of unit production) leads to a contradiction: on the one hand, low production costs (ceteris paribus) are ensured by the use of automatic lines, special equipment; on the other hand, the design and manufacture of such equipment often exceeds 1.5–2 years (even under current conditions), that is, by the time the product is launched, it is already obsolete.

The use of universal equipment (non-automatic) increases the complexity of manufacturing, that is, the price, which is unacceptable for the market. This problem is solved by creating a flexible production system in which integration takes place:

• equipment;
• (blanks, parts, products, fixtures, equipment, basic and auxiliary materials);
• main, auxiliary and service processes of production;
• services by merging all service processes into a single system;
• information flows for decision-making on all divisions of the system, as well as means of displaying information;
• personnel due to the merging of professions (designer-technologist-programmer-organizer).

Source - Enterprise Economics: tutorial/ I. S. Bolshukhina; under total ed. V. V. Kuznetsova. - Ulyanovsk: UlGTU, 2007. - 118 p.

At factories along the way material flow various logistics operations are carried out with it, which together represent a complex process of converting raw materials, materials, semi-finished products and other objects of labor into finished products.
The basis of the production and economic activity of the enterprise is manufacturing process , which is a set of interrelated labor processes and natural processes aimed at manufacturing certain types of products.
The organization of the production process consists in combining people, tools and objects of labor into a single process for the production of material goods, as well as in ensuring a rational combination in space and time of the main, auxiliary and service processes.
Production processes at enterprises are detailed by content (process, stage, operation, element) and place of implementation (enterprise, redistribution, workshop, department, section, unit).
The set of production processes occurring in the enterprise is a total production process. The process of production of each individual type of product of the enterprise is called a private production process. In turn, in a private production process, partial production processes can be distinguished as complete and technologically separate elements of a private production process that are not primary elements of the production process (it is usually carried out by workers). different specialties using equipment for various purposes).
As a primary element of the production process should be considered technological operation - a technologically homogeneous part of the production process, performed at one workplace. Technologically separate partial processes are stages of the production process.
Partial production processes can be classified according to several criteria: according to the intended purpose; the nature of the flow in time; way of influencing the object of labor; the nature of the work involved.
For the intended purpose distinguish between main, auxiliary and service processes.
Main production processes - processes of transformation of raw materials and materials into finished products, which are the main, profile products for this enterprise. These processes are determined by the manufacturing technology of this type of product (preparation of raw materials, chemical synthesis, mixing of raw materials, packaging and packaging of products).
Auxiliary production processes are aimed at manufacturing products or performing services to ensure the normal flow of the main production processes. Such production processes have their own objects of labor, different from the objects of labor of the main production processes. As a rule, they are carried out in parallel with the main production processes (repair, packaging, tool facilities).
Service production processes ensure the creation of normal conditions for the flow of the main and auxiliary production processes. They do not have their own object of labor and proceed, as a rule, sequentially with the main and auxiliary processes, interspersed with them (transportation of raw materials and finished products, their storage, quality control).
The main production processes in the main workshops (sections) of the enterprise form its main production. Auxiliary and service production processes - respectively in auxiliary and service shops - form an auxiliary economy. The different role of production processes in the overall production process determines the differences in control mechanisms various types production departments. At the same time, the classification of partial production processes according to their intended purpose can only be carried out in relation to a specific private process.
Combining the main, auxiliary, service and other processes in a certain sequence forms the structure of the production process.
Main production process represents the production process of the main product, which includes natural processes, technological and work processes, as well as inter-operational waiting.
natural process - a process that leads to a change in the properties and composition of the object of labor, but proceeds without human intervention (for example, in the manufacture of certain types of chemical products). Natural production processes can be considered as necessary technological breaks between operations (cooling, drying, aging, etc.)
Technological process is a set of processes, as a result of which all the necessary changes occur in the object of labor, i.e., it turns into finished products.
Auxiliary operations contribute to the implementation of the main operations (transportation, control, sorting of products, etc.).
The working process - the totality of all labor processes(main and auxiliary operations). The structure of the production process changes under the influence of the technology of the equipment used, the division of labor, the organization of production, etc.
Interoperative decubitus - breaks provided by the technological process.
By the nature of the flow in time distinguish between continuous and batch production processes. In continuous processes, there are no interruptions in the production process. Production maintenance operations are carried out simultaneously or in parallel with the main operations. In periodic processes, the execution of basic and maintenance operations occurs sequentially, due to which the main production process is interrupted in time.
By way of impact on the object of labor allocate mechanical, physical, chemical, biological and other types of production processes.
By the nature of the work involved production processes are classified into automated, mechanized and manual.