CZ15451U1 - System for carrying out automated multi-modular control of manufacture preparation phase including diagnostics - Google Patents

Description

System for automated multi-module regulation of the preparatory phase of production including diagnostics

Technical field

The technical solution relates to a system for the implementation of automated multi-module regulation of the preparatory phase of production including diagnostics (hereinafter AVDRS).

BACKGROUND OF THE INVENTION

The state of technical preparation of production (TPV) and its management is usually defined by twelve basic stages and approximately two hundred basic activities registered, of which the main activities are controlled and regulated. This TPV characteristic refers to a medium-sized enterprise with small and batch production. Of the twelve basic stages, three to five are critical and form the critical path of TPV.

The quality of innovations and technological fulfillment of deadlines and the level of production costs are most influenced by three critical stages at the end of the TPV cycle in the phase of technology transfer, which are listed in chronological order: elaboration of technological procedures including technical economic standards (THN), special tools and single-purpose machines ) and production of special tools and JÚS.

The specified critical stages at the end of the TPV cycle accumulate time, capacity and value slips, thus shortening the running time and limiting the possibility of meeting deadlines, especially in the stage of special tool production and JÚS, thus significantly reducing the possibility to complete and equip production20 after the introduction of the innovated product with a complete set of special tools and JÚS as specified in the technological procedures for the established and repeated production of the innovated product.

After the privatization of industrial enterprises, many qualified workers left for better-paid jobs to foreign companies, and as a result, the level of normative basis for critical stages of TPVs often dropped and the TPV stages scheduling was often carried out without a capacity balance of TPVs. In these circumstances, the feasibility of TPVs and annual innovation programs constructed in this way has been and is still inaccurate and uncertain. In particular, the accurate identification of time and capacity constraints that determine the feasibility of product innovation within a set deadline and quality, either with overtime or even collaboration in another enterprise, is difficult to detect in small and medium-sized enterprises with up to 250 employees. and inaccurate or missing capacity balances of critical stages of TPV.

For larger enterprises with more than 250 employees, where comprehensive production management systems have been implemented, the throughput of pre-production critical stages of TPV is not determined at all or only inaccurately, so the risks of non-fulfillment of deadlines and quality of innovated products become blurred. or even bankruptcy of industrial enterprises. If the capacity balance is performed at all then it is usually locally for the total capacity of the TPV, which does not ensure throughput through the critical stages at the end of the TPV cycle.

The basic goal of TPV management innovation, including the technology transfer phase, is to significantly increase the accuracy of quantification of real R capacity resources designed and earmarked for product and technology innovation, especially in the three critical stages at the end of the TPV cycle, where congestion, disproportions and tensions between company capacity R and required capacity resources P to meet the deadline and quality of orders.

As an example of a particular business practice we can mention statistically determined values of real capacities of three critical stages R _L R ₂ , R ₃ , which are equidistant of annual capacity of theoretical capacities T _h T ₂ , T ₃ calculated from monthly funds of working time workers of the mentioned critical stage:

1. processing of technological processes incl. THN: R | - 0.4 Ie

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2. construction spec. tools and JUS: R ₂ = 0.8 T ₂

3. production spec. tools and JUS: R ₃ = 0.6 T ₃ .

Real capacity R is generally a part of theoretical capacity T, which is intended for capacity coverage of product and technological innovations and therefore the remaining part of capacity T - R covers so-called series maintenance, which is capacity coverage of already established and repeated production of worn parts and components. and worn spec. tools and JUS.

In the above way, the accuracy of the determination of the actual limiting factors and in particular the technical dimensions determining the throughput of critical stages at the end of the TPV cycle, where slips and disproportions from previous stages accumulate, is particularly increased.

The required capacity sources P as a regulated quantity have also been subject to demanding methodology and specifications based on the classification and sorting of newly designed and newly manufactured components and special tools as well as JÚS into classes and groups according to construction-technological complexity and similarity. We created sets of qualitatively and quantitatively most frequently used technical values, representing systems of value gauges, assembled into a value matrix NORMATIVE and corresponding quantity quantity matrix, which creates a matrix system of frequency of value pulses. Only after multiplication of both matrices we reach the numerical values weekly, monthly and yearly, which specify the conditions of throughput by the mentioned stages at the end of the TPV cycle.

Working selection of corresponding and correct values of normative and quantity and multiplication of both matrices by automated minicomputer enables to quickly and accurately identify invisible and intangible time and capacity disproportions. Further to compile and evaluate their course in the annual TPV cycle also using a minicomputer and to print the technical documentation in the form of protocols on the eligibility of CA and throughput through the critical stages for planning and managing the TPV course.

Moreover, already precisely identified and measured disproportions of technical variables can again be automatically controlled and corrected by interactive changes using a minicomputer, usually without the need for capacity or financial resources.

The advantage of the above-mentioned automated method remains that the numerical and graphical outputs of the minicomputer are relatively easy and quick to control by means of a hand-held calculator which is also protected.

The essence of the technical solution

In the initial initial phase of TPV control implementation, the first stage of innovation works analogously to an automated micrometer, which uses programmable minicomputer functions to automate the cycle of value pulses, sorting, and sorting. disproportions in the annual cycle. Automatically implemented interactive changes regulate disproportions and maintain the state of equilibrium and adaptivity in the preparatory and implementation phases of tangible, ie technical systems.

The system of automated control by interactive changes enables overload and disproportionation correction to be prevented before timely detected and measured disproportions cause losses or hidden defects in the material production process, ie machining, forming, assembly, etc., especially due to insufficient production of special tools, JÚS and mechanization means for operational and interoperational manipulation, such as clamps, loaders, magazines, roller tracks, etc. And just the above-mentioned more precise calculation and visibility and measurement of required, real and theoretical P, R, T and consequently R enables correction of disproportions preventively in the so-called incubation period, which is one of the basic advantages compared to the current state of TPV regulation and control, especially in the phase of technology transfer.

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The main benefit of the solution is the possibility to identify, measure and diagnose the occurrence of time, capacity and value disproportions in the technical preparation of TPV production with a focus on the technology transfer phase. At the same time, the detected, localized, quantified and displayed disproportion, which is usually intangible, invisible and difficult to detect, automated, fast, accurate and effective in TPV.

This system solution enables the combination of interactive control with automatic adaptive adjustment of the optimal equilibrium state on the critical TPV path, especially for the most overloaded critical stages at the end of the TPV cycle and selection of the optimal control method with respect to the type and degree of disproportion.

It is precisely the timely and preventive identification of the type of disproportion and the precise quantification of the degree of disproportion that enables the correct ordering of regulatory measures and time, capacity and value protection to protect the company against default, reduced quality and hidden defects of innovated products. phase, loss of credit at the bank, loss of good partners and customers or even bankruptcy.

System integration and pre-production phase management, especially in the field of technology transfer, avoids the risk of the inverse effect of losses due to obstruction on the critical path of TPV caused by intangible or difficult to detect disproportions compared to disproportions in the material manufacturing sector.

Therefore, there is a greater risk of abuse by unfair competition and it is for these reasons that the proposed TPV management integration system significantly increases financial and economic security. AVDRS enables qualified selection as well as reliable partnership of mainly exporting companies with foreign companies mainly in the EU and in case of need of foreign partner it is possible to shorten the lead time and order dates in the pre-production phase up to one half.

At the time of the accession of new states to the EU, especially in exporting companies and in the banking credit sector, AVDRS is an accurate and fast source of numerical values and information on the exporter's ability to meet its obligations under the export contract. AVDRS, especially from the point of view of risk elimination in the pre-production and pre-export phases, ensures the entire order process through critical points and helps especially for small and medium-sized enterprises to increase financial and economic security in the most risky chain links.

Elemental vertical integration enables the localization, identification, display, quantification and control of invisible, intangible and non-electrical deviations and disproportions, as well as determining the degree of congestion and implementing appropriate technical and organizational measures to balance the system or at least adaptive state of the system and TPV.

Horizontal integration works as a flexible interconnection of the preparatory and implementation phases of technological preparation of TgPV production, construction preparation of KPV production, material technical support of MTZ and start of new LV production by simply extending and debugging the input data of horizontally connected modules - stages TPV, TgPV (Ml), KPV ( M2), MTZ (M3) and NNV (M4).

Combining elementary vertical integration and a selected range of horizontal integration TgPV, KPV, MTZ and NNV focuses on correcting disproportions in the pre-production phase and losses in the production phase, especially value, before their materialization and formation in both pre-production and production phase, thereby correcting preventively significant losses before the overload of the production phase, mainly through interactive changes without increasing the demand for technical and financial resources by optimizing the use of existing resources and capacities.

The above-mentioned technical solution enables preventive and even in advance implementation of technical and organizational regulatory measures with regard to the detected degree of deviation. The amount of savings in the first year of introduction is estimated at 5% of the annual production of goods in CZK.

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In banking and business practice, in relation to international quality standards, the system allows to prove the ability to fulfill the main contractual conditions, which are the contract term and quality, including agreed technical parameters, before establishing contractual relations. BRIEF DESCRIPTION OF THE DRAWINGS

The technical solution will be described in more detail with reference to the accompanying drawings, in which Fig. 1 shows a diagram of an implementation model, Fig. 2 shows a diagram of functional and information interconnection, and Figs. AVDRS.

DETAILED DESCRIPTION OF THE INVENTION FIG. 1 shows an implementation model where:

Mi + M ₄ are pre-production and production modules;

M | is an initial module in technology preparation (TgPV) focused on throughput through critical stages in the field of technology transfer

- technological processes incl. THN

- design spec. tools incl. JUS

- production spec. tools incl. JÚS;

M ₂ is a follow-up module in design production preparation (KPV)

- BOM and techn. conditions

- prototype design drawings

- prototype production

- technological design;

M ₃ is material-technical security module (MTZ)

1. starting materials

2. semi-finished products

3. Finished parts purchased

4. machinery and technical equipment

5. tools

6. realiz. stage of technologist, project;

M ₄ is a new production start-up module (NNV) of the production phase

7. technical and technological production equipment of the enterprise:

forming machining surface finishing assembly.

Fig. 2 shows functional and information interconnection, where:

Stage management through critical stages of the minicomputer:

A) Annual Innovation Program

B) Data base of products

C) Diagnostic display of actual state - original version

D) Regulation of deviations, monitoring of the regulated state, implementation of interactive changes to IT, printing of protocols on CA eligibility and documentation plan.

Phase of realization through critical phases:

Mi is the initial module in the technological preparation of production (TgPV), indicating the critical stages of TgPV

1 technological procedures incl. THN

-4GB 15451 Ul Special tool construction incl. JÚS production spec, tools incl. JÚS

M ₂ is a subsequent module of structural preparation of production (KPV) with indication of critical stages of KPV prototype construction

5 prototype production.

Fig. 1 and 2 show a horizontal integration preproduction mechanisms (modules) m] to M ₄ (TgPV, KPV, MTZ and NNV). Vertical integration creates the internal structures of these horizontal models Mi to M ₄ and proceeds in three basic phases:

- detection and measurement of deviation (temporal or capacitive disproportion); io - regulation of deviations;

- management and planning of activities in critical phases and throughput on the critical TPV path.

These three basic phases are numerically specified and summarized in the Eligibility Protocols, which have three basic parts:

- timetable for the annual innovation program;

- capacity balance and determination of P, R, T values;

- a histogram of capacities in the annual course of the innovation and procurement program.

The following Figures 3 and 4 show two variants of the functional interconnection of said vertical integration.

Fig. 3 shows an automated control module consisting of a normative matrix NM and a product matrix VM, which are connected to a modular formation by a histogram of the capacitance HK. The input of the NM normative matrix is linked to the TLD printer of the Annual Innovation Agenda. The VM product matrix is interconnected with the progress of orders of the PZIP innovation program. The output of the modular formation of the HG capacitance histogram is coupled to a comparator modular member that measures and quantifies the disproportion when the required capacity P is greater than the real capacity R.

Fig. 4 shows an embodiment with a higher degree of automation of control, planning and management of the pre-production phase of the company incorporated. Here, the modular formation of the capacity histogram is directly linked to the automated KB capacity balance. The PML comparator modular output is connected to the ZL automated timing optimizer, which, via a minicomputer, creates an adaptive control and control mechanism that automatically adjusts itself to a predetermined degree of pre-production phase equilibrium (for example max. Disproportion up to 10% R).

The annual innovation program, indicating the product priorities and the orders received, is handed over to the PL planner, who designs and makes interactive changes. The output from the minicomputer for PL planners is then a deadline plan based on capacity balance including product and order priorities, from which specific tasks of TPV employees are derived, see UPTPV.

The automated module detects and measures disproportions, diagnoses, regulates and controls the product and technology innovation process along the critical TPV path. The whole solution incorporates and corrects unscheduled tasks, delays, and capacity disproportions through the interactive changes adopted by the enterprise 40 and made by the PL scheduler or other authorized personnel.

Example 1

Gradual realization directly in the manufacturing company, with a continuous realization period of 6 months to 3 years, depending on the scope of the solution.

The solution will be described in an exemplary medium-sized enterprise without branch plants with its own R&D base, which is a manufacturer of textile machines. Small diameter textile machines are divided into a number of types, which are further subdivided into individual types according to the size and fineness of the fabric. This also determines the type of production, which can be characterized as small-series irregular-repeated, the size of production series ranges from 10 to 160 pieces. In terms of innovation pace, we can speak of an average of four verification series of new types of textile machines per year. The weight of the complete machine, which consists of about three thousand manufactured and purchased parts, ranges from 200 to 400 kg.

The Technical Production Preparation Unit is a part of the Technical Department and provides technological preparation of production, including production and tool management, according to the design documentation taken from the Technical Development Department. TPV planning is carried out on the basis of an innovative program and a production plan. Due to the instability of requirements for the assortment of textile machines, only the annual TPV plan is elaborated in detail. Capacitive balancing is only performed at critical stages, which have a decisive impact on the ongoing time of technological preparation of production. In the conditions of a particular company these are the following critical stages: technological procedures of components included

THN, construction of special tools and production of special tools.

The basic prerequisite for drawing up the plan and balancing capacities are the labor intensive norms of the above-mentioned critical stages of TPV, which were determined by analysis and appropriate sorting of data contained in the existing records. Technological workmanship standards indicate the average workmanship workmanship, including the determination of THN-Material and THN-Power in hours for three component groups and three complexity classes. Standards of labor intensive construction of special tools indicate the average labor intensive of design documentation in hours per kind of special tool divided into 5 groups and 3 complexity classes. Similarly, norms of labor intensive production of special tools are set, with normative values given in norm-hours per piece of special tools.

Equally important is the determination of the available resources available for balancing the TPV stage. The basis is the theoretical available capacity, which is given by the planned number of workers ensuring the given stage with an effective employee fund, while the allocation of capacity to individual months is carried out according to the planning calendar.

The actual implementation of the annual schedule of TPV with a capacity balance is carried out by a mini-computer.

The preparation of input data, which includes information on the material tasks of the critical stages of TPV and their timing, is obtained as follows. Substantive tasks of TPV are taken over from the TPV plan and specified during construction-technological checks. The tasks of the technological service of production are qualified on the basis of statistical data. The following planning units are used for individual planned stages of TPV. Technological procedures of parts - number of parts - number of parts produced, construction of special tools - number of types of special tools, production of special tools. The required deadlines for the implementation of TPV tasks are taken from the production schedule and based on experience, a proposal is made to start and end individual stages. These data are recorded in a universal form according to individual tasks, which creates a modular organization of input data allowing their rapid preparation when changing plans.

After entering the input data and eventually adjusting it, the actual capacity calculation is performed with the display showing the discrepancies between the required and real capacity in individual months, expressed as a percentage. Here, the user has the option to decide whether the proposed plan fits or not. If the plan is unsatisfactory, ie the capacity discrepancies are too high, the user can make corrections by shifting the start and end times of individual tasks. Then the capacitive calculation and the new values are displayed again. Once a satisfactory layout has been created, a TPV layout report is printed to the printer.

The printing of the TPV plan is performed separately for each critical stage of the TPV on three sheets. It includes printing of input data and output data in the following arrangement: a line plan of the given TPV stage, a graphical representation of the comparison of required, real and theoretical capacity in individual months and per year, with a listing of used normatives of priority.

The press reports processed in this way will be received by the head of the respective stages, the TPV planner and the head of the TPV department.

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Routine control of plan fulfillment is performed at regular TPV dispatching centers once a week in physical units - planning units - according to individual tasks. Once a month, the dispatching center is associated with reporting the actual results in planning units, hours worked in total and planned tasks broken down by groups and complexity classes regardless of individual tasks. Reporting is performed on a universal form that is also used to write input data.

When reviewing plan fulfillment, the plan update is based on actual results. The TPV plan update is also performed whenever a significant change to the TPV plan and production plan is made. Norms and available capacities are updated once a year on the basis of a set of monthly statements and a work plan.

Although the described method is connected with simplification of the whole issue, it brings a substantial refinement of the TPV plan and in the most important critical stages, bottlenecks are discovered with considerable accuracy both in terms of time and matter in advance of up to one year.

Another benefit is the speed with which the TPV is processed in the case of changes to the innovation program and production plan15 that often occur in the manufacture of textile machinery. The new annual TPV plan according to the described method can be processed in practically one shift, when the change of input data due to their modular arrangement can be processed in about 8 hours and the actual compilation of the plan on the computer, including editing lines in an interactive way and printing in one hour.

The refinement of the TPV plan and the possibility of its rapid updating allow more efficient regulation of the technical preparation process. The whole system of planning and updating of the normative base, including the verification of real capacities based on the reporting of actual results, leads to a permanent refinement of the starting base and hence the planning of the TPV.

Example 2

Implementation of the first stage of the automated multi-module control and regulation system in the 25-phase turn-key technology transfer phase, with a running time of 2 to 4 weeks after delivery of the initial set of information.

The turnkey solution will be described on the example of an engineering company with up to 250 employees, which is the manufacturer of motorcycles produced 80% for export with an innovation cycle of 3 to 5 months. The individual implementation steps and activities were carried out in the following order:

- general constructional and technological characteristics of production and products, level of their technical equipment and selection of type representatives;

- the creation and completion of sets of normative values for critical stages within the existing normative base;

- compiling a default input data set;

- installing AVDRS software on the company computer;

- adjustment of AVDRS software to input data and business limiting factors;

- automated printing of PZ capability protocols for the critical stages of TgPV, including technology transfer and planning documentation of the TgPV plan, including tools, in the annual course of the innovation program, broken down as follows:

1. technological procedures including THN, PZ-1 eligibility protocol, TP technological procedure;

2. construction of special tools including JÚS, certificate of competence PZ-2, construction of KN tools;

3rd tool shop, production of special tools including JÚS, certificate of competence PZ-3, production tools HV.

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All of which contain a time schedule of the annual plan, a capacity balance of P, R, T values and a histogram of P, R, T capacities;

- design and implementation of interactive changes to IT;

- checking and verifying the accuracy and functionality of automated documents, documents and values;

- handing over the company computer back to the implementation company and training the operators for the AVDRS software installed;

- evaluation of the functionality and accuracy of AVDRS in operational conditions, including design of measures and conclusions as well as references, including the incorporation of AVDRS into existing business organization and management.

The implementation company staff participated in the implementation of AVDRS in the following steps and activities: collaboration on the development of the initial set of information for AVDRS, ensuring and implementing the integration of AVDRS into the existing business management system, operational testing, verification and testing Three to six months after the introduction of AVDRS, they refined and tuned the initial input data set and the company normative base.

Industrial applicability

The system of automated multi-module regulation of the preparatory phase of production including diagnostics according to this technical solution will find application especially in small and medium-sized production companies.

In the current period after the accession of new Member States to the EU, especially in export industry20 and in the banking credit sector, AVDRS is an accurate and fast source of numerical values and information about the manufacturer's ability to meet its obligations under export contracts, especially in terms of risk elimination. pre-production and pre-export stage, during which the whole supply is ensured through critical points and stages.

Claims (3)

PROTECTION REQUIREMENTS 25 1. System of automated multi-module regulation of pre-production phase including diagnostics, consisting of normative matrix block and product matrix block, which are connected with modular histogram formation of measured and displayed values of required capacity P, real capacity R and theoretical capacity T, the matrix is connected to the deadline display unit, the input of the product matrix block is connected to the block s 30, an innovative program of product and / or order flow, and output from the modular histogram formation of the measured and displayed capacitance P, real capacitance R, and theoretical capacitance T values is coupled to a comparative modular member of the required capacitance P and real capacitance R element. a technological preparation preparation block and / or a construction preparation preparation block connected thereto. 35 System according to claim 1, characterized in that a material-security block and / or a new production start-up block is connected thereto. System according to claim 1 or 2, characterized in that the modular histogram formation of the measured and displayed values of the required capacity P, the real capacity R and the theoretical capacity T comprises a block of capacity balance and for outputting a comparative modular term. 40, an optimization member for automated disproportion control, balance adjustment, and overall adaptability of the pre-production stage is coupled to allow passage through critical stages of the technical preparation of TPV production on a critical path.