CZ20041154A3 - Method of automated multi-modular control of manufacture preparative phase including diagnostics and system for making the same - Google Patents

Abstract

The method of automated multi-modular regulation of the preparatory phase of production consists in the creation of normatives and quantitative values of technological processes, construction of tools and production of tools, then a set of input data of technological processes, construction of tools and production of tools is carried out identification, localization, registration and quantification of time, capacity and value disproportions, which are further displayed and corrected and regulated by interactive changes. To perform the method, a system consisting of one block of a normative matrix and another block of a product matrix, which are coupled to a modular capacitance histogram formation, is used, wherein the input of one block is connected to the display unit of the term bar chart, the input block is connected to the block with the innovation program and / or or the progress of the orders, and the output of the modular capacity histogram formation is connected to the comparative modular member of the required capacity capacitor P and the real capacity R, and a manufacturing process block and / or a manufacturing design block is attached thereto.

Description

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The method of automated multi-module regulation of the preparatory phase of production consists in creating normative and quantitative values of technological processes, tool design and tool manufacturing, then creating a set of process data input, tool design and tool manufacturing, followed by identification, location, registration and quantification of time, capacity and value disproportions, which are further displayed and corrected and regulated by interactive changes. To perform the method, a system consisting of one normative matrix block and another product matrix block interconnected with a modular capacity histogram formation is used, wherein the input of one block is coupled to the deadline display unit, the input of another block is coupled to the innovation program block and / or In the course of the orders, the output of the modular capacity histogram formation is connected to the comparator modular member of the required capacity P element and the real capacity R, and further connected to a technological preparation block and / or a structural preparation block.

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A method of automated multi-module control of the preparatory stage of production including diagnostics and a system for carrying out this method.

Technical field

The present invention relates to a method of automated multi-modular control of a preparatory production phase including diagnostics and a system for performing the method (hereinafter referred to as AVDRS).

Background

The state of technical preparation (TPV) and its management is usually defined by twelve basic stages and approximately two hundred basic activities recorded, of which the main activities are controlled and regulated. This TPV characteristic refers to a medium-sized enterprise with single-piece and small-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.

-2The specified critical stages at the end of the TPV cycle accumulate time, capacity and value slips, thus reducing the average 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 production in the first year 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.

-3 The basic objective of TPV management innovation, including the technology transfer phase, is to significantly increase the accuracy of quantification of the actual 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 stress are most common. between the real business capacity R and the required capacity resources P to meet the deadline and quality of orders.

As an example of a particular business practice, the following values can be found:

1. Processing of Tg procedures incl. THN: R 1 = 0.4 T _x

2. construction spec. tools and JÚS R ₂ = 0.8 T ₂

3 .. production spec. tools and JÚS. R ₃ = 0.61 T ₃

This measure has significantly improved the accuracy of the determination of the actual limiting factors of capacity balances, especially for the critical stages at the end of the TPV cycle and in particular in the technology transfer phase.

Also, the required capacity sources P have undergone demanding specification specifications based on the classification and sorting of newly designed components and special tools and JUS into groups according to the construction-technological complexity. The sets of the most frequently used value dimensions, ie systems, value gauges and impulses , compiled into a value matrix - normative and corresponding quantity matrix, ie a system of frequency of value pulses.

-4The selection of correct values and multiplication of both matrices made and automated by the minicomputer enabled to identify and quantify invisible and intangible time and capacity disproportions, to compile their course in an annual cycle using a minicomputer, possibly in printed form as technical documentation.

In addition, such precisely identified and measured disproportions can be automatically corrected and controlled by means of a minicomputer by interactive changes, usually without the need for capacity or financial resources.

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 searching, sorting and sorting value pulses and measuring and summarizing the measured values. 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.

This method of automated control by interactive changes makes it possible to prevent overloads and disproportions preventively before timely detected and measured disproportions cause losses or hidden defects in the material production process, ie. machining, forming, assembly, etc., especially inadequate production equipment with special tools, JÚS and mechanization means for operational and in-operation handling, such as clamps, loaders, magazines, roller tracks, etc. And just

-5 • · • 4 · · · · 4 · · ··· specified precision of calculation and visibility and measurement of required, real and theoretical P, R, T and consequently also the course of P / R voltage allows correction of disproportions preventively in so-called incubation This is one of the basic advantages compared to the current state of TPV regulation and control, especially in the technology transfer phase.

The main benefit of the solution is the possibility to identify in time and accurately 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 depicted disproportion, which in TPV is usually intangible, invisible and difficult to detect, automated, fast, accurate and effective.

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.

reduced product quality and from that

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 the deadline of the contract, the contract and hidden banks, loss of good partners and customers or even bankruptcy. System integration and pre-production phase management, especially in the field of technology transfer, prevents the risk of the “inverse effect of the loss of inverse • • • • • • • • • • • • • • • • • • •

-6 due to obstruction on the critical path of TPV caused by intangible or hard to detect disproportions compared to disproportions in the material manufacturing sphere.

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 to increase financial and economic security in the most risky links of the chain.

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.

• 9 9 9

9 9 9 9 9

9999 9 · ····································

-7Horizontal integration works as a flexible interconnection of the preparatory and realization phase of technological preparation of TgPV production, construction preparation of KPV production, material technical support of MTZ and start of new LV production by simply expanding and debugging input data of horizontally connected modules (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 savings in the first year of introduction are estimated at 5% of annual production of goods.

In banking and business practice, in relation to international quality standards, the system enables 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

BRIEF DESCRIPTION OF THE DRAWINGS The invention will now be described in more detail by way of example with reference to the accompanying drawings, in which: Figure 1 shows a schematic of an implementation model;

Fig. 3 is a schematic diagram of the functional and information interconnection; and Figs.

Examples of technical solution

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 irregularly repeated, while 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 carried out at critical stages that have a decisive impact on the continuous technological time. · · · ··· · · · · · ··· · · · · · · · ·· ··· ··· ·· ·

-9Preparation production. In the conditions of a particular company these are the following critical stages: technological procedures of components including 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 specify the average workmanship workmanship, including the determination of THN-Material and THN-Power in hours for three component groups and three classes of complexity. 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 employees providing the given stage with an effective employee fund, while the allocation of capacity into individual months is carried out according to the planning calendar.

The real available capacity R is determined by the ratio of the theoretical capacity T, which was determined according to the previous statistical monitoring in the selected company as follows: Technological procedures of components Ri - 0,43 Ti

Design of special tools R ₂ - 0,80 T ₂

Production of special tools R ₃ - 0,61 T ₃ • 9 • 99 • 999 ··· · ··

-10Theoretical available capacities, with residual capacity dedicated to other tasks. The actual elaboration of the annual schedule of TPV with a capacity balance is performed on a desktop computer.

The preparation of input data, which includes information on the material tasks of the critical stages of the 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.

· «9 9 99 ·« 9 9 9 99 · 9 9 99

999 9 9 9999

9999 9 9 99 · ···

9 9 9 9 9

9999 99 999 999 99

-11 Printing of the TPV plan is performed for each critical stage of the TPV separately 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 prepared in this way will be received by the head of the relevant stages, as well as the TPV planner with the head of the TPV department.

Routine checking of plan fulfillment is performed at regular TPV control rooms once a week in physical units of 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 method described is connected with simplification of the whole issue, it brings a substantial refinement of the TPV plan »and in the most important critical phases they reveal a considerable ·

9 ··· 9 »

* 9 · 9 9 9

9 9 9999 • · · ·· 4 accuracy of the bottlenecks, both factually and temporally, up to one year ahead.

Another benefit is the speed with which the TPV is processed in the case of changes to the innovation program and production plan, which 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 update 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 thus the planning of TPV.

Example 2

Implementation of the first stage of an automated multi-module control and regulation system in the turn-key technology transfer phase, with an ongoing implementation 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:

• ··· 4

4

4444 44

-13General structural 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 the critical stages within the existing normative base; building a default input data set;

installing AVDRS software on a corporate computer;

adjusting AVDRS software to input data and business constraints;

automated printing of protocols on the eligibility of PZ for critical stages of TgPV including technology transfer and planning documentation of the TgPV plan including tools in the annual course of the innovation program 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, inspection of KN tools;

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

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;

testing and verifying the accuracy and functionality of automated documents, documentation and values; handing over the company computer back to the implementation company and training the staff on the installed AVDRS software;

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 organization and business management.

-14 Implementing company staff participated in the implementation of AVDRS in the following steps and activities: collaboration to build the default AVDRS information set, ensuring and implementing the integration of AVDRS into the existing business management system, testing, verifying and testing the functionality and accuracy of AVDRS results in operating conditions; continuously 3 to 6 months after the introduction of AVDRS, they refined and tuned the initial set of input data and the normative base of the company.

Industrial applicability

The method of automated multi-module control of the pre-production stage including diagnostics according to the present invention will find application especially in small and medium-sized production companies.

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Claims (4)

PATENT CLAIMS 1. A method of automated multi-module control of the preparatory stage of production, including diagnostics, characterized in that normative and quantitative values of technological processes, tool design and tool manufacturing are created, then a set of input data of technological processes, tool design and tool manufacturing is generated. , localization, registration and quantification of time, capacity and value disproportions, which are further displayed and corrected and regulated by interactive changes. Method according to claim 1, characterized in that the quantification of the disproportions is performed by summing the value pulses assembled in the normative matrix and the product matrix. A system for carrying out the method according to any of the above claims, consisting of one normative matrix block and another product matrix block that are connected to a modular capacity histogram formation, wherein the input of one block is connected to the term time chart display unit, the input of another block is connected to a block with an innovative program and / or order flow and the output of the modular capacity histogram formation is connected to a comparator modular member of the required capacity P element and the real capacity R, characterized by being connected to the technological preparation block and / or block of structural preparation of production. System according to claim 3, characterized in that a material-security block and / or a new production start-up block is connected thereto. · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · The system of claim 3 or 4, wherein the modular order histogram formation comprises a capacity balance and an output of the comparator modular member is coupled to an optimization member for automatically adjusting the system equilibrium on its critical path. • · · · · 1> 0 Xecq ~ 4SET 9 ····· · · 4/4 «· ··· · PZ1P = Progress of orders and innovation program PL «TPV scheduler, which also makes interactive changes TLD = Deadline chart including product priorities and orders UPTPV = Tasks for TPV staff MM »normative matrix VM« product matrix HK «Histogram of capacities P «required capacity oita