The relevance of the topic I have chosen is that the main goal of production activities is to increase profits and improve production efficiency. One of the main factors for maximizing income is improving the production process at the enterprise. The organization of labor and the effective construction of production processes affect not only profit, but also the speed of the enterprise, the amount of intangible and material resources expended. The listed indicators are extremely in demand in the current crisis situation. Since most Russian enterprises are faced with problems of unprofitable production of products, violation of the management hierarchy, irrational use of equipment and reduction in production personnel.
To accurately understand the improvement of the production process, how it happens, what it interacts with and what it is aimed at, it is necessary to understand the basic concepts.
The production process is the totality of all the actions of people and tools needed in a given enterprise. Methods of organizing the production process include a set of organizational and technical techniques, methods of combining production factors in space and time. A little higher, we found out that the rational structure of production is a necessary condition for allowing an enterprise to function effectively in a market economy.
One of the ways to improve production processes is its comprehensive mechanization and automation. Mechanization and automation refers to the widespread replacement of manual operations with machines and mechanisms, the introduction of automatic machines, individual lines and production facilities. And comprehensive mechanization is a way of performing the entire complex of work included in the production cycle using mechanisms and machines.
Another option related to our topic: efficient use of fixed assets. The result increases in accordance with the necessary measures:
Rice. 1 - Measures for the effective use of PF
The next area of production improvement is capacity management. Production capacity is determined by the weakest link, or bottleneck. To increase overall production capacity, the bottleneck needs to be “expanded.” There is no need to spend time improving each unit of equipment efficiency or individual part of the production process. In general, capacity is not determined by the hours of downtime of a single piece of equipment or employee. Production capabilities are limited by the capacity of the weakest link. As soon as it is discovered, the enterprise will have prospects for development.
1. If the problem is “bottlenecks,” then one of the important methods for increasing production capacity is to identify and eliminate them. Identifying bottlenecks:
2. To maximize production capabilities, it is necessary to equalize the load in different production areas. There is no need to strive for the highest productivity of certain types of processes, since bottlenecks form in the system as a whole.
3. Downtime of people or equipment in the bottleneck area is costly, as it means the entire production is idle. In fact, downtime of people or equipment in individual areas does not in any way affect the performance of the system as a whole and does not pose a problem in itself; the problem arises when downtime in one place leads to a shutdown of the entire production process.
4. Total indicators of production capabilities and capacity utilization contain little information for decision making. Diagnosis of problems and selection of ways to improve production require that the subject of analysis be certain types of resources. For example, to increase production capacity, you can reduce the changeover time of processes or equipment, but this is only effective if the changeover time in areas that are bottlenecks is reduced. By reducing the time for changeover in other parts of production, we increase their throughput, but not the throughput of the enterprise as a whole. Moreover, bottlenecks may be the result of insufficient equipment capacity or lack of personnel, and some analysis must be done to identify the real cause. For example, a hospital may have a sufficient number of operating rooms, but if there are not enough nurses and surgeons, some of the operating rooms will be empty and the number of operations performed will be limited by a lack of staff rather than equipped premises.
5. Finally, if production volume is subject to fluctuations, it is necessary to have spare capacity at bottlenecks. If the system is poor at maintaining average production, then trying to increase it may result in either backlogs, costly excess inventory, or both.
Production capacity also depends on the structure of production processes. Care should be taken to ensure that production processes correspond to the structure of the products being manufactured.
The next way to improve production at an enterprise is to have competent personnel. And in the majority, the most stringent requirements should apply to management personnel. These include: managers, executives, directors, heads, commanders, commissioners, foremen, chairmen, specialists.
These positions include the most important functions:
The responsibilities of managers include not only knowledge of these functions, but also mandatory implementation and compliance with them. If we talk about this metaphorically, then such employees are like a solid foundation in the construction of a huge multi-story building; they lay the foundation, direct the work in the right direction, motivate workers and control the quality of its execution.
Another option for improving production is the introduction of innovations, that is, continuous improvement of production. Innovation at an enterprise is a form of manifestation of scientific and technological progress at the micro level. They contribute to updating the range of products, improving their quality in order to meet consumer needs and maximize the organization’s profits. Innovation can occur in both technical, labor and management aspects. From a technical point of view, this is not only, as we said earlier, mechanization (the transition from manual labor to machine labor) of production, it is also the replacement of all machinery and equipment with newer and more modern ones. After all, every thing is subject to not only physical, but also moral wear and tear. Cars and computers that were in demand and new a few years ago can no longer compare with the new technology of this year. New things can increase production productivity several times and thereby take the enterprise to a new level. Therefore, replacing outdated equipment with new ones can maximize the profit of an enterprise and is one of the ways to improve production. However, innovation does not only consist of new equipment, replacing all equipment with more modern ones, it is also innovations that affect the employees of the enterprise. Every year the work is being improved: new programs and calculation schemes are created, companies adopt new regulations and criteria for placing employees in positions. New knowledge must be acquired through advanced training courses or through self-development. The development of knowledge in the field of organizational structure, management methods, selection of the most suitable organizational structure, knowledge of the theory of motivation, factors determining the effectiveness of management is a criterion for success in any organization. Having them, you can competently distribute work, motivate staff to perform high-quality and fast work, manage inventories, supply chain and supplies.
Thus, we found out that improving production at an enterprise is necessary to maximize profits, and this is what every company strives for. Find out that some of the ways to improve are: mechanization and automation of production, efficient use of fixed assets, enterprise capacity management, recruitment of competent personnel, innovation and continuous improvement of the company and employees (training).
master's student
Irkutsk State University
master's student
Knyazyuk Nadezhda Feofanovna Doctor of Medical Sciences, Head of the Department of Management, Irkutsk State University Siberian-American Faculty of Management
Annotation:
This article discusses the concepts and principles of the production process, confirms the need to analyze and improve the production process using the example of OJSC Sortavala DSZ.
This article discusses the concepts and principles of the production process, confirms the need to review and improve the production process as an example of "Sortavala DSZ."
Keywords:
production; process; crushed stone
UDC 65
Concept of the production process
Modern production is a complex process of transforming raw materials, materials, semi-finished products and other items of labor into finished products that meet the needs of the consumer.
The totality of all actions of people and equipment carried out at an enterprise to produce specific types of products is called the production process.
The technological process is the basis of the production process, within which the transformation of raw materials into the finished product occurs. During implementation technological process there is a change in all forms, as well as the physical properties of the original material.
The technological process is not the only component of the production process. Incorporating many processes that do not change the properties of raw materials and materials, but help transform raw materials into finished products. Such processes can be: transport, warehouse, service, natural and many other processes.
In the production process, labor processes are combined with natural ones, in which changes in objects of labor occur under the influence of natural forces without human intervention (for example, drying painted parts in air, cooling castings, aging of cast parts, etc.).
Varieties of production processes. According to their purpose and role in production, processes are divided into main, auxiliary and servicing.
The main process is the process during which the production of products aimed at the end consumer is carried out.
Supporting processes are designed to ensure efficient and uninterrupted operation main processes.
Together, the main processes form the basis of production.
In modern conditions, especially in automated production, there is a tendency to combine basic and servicing processes. Thus, in flexible automated complexes, basic, warehouse, picking and transport operations are combined into a single process.
Servicing processes are processes during which the actions necessary for the effective functioning of both main and auxiliary processes are performed.
In order to begin to improve the production process, you need to analyze it comprehensively, that is, you need to conduct a comprehensive analysis of activities in order to know what state production is in now. The results of the comprehensive analysis will be the starting point to begin developing the improvement of the production process. As an example, let us take OJSC “Sortavala Crushing and Screening Plant”.
Using the example of this enterprise, we will consider how the organization analyzes its activities and what decisions will be made on the basis of a comprehensive analysis.
The basis is a plan - a factual analysis. Key indicators are selected that, from the manager’s point of view, relate to the production process and have the maximum impact on the organization as a whole. Planned and actual data are compared according to reports on the number of finished products produced, according to preparatory work(stripping, drilling, etc.), according to the report on the cost of finished products.
If the production plan for the period January-June is not fulfilled by 14%:
Stripping - failure to complete by 79%, because stripping work was planned from April, in fact the work was carried out only in May in the amount of 63% of the planned volume;
Drilling - failure to complete by 14%
Explosion - non-fulfillment by 28% as a result of lower GM yield per 1 running meter. compared to the planned indicator;
Excavation - non-compliance by 14%;
Transportation - non-fulfillment by 17%;
Processing - non-fulfillment by 14%.
The cost of products sold in June 2015, with a decrease in the volume of product shipments by 16% compared to the plan, increased by 27% as a result of an increase in the average unit cost: plan - 162 rubles, actual - 207 rubles.
Reasons for the increase in cost of goods sold per ton:
Increase in the cost of manufactured products by fuel fractions compared to the plan as a result of failure to fulfill the sales plan;
More expensive opening balances by fraction compared to plan.
The actual cost of 1 ton of sold products in June 2014 was 20% lower than the level of June 2013 (258 rubles) due to an increase in production costs as a result of increased production volumes and rising costs in 2014:
For repairs - in connection with the emergency failure of the DSO (repair of the N-4800 crusher), unplanned repairs of BelAZ dump trucks and quarry equipment;
For wages with payments to social security - due to the failure to outsource repair personnel, the increase in piece rates and additional payments to workers for professional skills; for fuels and lubricants - in connection with unplanned types of work.
Since the beginning of the year, the cost of goods sold has increased by 17% due to the failure to fulfill production volumes by 14%, repair work of the DSO and quarry equipment, write-off of 35.5 thousand tons of GP balances, as well as due to the use of crushed stone for our own needs.
Dynamics of costs by budget items (plan June 2014 - actual June 2014).
Cost savings in June by 0.6 million rubles. compared to plan as a result:
Item “Maintenance and Repair” (+2.1 million rubles or -43%) due to unplanned replacements of DSO spare parts in connection with emergency repairs of the N-4800 crusher, on conveyors as a result of wear of the high-speed shaft and intermediate gear, as well as due to unplanned repairs of technological transport (repair of steering and chassis), ECG (replacement of the bucket wall as a result of wear of the bucket), auxiliary transport (repair of the chassis of the T-15.01 bulldozer), household goods. transport (unscheduled repairs of the ED-405 vehicle, MAZ 55102 dump truck and truck crane), overexpenditure on the services of third-party organizations for maintenance 3 of the diesel locomotive TEM No. 037 due to changes in the repair schedule and repair of DSO vibrators.
Since the beginning of the year, there has been an overexpenditure of 4% due to unplanned repairs, due to emergency failure of the enterprise equipment.
Article “Payroll + insurance premiums” in June +1.4 million rubles. (repair personnel were not outsourced, payments under contract agreements, additional payments to workers for professional skills, increase in piece rates due to the overfulfillment of the production volume of the state enterprise by 11%).
Since the beginning of the year +4.5 million rubles. through the payment of bonuses based on work results in March, one-time bonuses by order of the General. Directors, failure to outsource maintenance personnel since April, additional payments to workers for professional skills in June.
Article “Rent” overexpenditure 0.3 million rubles. in connection with the unplanned rental of a diesel locomotive for the period of major repairs of its own
Article “Electricity” (-0.4 million rubles or -33%) due to:
1. reduction in consumption (-33%) for drilling, hydrocarbons production, shipment of hydrocarbons and experimental work as a result of failure to fulfill the planned volumes of drilling work and failure to fulfill the shipment plan by 16%, which compensated for the excess consumption of electrical energy during hydrocarbons processing
2. tariff reduction by 32%.
Since the beginning of the year, savings of 2.2 million rubles. due to a reduction in the volume of electricity consumption in the extraction and processing of hydrocarbons, as well as in the shipment of gas generators by 188 thousand kW (7%), a reduction in the tariff compared to the planned one by 23%.
Factor analysis
Article "fuels and lubricants"(-0.2 million rubles or -6%) due to: 1. an 8% increase in consumption of quarry equipment and technological transport due to an increase in the volume of transportation of raw materials and screenings; 2. reducing the price of diesel fuel by 16%.
Since the beginning of the year, savings of 0.3 million rubles. due to a reduction in the price of diesel fuel by 14%, which compensated for the overexpenditure in the volume of consumed diesel fuel by 12% due to the involvement of a Karelvzryvprom excavator for loading and the involvement of a Dressta loader for loading crushed stone 3-10 instead of an electric one. EKG 5A, gasoline by 18% due to an increase in consumption by PAZ buses due to the need for visa approval of railway documents and delivery of goods and materials.
Article " BVR" savings of 2.6 million rubles. due to the provision of rock mass in April.
Since the beginning of the year, savings of 2.2 million rubles. due to failure to fulfill the planned volumes of drilling and blasting operations.
Article " Third-party company services" savings of 0.7 million rubles. due to failure to outsource repair personnel and failure to certify workplaces (work has begun, completion is planned in August)
Article “Other expenses”"(+0.1 million rubles or -78%) due to the creation of a reserve for reclamation.
After carrying out the plan-factual analysis, a focus group is assembled, which may consist of both enterprise managers and invited experts. The focus group offers solutions to eliminate problems that have arisen through improving the production process, introducing automation and control systems, and appoints those responsible. For example: proposals for improving the activities of the enterprise:
Due to the increase in the volume of GP production from June to 110 thousand tons monthly, it is necessary to agree with the Commercial Department of the increased volume of GP sales through TD.
In addition, it is necessary to ensure a daily supply of cars according to approved plans.
Responsible for implementation: Ivanov I.I.
The balance of GP in the warehouse as of July 1, 2014 amounted to 25 thousand tons of 5-20 mm and 16 thousand tons of 3-10 mm.
An increase in production volume by an average of 10% until the end of the year requires an increase in costs for the use of consumables for repairs corresponding to the increased volume in the amount of 2,600 thousand rubles. Overexpenditure since the beginning of the year by 4% occurred as a result of emergency equipment failures.
Responsible for implementation - Ivanov I.I.
To ensure the fulfillment of production volumes of up to 110 thousand tons of gas production per month, it was agreed with the management company to increase the payroll for the main technological workers and repair personnel in the amount of 671 thousand rubles. per month.
Purchase and installation of a fuel consumption monitoring and transport monitoring system (cost 600 thousand rubles) in order to effectively use equipment and reduce fuel consumption by 10% (270 thousand rubles/month, 1620 thousand rubles for the period July-December) .
Purchase of truck scales for weighing products shipped by the plant. In July, changes were made and agreed upon in the 2014 IP, and work is currently underway to select a contractor.
Introduction of a unified dispatch service in order to reduce organizational downtime and increasing the efficiency of the crushed stone production line. The estimated implementation date is 01.10.15. To date, a design contract has been drawn up for the renovation of premises and software(“SKADO” St. Petersburg).
To increase the speed of shipment of finished products fr.5-20 it is necessary:
Installation of railway scales directly under the loading bunker, which will reduce the time for shunting work by 1.5 times and increase the volume of shipment to 90 cars per shift. The estimated cost of work and equipment is 3.5 million rubles. The work must be completed in the autumn, when the volume of crushed stone shipments decreases. Completed questionnaires were sent to potential contractors.
The need for implementations and changes, as well as financial opportunities, is calculated, and then the improvement process begins.
As a result, as we see, the production process is one of the main processes of the organization; quite large amounts of money are spent for its proper operation; also in modern conditions, it is necessary to constantly improve in order for the entire organization not only to survive, but to be stable and profitable.
Bibliography:
1. Vader Michael. Lean manufacturing tools. Mini-guide to implementing lean manufacturing techniques: textbook. Manual/Michael Vader. - M.: Alpina Publishers, 2010. - 125 p.
2. Goryunov Yu.Yu. Theory and methods of decision making: textbook. / Yu.Yu Goryunov. - Penza: RGUITP, 2010. - 50 p.
3. KeenanKate. Effective management: textbook. Benefit/ Kate Keenan. – M: Eksmo, 2006. - 315 p.
4. Ladanov I.D. Practical management: textbook. Allowance / I.D. Ladanov. - M.: Corporate strategies, 2004. - 496 p.
Reviews:
06/8/2015, 19:23 Skripko Tatyana Aleksandrovna
Review: I recommend redoing the first part in the form of a description theoretical developments of the problem at hand, rather than a basic description of the key term. The second part of the enterprise is normal. For revision.
06/09/2015, 18:49 Degtyar Andrey Olegovich
Review: The article does not meet the requirements. The title of the article should be clarified, since for different types of production processes there may be different principles of improvement. The first part of the article resembles the presentation educational material. There is no justification for the relevance of the topic, statement of the problem, or analysis of publications on the topic of the article. The article needs improvement.
Benefit
BASICS OF PRODUCTION PROCESS TECHNOLOGY
Industry, its structure and characteristics
Industry is the leading sector of the national economy, operating along with other sectors - agriculture, forestry, transport, communications, etc. Industry includes industrial enterprises (factories, factories, power plants, mines, mines, workshops, combines, etc.) and their associations, as well as research, design, engineering and technological institutes, laboratories, bureaus and other organizations.
Industry creates conditions for more efficient use of the country's material and labor resources, to achieve maximum results at optimal costs. The social division of labor has led to the emergence of a number of industries, each of which is specialized in the production of individual products and even their parts.
An industrial sector is a collection of related enterprises characterized by the unity of the economic purpose of the products produced, the uniformity of the raw materials consumed, the commonality of technological processes and technical base, a special professional composition of personnel and specific working conditions.
Industry supplies individual industries with means of production, and above all tools, extracts minerals, processes various raw materials, and produces industrial and food products.
According to the nature of the impact on the subject of labor, industry is divided into mining and manufacturing. The first is engaged in the extraction of minerals and other substances provided to humans by nature, the second - processes raw materials and materials into finished products. According to the economic purpose of the products produced, industry is divided into two divisions - A and B. Group A industry is mainly engaged in the production of means of production and includes industries that produce elements of both basic (machines, mechanisms, apparatus, structures, etc.) and circulating elements resources (raw materials, materials, fuel, energy). Group B includes the light and food industries, producing mainly consumer goods and food products.
In the production process, all sectors of the economy interact, supplying each other with raw materials, materials, tools, and providing the non-production sphere and science with everything necessary.
The technical equipment of industry in all sectors of the national economy serves as the basis for a steady increase in labor productivity and a continuous increase in the scale of production.
Industry is the basis for the restructuring of agricultural production. It processes agricultural raw materials and produces the bulk of consumer goods. Consequently, the satisfaction of the immediate needs of the people largely depends on the development of industry.
The development of industry, especially heavy industry, contributes to a more rational distribution of productive forces, the comprehensive development of all economic regions of the country, and the appropriate use of natural resources.
Production and technological processes
Each enterprise unites a team of workers, at its disposal are machines, buildings and structures, as well as raw materials, materials, semi-finished products, fuel and other means of production in the amounts necessary for the production of certain types of products in a specified quantity within a given time frame. At enterprises, a production process is carried out, during which workers, using tools, transform raw materials into finished products needed by society. Each industrial enterprise is a single production and technical organism. The production and technical unity of an enterprise is determined by the common purpose of the manufactured products or the processes of their production. Production and technical unity is the most important feature of the enterprise.
The basis of the activity of each enterprise is the production process - the reproduction process material goods and industrial relations, the production process is the basis of the activities that transform raw materials and semi-finished products into finished products that meet their intended purpose.
Each production process includes main and auxiliary technological processes. Technological processes that ensure the transformation of raw materials into finished products are called basic. Auxiliary technological processes ensure the manufacture of products used to service the main production. For example, preparation of production, production of energy for own needs, production of tools, equipment, spare parts for repairing enterprise equipment.
By their nature, technological processes are synthetic, in which one type of product is made from various types of raw materials; analytical, when many types of products are made from one type of raw material; direct, when the production of one type of product is carried out from one type of raw material.
The variety of production products, types of raw materials, equipment, work methods, etc. also determines the variety of technological processes. Technological processes differ in the nature of the products manufactured, the materials used, the methods and methods of production used, organizational structure and other characteristics. But at the same time, they also have a number of characteristics that make it possible to combine various processes into groups.
It is generally accepted to divide technological processes into mechanical and physical, chemical and biological and combined.
During mechanical and physical processes, only the appearance and physical properties of the material change. Chemical and biological processes lead to deeper transformations of the material, causing a change in its original properties. Combined processes are a combination of these processes and are the most common in practice.
Depending on the type of prevailing costs, technological processes are distinguished: material-intensive, labor-intensive, energy-intensive, capital-intensive, etc.
Depending on the type of labor used, technological processes can be manual, machine-manual, automatic and hardware.
In any technological process, it is easy to identify a part of it that is repeated with each unit of the same product, called the technological process cycle. The cyclic part of the process can be carried out periodically or continuously; accordingly, periodic and continuous technological processes are distinguished. Processes are called periodic, the cyclic part of which is interrupted after the inclusion of a (new) object of labor in these processes. Continuous technological processes are those that are suspended not after the production of each unit of product, but only when the supply of processed or processed raw materials stops.
The main elements that determine the technological process are purposeful human activity or labor itself, objects of labor and means of labor.
Purposeful activity or work itself is carried out by a person who expends neuromuscular energy to perform various movements, observe and control the impact of tools on objects of labor.
The object of labor is what human labor is directed towards. The objects of labor transformed during the processing process into finished products include: raw materials, basic and auxiliary materials, semi-finished products.
The means of labor are what a person uses to influence the object of labor. Means of labor include buildings and structures, equipment, vehicles and tools. In the composition of the means of labor, the decisive role belongs to the instruments of production, i.e., equipment (especially working machines).
Types of production, their technical and economic characteristics
The type of production, as the most general organizational and technical characteristic of production, is determined mainly by the degree of specialization of workplaces, the size and constancy of the range of production objects, as well as the form of movement of products through workplaces.
The degree of specialization of workplaces is characterized by the serialization coefficient, which refers to the number of different operations performed at one workplace.
Nomenclature refers to the variety of production objects. The range of products manufactured at the workplace can be constant or variable. The permanent nomenclature includes products the production of which continues relatively for a long time- a year or more. With a constant nomenclature, the production and release of products can be continuous and periodic, repeated at certain intervals; with variable nomenclature, the production and release of products changes and may be repeated at indefinite intervals or not repeated.
There are three types of production: single, serial and mass.
Unit production is characterized by a wide range of manufactured products and a small volume of their output. Single production is characterized by the following features: the use of universal equipment, universal devices and tools, placement of equipment in groups by type, the longest cycle for manufacturing parts. Experimental, repair and other production workshops are organized according to the principle of unit production.
Serial production is characterized by a limited range of products manufactured in periodically repeating production batches (series) for a given output volume.
A production batch is a group of products of the same name and standard size, launched into processing simultaneously or continuously over a certain time interval.
Serial production is conventionally divided into small-scale, medium-scale and large-scale. Serial production is characterized by the serial coefficient (K) of assigning operations to one workplace. If one workplace is assigned from 2 to 5 operations, i.e. coefficient K = 2/5, then such production is considered large-scale, with K = 6/10 - medium-scale, with K > 10 - small-scale.
Serial production is characterized by the following features: the need to re-adjust machines from operation to operation, since several operations are assigned to one workplace, the arrangement of equipment along the flow (in large-scale production) or on a group basis (in small-scale production), the presence of interoperational storage of products, a long production cycle of products .
Mass production is characterized by a narrow range and large volume of products produced continuously over a long period of time. In mass production, one invariably repeating operation is performed at each workplace. Mass production is characterized by the following features: the arrangement of equipment in the sequence of operations, the use of high-performance equipment, special devices and tools, the widespread use of transport devices for transferring products along the production line, mechanization and automation of technical control, short cargo flows on the processing line, the shortest production cycle duration.
As the degree of specialization of workplaces increases, the continuity and direct flow of products through workplaces, i.e., during the transition from single to serial and from serial to mass production, the possibility of using special equipment and technological equipment, more productive technological processes, advanced methods of labor organization, as well as mechanization and automation of production processes. All this leads to increased labor productivity and reduced production costs.
The main factors contributing to the transition to serial and mass types of production are an increase in the level of specialization and cooperation in industry, the widespread introduction of standardization, normalization and unification of products, as well as the unification of technological processes.
Forms of organization industrial production
Industrial production is distinguished not only by a high level of technical development, but also by very advanced and constantly developing forms of organization, which have a great influence on both its economy and location. The main forms of organization of industrial production are concentration, combination, specialization and cooperation.
Concentration is the concentration of the means of production of labor, and therefore the output of products in large enterprises.
The technical and economic advantages of large enterprises, in particular the possibility of systematic modernization of equipment, increasing its productivity, reducing specific capital investments, more economical use of labor, raw materials and fuel, better opportunities for combining and specializing production, contribute to increasing labor productivity and reducing production costs. However, it should be noted that large enterprises are not always the most efficient. Question about optimal sizes industrial enterprises are decided taking into account the nature of production and the conditions for providing them with raw materials, fuel, energy, water, labor force, conditions for the discharge of wastewater and harmful gases, as well as taking into account the consumption of their products.
Combination is a form of industrial organization in which production facilities producing various products are combined into one enterprise - a plant.
The plant is characterized by the technological and territorial unity of its production facilities and constant connections between them. These production facilities are located on the same territory as close as possible to each other, they have a common energy base and fuel facilities, a common repair base and water supply system, a unified transport network and storage facilities, a unified system of administrative management, technical management, logistics and sales of products.
There are three types of combination:
A combination that has developed on the basis of successive stages of raw material processing, for example textile mills consisting of spinning, weaving and finishing shops; metallurgical plants combining the production of cast iron, steel and rolled products.
Combination based on the use of industrial waste, for example: the production of cement from blast furnace slag, the production of sulfuric acid based on sulfur dioxide gases in non-ferrous metallurgy, or the use of wood waste to produce hydrolytic alcohol.
Combination that arises on the basis of complex processing of raw materials or fuel, for example: energy-chemical use of fuel, i.e. its simultaneous use to produce chemical products and energy, simultaneous production of electrical energy and heat at thermal power plants, extraction of several metals from the same ores .
Combination is widespread in ferrous and non-ferrous metallurgy, chemical, forestry, textile and other industries.
Combination reduces capital costs for the construction of enterprises, it promotes the comprehensive, integrated use of raw materials and fuel and the disposal of production waste, reduces transport costs for the transportation of raw materials, fuel and semi-finished products, speeds up production processes and reduces labor costs, which ultimately ensures an increase in labor productivity and reducing production costs.
Specialization is a process of social division of labor in which there is a separation and isolation of industries focused on the production of a certain product or part of it, as well as on the implementation of a separate technological operation.
There are three types of specialization:
1. Subject - specialization in the production of a specific finished product, for example, an automobile plant, a shoe factory.
2. Detailed - specialization in the production of parts of the product, individual parts, for example, a bearing plant, a plant that produces individual parts of radio receivers...
3. Stage (technological) - specialization in performing a specific production operation, for example, a foundry, an assembly plant, a spinning mill.
The higher the level of specialization, the fewer types of finished products and parts of the annual product the enterprise produces, and the fewer technological operations it performs.
The development of specialization in industry is associated with mass production and flow of production, the introduction of specialized, high-performance equipment, “the use of advanced technologies, mechanization and automation of production processes, increasing the qualifications and productivity of workers, workers and engineering personnel, which reduces the cost of production while simultaneously improving its quality All this determines the high economic efficiency of industrial specialization.Specialization in industry cannot be successfully carried out without cooperation.
Cooperation is close production ties between individual enterprises or industries that jointly participate in the production of a specific finished product.
Cooperation promotes the division of labor in industry and its specialization, which ultimately leads to better use of the production capabilities of each enterprise, increasing their productivity and reducing production costs.
The development of specialization and cooperation creates new opportunities for the rational placement of production. Isolation of individual processes for processing raw materials, semi-finished products, manufacturing parts, machine components as independent production makes it possible to place each of them in the most rational way. In this way, issues of its organization, technical progress, specialization and cooperation, assortment and quality of products are more correctly resolved, production management is simplified and cheaper .
Industrial cooperation between enterprises requires strict standardization of technological processes and certain types of supplied products. Standardization is a set of measures aimed at a limited number of varieties of different products, materials, products, processes, etc. Standardization ensures the production of products with strictly defined properties, quality and dimensions, ensures the interchangeability of parts and assemblies, as well as the possibility of mechanized assembly of machines.
Standardization is closely related to product unification. Unification means the use in the production of machines and other products of the same type of parts and assemblies, equipment, tools, homogeneous graded materials, etc.
Reducing the number of used types and sizes of parts, assemblies, mechanisms, devices, and tools significantly simplifies and reduces the cost of machine design, their production and operation.
As a result of standardization and unification of products and their components, an increase in serial production is achieved, the creation of prerequisites for improving economic indicators, an increase in labor productivity, a reduction in production costs, a reduction in the time required for technical preparation of production and a reduction in the costs of its implementation.
Process elements
The technological process of production of any product includes three main elements: the subject of labor, the means of labor and labor,
Objects of labor. Objects of labor are understood as the totality of forces, substances and objects of nature that people influence in the process of their production activities; are the natural basis of material production, one of the necessary material conditions for people’s lives.
The “Object of Labor” element combines raw materials, materials, semi-finished products, fuel, etc.
Raw materials are one of the most important elements of production, affecting the technology and quality of products. The success and economics of industry depend on the supply and quality of raw materials.
Raw materials are objects of labor that have undergone changes during the process of their extraction or production. Thus, viscose fiber obtained from wood is a raw material for the textile industry; iron ore mined from the depths of the earth is a raw material for the metallurgical industry, etc. Depending on their origin, raw materials are divided into natural and artificial.
Natural raw materials are divided into organic and mineral. Organic includes wool, flax, cotton, wood, etc. Mineral includes iron ore, chalk, asbestos, etc.
Artificial raw materials are characterized by the fact that they are obtained mainly chemically from various types of natural materials. This type of raw material includes chemical fibers, synthetic rubbers, soda, etc. Artificial raw materials are divided into organic and mineral. Organic materials include: viscose, acetate fiber, etc., mineral materials include silicate, metal fibers, and other materials.
Depending on the participation in the manufacture of products, raw materials are divided into basic and auxiliary. The main ones also include objects of labor that form the material basis of manufactured products. Thus, iron ore forms the basis for the smelting of cast iron, textile fibers for the production of fabrics, metal for the production of machines and machine tools, and wood for the production of furniture.
Auxiliary items include those items of labor that do not form the material basis of the products being manufactured, but give them quality properties, ensure the operation of the equipment and the normal course of the technological process. For example, dyes give fabrics a certain color; fuel, lubricating oils, catalysts ensure the operation of equipment, the normal course or acceleration of the technological process.
A semi-finished product is a product whose production has been completed in one production area and is at the stage of transition to another area.
Fuel and energy. In the production process, a person uses not only various substances, but also energy. Processing parts on machines, melting and heating, electrolysis and other processes are unthinkable without the use of energy and fuel. Previously, it was human muscular energy, then they began to use more advanced energy - hydraulic, thermal, mechanical, intra-atomic, etc. Electric current, fuel, water vapor, compressed air, and gases are used as energy-cooling agents. Raw materials, as one of the main elements of the production process, have an increasing impact on industrial production and its economy. The economic efficiency of social production largely depends on the range and quality of raw materials.
The economic results of industrial enterprises are largely determined by the level of costs of raw materials and fuel for the production of finished products. This is explained by the fact that in all manufacturing industries, the costs of raw materials and fuel constitute the largest part of production costs.
Preparation of mineral raw materials for processing. Any mineral extracted from the bowels of the earth, in addition to the useful mineral part, always contains a certain amount of low-value or useless, and sometimes harmful, impurities for the given production.
Therefore, at present, not a single type of raw material is processed without preliminary preparation or enrichment.
Enrichment refers to a number of technological processes for the primary processing of mineral raw materials, with the goal of separating useful minerals from impurities that are of no practical value under current conditions.
The task of enrichment is also to create conditions that allow efficient consumption of minerals in the relevant industries.
The enrichment process includes the following stages: crushing, sorting and enrichment.
Crushing is carried out in order to obtain a certain piece size. For crushing, various crushing machines are used - neck, roller, cone, hammer, drum, etc. After crushing, the raw materials are sorted to separate them into grades according to the size of the piece. Sorting devices of various designs are used for sorting.
Mineral enrichment methods are based mainly on the use of physical and physical-mechanical properties of minerals - specific gravity, size, coefficient of friction, shape, color, magnetic permeability, wettability and some other properties.
Beneficiation based on the difference in the specific gravity of valuable components and waste rock is called gravity.
The process of magnetic enrichment is based on the difference in the magnetic properties of minerals. Mineral grains with high magnetic susceptibility are easily deflected in a magnetic field or stick to a magnet, while non-magnetic grains pass freely through a magnetic field.
The flotation concentration method is based on the use of the physical and chemical properties of minerals based on the principle of their wettability by liquid.
Ways to reduce the consumption of raw materials and supplies. The type of feedstock determines the nature of the technological process and its modes, affects the yield, quality and cost of the finished product and a number of other production indicators. Correctly selected raw materials (materials) should be available (non-scarce) and cheap, not require large amounts of labor, time, energy during processing, ensure the best use of equipment and the highest yield of a high-quality product. For example, replacing ethyl alcohol with petroleum gas not only changes the technology for producing synthetic rubber, but also triples its cost; One ton of plastic replaces on average about three tons of non-ferrous metals.
With the development of technology and the growth of labor productivity, the share of the cost of raw materials in the cost of industrial products is constantly increasing. Therefore, economical and rational use of raw materials has great importance, especially for material-intensive technological processes.
With modern scales of production, savings in raw materials and materials turn into large additional reserves.
Savings in materials usually manifest themselves in the form of a reduction in consumption rates, i.e. processing allowances are reduced, the shape of the workpieces approaches the configuration of the finished product, and therefore less time is spent on manufacturing products.
Saving materials reduces the need for them among consumers. This leads to a reduction in labor costs at enterprises producing raw materials and to a reduction in transportation costs.
Other areas for reducing the material consumption of products are:
a) improving product designs;
b) improvement of technological processes;
c) rationalization of planning and organization of production;
d) comprehensive strengthening of labor discipline;
e) liquidation of marriage;
f) reducing the weight of machines through the use of more economical materials, welded-cast and welded-stamped structures, rational rolled profiles, replacement of cast blanks with forged ones, steel with high-strength cast iron, non-ferrous metals with plastics and wood with plastics.
Tools. To perform any technological process, a person creates and uses various means production, among which the tools of labor (machines, machine tools, apparatus, etc.) play a decisive role.
The development and improvement of technological processes is associated primarily with changes in technology.
Technology is a set of artificially created tools of labor, human activity, and, above all, tools for influencing the environment in order to produce the necessary material goods.
The nature of technology has changed and is changing during the historical development of production. From simple primitive stone and wooden tools of primitive society, man came to modern machines, automatic lines, workshops and automatic factories, space rockets and ships.
Depending on their purpose and natural material characteristics, tools and means of labor are divided into groups.
Buildings belong to that part of the means of labor that is not directly involved in the production process, but contributes to its normal implementation. The group of industrial buildings includes the buildings of the main and auxiliary workshops, laboratories, as well as all premises directly serving production (offices, warehouses, garages, depots).
Structures are a variety of engineering and construction objects (mining workings, overpasses, dams, water intakes, wastewater treatment plants, bunkers, tanks and other devices) necessary for production.
Power plants are energy equipment designed to produce or process (convert) energy. This group includes a variety of engines, steam engines, turbines, electric generators, compressors, electrical transformers, rectifiers, etc.
Working machines and equipment are tools of labor intended for technological purposes. These include melting and heating furnaces, various machine tools, presses, mills, filters, autoclaves, etc., as well as machines and mechanisms for moving objects of labor during the production process (transformers, conveyors, cranes, roller tables, etc.). According to the method of influencing the object of labor, machines and equipment are divided into mechanical, thermal, hydraulic, chemical, and electrical. Working machines and equipment are the most important elements of fixed assets that determine the production capacity of an industrial enterprise. Equipment can be universal or special. The first can be used for work of various types, the second can only be used to perform certain operations.
Transmission devices are designed to transfer electrical, thermal and mechanical energy from the engine machine to the working machines. These are power lines, air and steam pipelines, gas and water distribution networks, etc.
Vehicles include vehicles such as electric cars, cars, locomotives, wagons and other inter-shop and intra-shop transport vehicles.
The group of laboratory equipment represents a variety of control and testing equipment, as well as measuring, regulating, counting devices and instruments.
The last group includes a variety of tools and devices (technological equipment, production, household and other equipment).
Labor in technological processes. When performing each technological process or part of it, one or another amount of labor of a worker of appropriate qualifications is spent. All labor, considered as the expenditure of the worker’s physical strength, as the work of the brain and nerves, is the basis of all production.
Labor costs are measured by its duration - the time during which it is carried out. This time is divided into different types according to the nature of its use.
Construction Basics technological process
Organization of the technological process. The organization of a technological process is understood as a rational combination of living labor with material elements of production (means and objects of labor) in space and time, ensuring the most efficient implementation of the production plan.
The organization of the technological process is based on the division of labor (unit form) and its specialization in individual jobs. As a result of specialization, the manufacture of products and their parts occurs in designated areas of the enterprise with the sequential transfer of the subject of labor from one workplace to another. Thus, the total technological process is divided into separate parts, separated in space and time, but interconnected by the purpose of production.
The division of labor necessarily presupposes its combination, since each partial work acquires a certain meaning only in combination with other partial works. Therefore, the specialization of labor receives its complement in its cooperation. Consequently, the objective need to organize the technological process arises from the internal division of production into separate but interconnected parts.
Composition of the technological process. The technological process includes a number of stages, each of which consists of production operations. An operation is a technologically and technically homogeneous part of the process completed at a given stage, which is a complex of elementary work performed by a worker (or workers) when processing a specific object of labor at one workplace,
An operation is the main part of the technological process, the main element of production planning and accounting. The need to divide the process into operations is generated by technical and economic reasons. For example, it is technically impossible to simultaneously process all surfaces of a workpiece on one machine. And for economic reasons, it is more profitable to divide the technological process into parts.
An operation consists of a number of techniques, each of which represents a completed elementary work (or a set of completed actions). Techniques are divided into individual movements. Movement is a part of a technique characterized by a single movement of the worker’s body or limbs.
This division of the technological process into individual elements is of great importance, since it makes it possible to analyze it, identify the smallest features of labor costs, and this is especially important for standardizing work and revealing the reserve for growth in labor productivity.
Structure of the technological process. The structure of a technological process is understood as the composition and combination of elements that determine the design of the process, i.e., the types, quantity and order of production operations. The process flow diagram may be simple or complex. It depends on the type and nature of the products being manufactured, the quantity and nomenclature, the requirements for them, the type and quality of source materials, the level of technology development, cooperation conditions and many other factors.
Simple processes consist of a small number of operations, their raw materials are a homogeneous mass or include a small number of components. The products of such processes are generally homogeneous. Their technological scheme is relatively simple. These include the processes of brick, glass, spinning production, mining enterprises, etc.
Processes of the second type are distinguished by the complexity of their construction scheme, multi-operation, and a wide variety of materials used and equipment used. Complex processes have a developed form of organization and require significant space. Examples of these can be processes in mechanical engineering, metallurgy, chemical industry, etc.
Development of technological process. The basis of any industrial production, as noted, is the production process, which includes a number of technological processes.
Before starting the manufacture of a production object (machines, devices, mechanisms, etc.), it is necessary to design the technological process.
Process design is difficult work. All technical and economic indicators of the developed process depend on how carefully it is performed. Technological design consists, first of all, in choosing the most economical method for obtaining blanks and parts for given specific conditions, establishing a rational sequence of processing operations, assigning the necessary production tools and regulating their use, as well as determining the labor intensity and cost of the manufactured product.. Technological process must be planned so that equipment, tools, fixtures, raw materials, production areas are used most fully and correctly, subject to maximum ease and safety of work.
To compile a technological process, it is necessary to have a number of initial data. These include:
type and nature of production facilities;
product release program;
the requirements it must satisfy;
production capabilities of the enterprise (availability of equipment, energy capacity, etc.).
For this purpose, drawings, diagrams, technical specifications, GOSTs, volume and production plan, equipment lists and passports, tool catalogs, instructions for testing, acceptance, as well as other regulatory and reference data are used.
Main technical document production is a working drawing, which is a graphic representation of the manufactured parts and products, the requirements for them in terms of shape, size, types of processing, control methods, brands of materials used, weight of workpieces and parts, and therefore, material consumption standards. In production, diagrams are also widely used to help one understand the sequence of work.
When developing a technological process, the volume of product output is also taken into account. With a large production plan, for example in large-scale and mass production, it is beneficial to use special types of tools and devices, specialized equipment and automatic lines. In conditions of single (individual) production, they focus on universal equipment and devices and a highly qualified workforce.
The formation of technology is significantly influenced by the conditions in which it should be implemented. If a technological process is developed for an existing enterprise, then when choosing its options it is necessary to focus on the available equipment, take into account the capabilities of procurement and tool shops, and the energy base. In some cases, this limits the choice of processing methods. When developing technology for a newly designed enterprise, these restrictions disappear.
The developed technological process is documented in a number of documents, technological maps, which regulate all the provisions, modes and indicators of the technology used.
The most important of these documents is the technological map, which contains all the data and information on the manufacturing technology of any part or product, a complete description of the production process by operation, indicating the equipment used, tools, devices, operating modes, time standards, qualifications and category worker.
The economist uses the specified documentation with the information it contains to standardize labor and establish the number of workers, determine the need for raw materials, materials, fuel, energy and analyze their consumption, calculate and analyze costs, plan work, etc.
Modern technology allows us to produce the same products or perform the same work various methods. Therefore, during technological design there are wide possibilities for choosing technological processes.
With the existing variety of methods and means of production, several technological process options are often developed and, when calculating the cost, the most effective option from an economic point of view is selected.
To reduce the number of compared options, it is important to use standard solutions, recommendations of regulatory and guidance materials and not consider those options from the implementation of which it is not expected to obtain tangible positive results.
Process products. The end result of the technological process is the finished product, i.e. such products and materials, the work process on which at this enterprise is completely completed, and they are completed, packaged, accepted by the technical control department and can be sent to the consumer. Products not completed by production are called unfinished.
Products are divided into the main one, which constitutes the purpose of production, and by-products, obtained along the way. For example, in blast furnace production the main product is cast iron, and the by-products are blast furnace slag and blast furnace gas, which are used in the national economy. In addition to the main and by-products, the production process usually produces so-called waste, which is divided, depending on the possibilities for further use, into returnable and non-returnable. The former may still be useful in other industries, the latter are called waste.
Carrying out a technological process, a person sets himself two tasks:
1) get a product that meets his needs;
2) spend less labor, materials, energy, etc. on its production.
Each product can satisfy one or another human need only if it has a quality that determines its purpose. Without proper quality, a product becomes unnecessary to a person and the labor and natural objects spent on it are wasted.
Product quality should be understood as compliance of its features and properties with the requirements of technical progress and reasonable demands of the national economy, resulting from the conditions of practical use of products.
The quality of a product is not its constant property. It changes with the production process and increasing demands placed on finished products by consumers.
Improving production technologies allows us to continuously improve the quality of products. The higher its level, the more effective and productive social labor. The use of more advanced products in the national economy leads to a reduction in operating and repair costs, extends service life and therefore, as it were, increases the volume of production of products. But improving the quality characteristics of goods often introduces significant changes into the production process, increases the complexity of the technology, and lengthens the work cycle. The number of operations and equipment increases, and the complexity of processing increases. All this can lead to an increase in costs, a decrease in capital productivity, and additional capital investments. Therefore, improving product quality should pursue strictly defined, economically justified objectives. But even if improving the quality of products requires additional costs, the value of the products usually increases in a greater proportion than the costs increase. Product quality is closely linked to profitability.
Ways to improve technological processes
Improvement of technological processes is the core, the core of the entire development of modern production. Improving production technology has been and remains one of the decisive directions of a unified technical policy, the material basis for the technical reconstruction of the national economy.
Since technology is a way of transforming the original subject of labor into a finished product, the relationship between costs and results depends on it. Limited labor and fuel and raw material resources mean that technology must become more economical and help reduce costs per unit of final product. Moreover, the more limited a particular type of resource is, the faster and on a larger scale the improvement of technology should ensure their savings.
Improving production technology, its intensification also means the creation and implementation of new processes that use less scarce raw materials, secondary fuel - raw materials, reducing the stage of processing of raw materials, creating low-operation, low-waste, non-waste technological processes.
Transition of technology to a qualitatively better high level the creation of fundamentally new technological processes is one of the main signs of the ongoing scientific and technological revolution. From a long-term perspective, this is the main way to implement fundamental changes in production efficiency and save resources.
In improving technological processes important have the following directions.
Typification of technological processes. The same product can often be obtained using different technological processes. The multitude of processing methods forces the use of typification of technological processes that are similar in nature. Typification consists in reducing diverse technological processes to a limited number of rational types and introducing these single-character processes in a number of industries.
When carrying out typing, first of all, products are divided into classes according to the commonality of technological problems solved during their manufacture.
The second stage of typification is the development of standard technology. If the products are very similar in design and technological characteristics, then a single technological process can be designed for them. If the degree of unification of products is less, then a technological process with less detail is developed for such products.
Standard technological processes contribute to the introduction of the most advanced technological processes into production. The use of standard processes simplifies the development of processes for specific products and reduces the time required for this, and also speeds up the preparation of production for product release.
Standard technological processes are used in enterprises of mass, large-scale, serial, and also small-scale production with repeated production of the same products. With small batches of products and frequent reconfiguration of equipment, their use does not provide a noticeable economic effect compared to processing using individual processes. Under these conditions, group technology is the most productive and economical.
To develop group technological processes, products are also classified. They are combined into classes based on the homogeneity of the equipment used to process them, and within classes - into groups based on the geometric shape, dimensions and commonality of the surfaces to be processed. The main product of the group is taken to be the most characteristic products that have all the characteristics of the products included in this group. For each group of products, a technological process is developed (called group) and group adjustment using the same technological equipment.
Group technology ensures savings in labor and material costs at all stages of production, makes it possible to effectively use working time, equipment and funds to further improve the technological level of production. Thus, the time spent on developing technological processes is reduced by 15-20% compared to the cost of developing individual processes, and the time spent on designing and manufacturing group equipment is reduced by an average of 50%.
In some cases, technology development follows the path of combination, which is understood as the combination of several different technological processes in a single complex. Combination ensures the most complete use of raw materials and waste, reduces capital investments, and improves the economic performance of production. The basis for creating combined processes can be:
Complex use raw materials
Use of production waste.
A combination of successive stages of product processing.
The degree of typification and combination is the most important indicator of the technical and organizational level of technology.
Economic efficiency and technical and economic indicators of technological processes
Using all the achievements of technological progress, old ones are improved and new, more efficient technological processes are introduced. It is very difficult to express economic efficiency with any unambiguous, generalized indicator. Technical progress usually produces a complex effect, which is expressed in saving living labor, i.e. increasing its productivity, saving materialized labor - raw materials, materials, fuel, electricity, tools, saving capital costs, improving the use of fixed assets, and improving quality products, making work easier and increasing safety.
Thus, the economic efficiency of the technology used is determined by a number of indicators that are directly related to technical improvement and economic development of production. Such technical and economic indicators represent a system of values characterizing the material and production base of an enterprise, the organization of production, the use of fixed and working capital, and labor in the manufacture of products. These indicators reflect the degree of technical equipment of the enterprise, equipment load, rational use of material and raw materials, fuel and energy resources, human labor in the production process, economic efficiency of the technology used, etc. Their use makes it possible to analyze technological processes, determine features, progressiveness the latter, identify bottlenecks, find and use production reserves. The solution to the listed problems is achieved by studying and comparing these indicators based on an analysis of the elements of the technological process in their interrelation, taking into account all interacting factors.
All technical and economic indicators are divided into quantitative and qualitative. The former determine the quantitative side of the technological process (the volume of products produced, the number of pieces of equipment, the number of employees), the latter determine its qualitative side (the efficiency of the use of labor, raw materials, materials, fixed assets, financial resources).
Technical and economic indicators can be natural and cost. Natural ones give one-sided characteristics (labor intensity, raw material consumption, process or operation time, etc.). Therefore, when addressing issues of economic efficiency of technology, cost indicators are also needed - cost, profit, capital productivity, etc.
In connection with the material objects of the production process, all technical and economic indicators can be combined into the following groups:
1. Technological indicators, i.e. indicators characterizing the properties of the subject of labor. These include, first of all, those indicators whose value affects the progress of the production process. For example, technological indicators characterizing wood pulp used in the pulp and paper industry include fiber length, moisture content, resin content, etc.; The properties of metal parts processed by cutting are determined, first of all, by the composition of the metal (alloy), its tensile strength (or hardness), and geometric dimensions. Although the total number of technological indicators is quite large, for each production process their number is quite limited.
Structural indicators, i.e. indicators characterizing tools. These include the properties of tools that influence the production process - the power of working machines, their passport data.
Labor indicators are indicators characterizing the industrial production personnel of an enterprise. These indicators include the number of workers by profession, category, as well as indicators characterizing qualifications, etc.
Production indicators characterize the progress of the production process and its results. These include the applied operating modes of the equipment (pressure, temperature, speed, etc.), the productivity of the equipment, site, workshop, consumption coefficients, indicators characterizing product quality, and many others.
Economic indicators influence the efficiency of the production process and characterize this efficiency. These include prices, tariffs, wage conditions, standard efficiency ratio of capital investments, production costs, etc.
From the entire set of indicators that make it possible to determine and compare the level of a technological process and its operations, it is necessary to highlight the following: cost, labor intensity, labor productivity, specific costs of raw materials and materials, energy and fuel costs, intensity of use of equipment and production space, capital productivity, value capital investments and their payback period. In some cases, other, private indicators are used that additionally characterize production processes: power supply, mechanization and automation ratio, amount of power consumed, etc.
The most important and general indicator is cost. It is formed from costs that differ in their purpose.
Scientific and technological progress in industry and its economic efficiency
Scientific and technological progress in content represents the progressive development of the productive forces of society in all their diversity and unity, which is reflected in the improvement of means and objects of labor, management systems and production technology, in the accumulation of knowledge, improved use of national wealth and natural resources, increasing the efficiency of social production.
The main task of technical progress is to save social labor in every possible way and ensure high rates of production growth. Its main directions are electrification, mechanization, automation, chemicalization, intensification, gasification.
Electrification means the maximum use of electrical energy as a motive force and for technological purposes (electrometallurgy, electric welding, electric heating, electrolysis, electric spark processing, etc.). The use of electrification speeds up production processes, increases productivity and labor standards, and creates the prerequisites for the introduction of mechanization and automation.
Mechanization is the replacement of manual labor with machine work.
Until now, manual labor still predominates in a number of production processes. Their mechanization continues to be an important direction of technical progress.
Automation is the highest form of mechanization, in which the technological process is carried out by automatic machines operating without the direct participation of workers, whose functions are reduced only to observation, control and adjustment. As a result of automation, work is made easier and productivity increases dramatically.
Chemicalization is the introduction into production of high-performance chemical processing methods and the maximum use of chemical industry products. It promotes the introduction of hardware processes that are easily automated, helping to increase labor productivity and reduce production costs.
Intensification consists of improving the use of labor tools per unit of time through the use of increased (intensive) operating modes (high speeds, high pressures, temperatures, special catalysts, oxygen, etc.); it dramatically speeds up production processes and increases their productivity.
Technical progress has not only economic but also social significance. It facilitates and radically changes people's work, helps reduce the length of the working day, and creates conditions for eliminating significant differences between mental and physical labor.
Scientific and technological progress, generating new technology, new materials, technological processes, methods of management and organization of production, making changes in the structure of production, represents the material basis for society’s constant achievement of saving living labor and embodied in the means of production. And this, in turn, serves as a source of expanded reproduction of the social product, growth of national income, accumulation of the public consumption fund, and a systematic rise in the material and cultural standard of living of the people.
The development of science causes qualitative changes in production technology. Technology is a form of influence of the means of labor on the subject of labor; the method of its transformation changes mainly as a result of changes in the means of labor. But there is a feedback when the requirements of technology necessitate the creation of new means of labor. Thus, the use of chemical materials in industry leads to the replacement of mechanical processing with shaping.
The main direction of technology improvement is expressed in the transition from discontinuous, multi-operational machining processes to progressive processes based on chemical, electrical, electrophysical and biological technology (plasma metallurgy, volumetric stamping, spindleless spinning and shuttleless weaving).
An important area of technology improvement is ensuring the most rational use of natural resources and environmental protection. Technological processes are being developed and introduced into production to ensure waste reduction and maximum recycling, as well as closed-cycle water use systems. New ones are being widely introduced effective ways and systems for the development of mineral deposits, advanced technological processes for their extraction, enrichment and processing, which make it possible to increase the degree of extraction of minerals from the subsoil and sharply reduce losses as a result harmful effects waste to the environment.
The organization of production has a significant impact on labor productivity. Often, even small improvements in the organization of production can significantly increase its efficiency, so this issue should be given great attention.
The organization of production is primarily influenced by the number of products to be manufactured per unit of time. Hence, the criterion for choosing the form of organization of the production process is the number of products to be manufactured, their nomenclature and labor intensity.
In mechanical engineering practice, there are two types of production processes: flow and non-flow. The in-line type is more efficient due to high labor productivity, short production cycle, simplification of planning, accounting and production management. In single, small-scale and medium-scale production, as a rule, a non-flow type of production process and organizational forms are used in the form of a site with a group arrangement of equipment, a technologically closed area and a subject-closed area.
The organization of production sites with a group arrangement of equipment is effective for the production of parts of a wide range, manufactured in units or in small quantities. In this case, the equipment is divided into groups based on the same purpose; blanks are processed in batches.
For example, there is a section of milling machines and there is a section of lathes, etc.; These areas are led by a master. This arrangement allows for more complete loading, but the disadvantage is the numerous movements of the product around the workshop from section to section until complete production. After processing, products are stored near machines or in specially equipped areas. After each operation, small-sized products are delivered to a central or intermediate warehouse for accounting and storage. The product that has passed the last operation and control is delivered to the finished products warehouse. This form of organization is characterized by low technical and economic indicators, complexity of planning, and significant movements of products.
Under these conditions, a contradiction arises between the desire to load the machines more fully and the order in which finished parts are received in time for assembly in accordance with the requirements of technological processes for assembling products and scheduling. Very often, the underutilization of a machine is explained not so much by the technical difficulties of loading it, but by the limitations imposed by assembly requirements. If these requirements are neglected and the machines are fully loaded, then there will be a need to increase storage space where finished parts will lie waiting to be called for assembly. With such an organization of production, the possibility of using a flow form is excluded.
With an increase in the number of parts to be manufactured per unit of time, they move to a more advanced organizational form - technologically closed sections.
The organization of technologically closed areas involves the grouping of products according to the homogeneity of their service purpose, constructive shapes and sizes. For each group of such products, a site is organized containing all types of equipment necessary for the complete production of each product in this group. An example of this form of organization would be areas for the production of spindles, fasteners, gears, etc.
The equipment is installed, if possible, in a sequence corresponding to the flow of technological processes of most parts of the group; This is ensured by the fact that standard technology can be used for similar parts.
Thus, organizational form closed areas theoretically creates the prerequisites for the implementation of continuous production processes, which allows: to improve the organization of planning and accounting; parts travel a shorter distance, the time for reconfiguring equipment when moving from processing one part to another is reduced, since their technological processes are similar; the production cycle becomes shorter; It’s easier to organize quality control.
Technological equipment in technologically closed areas can be connected by vehicles and various types of lifting and transport devices. All this ultimately makes it possible to achieve higher technical and economic indicators.
With a further increase in the output of products of the same range, subject-closed areas are organized. They are used to completely manufacture assembly units, for example, an engine, a gearbox, a gearbox, etc.
With a further increase in the number of parts produced per unit of time, it is advisable to organize the production process in a continuous form in the form of a production line.
The continuous production process means the continuity of movement of manufactured products and their uniform output per unit of time.
In this ideal representation, a continuous production process can be found in industries with a continuous production cycle (for example, in the production of petroleum products in oil refining, where production is “batchless”).
The continuous production process is characterized by:
1) direct flow, when the object of labor moves forward from one piece of equipment to another without return movement;
2) the continuity of movement of the object of labor in the process of its manufacture;
3) rhythmicity, when the product at the end of the production process comes off at regular intervals.
The highest level of flow in the production process will be if all three of these properties are present.
In mechanical engineering production, which is usually discrete, it is difficult to find such a process. The processes that come closest to the ideal flow form are those implemented using rotary lines.
Varieties of flow organization of production are variable-flow and continuous-flow forms. Moreover, recently the variable-flow form has begun to dominate, characterized by the periodic launch of several types of parts on the same equipment.
In production lines, equipment is placed along the process operations, which allows for the widespread use of multi-machine service and the best use of production space. All pieces of equipment are connected by vehicles to transfer the workpiece; the duration of each operation is equal to or a multiple of the release stroke. With flow-based production, there is no need for warehouses, with the exception of small intermediate reserves to compensate for changes in time spent on operations.
Since the flow form of organizing the production process is the most effective, it is natural to strive to use the flow method in single and small-scale production, which was the reason for the emergence of group technology.
On the other hand, serious changes have also emerged in mass production, which have given rise to a tendency to produce the same product in mass production alternately in batches of its different modifications. These changes are driven by the need to satisfy the rapidly changing needs of consumers. However, in this case, a contradiction arises between the desire, on the one hand, to satisfy the needs of the consumer as quickly as possible by producing different products, and on the other, to avoid interruptions in the production process by producing products in large quantities. Thus, in mass production, the problem of using the flow method arises.
Indeed, the tendency observed in mechanical engineering to accelerate the change of manufactured products changes the content of mass production, expanding the range of manufactured products and thereby bringing it closer to mass production in terms of nomenclature, and to mass production in terms of the number of parts produced per unit of time) These contradictory conditions cause difficulties in carrying out production in a continuous form.
In this regard, it is necessary to find ways to widely use the flow form not only in mass production, but also in serial and even individual production.
The trend observed in mechanical engineering to accelerate the change of manufactured products has led to the fact that multi-item, multi-batch production is beginning to dominate.
The degree of breadth of product range and batch size at different enterprises can vary significantly. For example, mass production enterprises maintain large volumes of production of products of several types, but with a large number of modifications; at other enterprises the range of products has sharply increased with small production volumes. Thus, among modern enterprises it is difficult to find an enterprise with a constant type of production (single, serial, mass).
In order for an enterprise to be competitive in the new conditions, its production must be characterized by high productivity, flexibility, mobility, i.e., be able to quickly and at minimal cost switch to the production of new products. At the same time, traditional organizational forms of the production process are focused on the corresponding types of production and therefore can no longer ensure high production efficiency in the new conditions.
Indeed, if, for example, in the first quarter it is required to produce a wide range of products in small batches, and in the second quarter - a smaller range of products in medium batches, then the organizational form of the production process, effective in the first quarter, will not be effective in the second quarter.
Thus, a search for new organizational forms of the production process is required, and for this it is necessary to understand the advantages and disadvantages of traditional organizational forms.
Traditional organizational forms in unit production provide high flexibility, but with low productivity, and in mass production - high productivity but lack of flexibility. The new organizational form must simultaneously provide both high productivity and flexibility in the production process)
