home For a beginner Organization of preparation for production of new products. Mastering production Methods for mastering new types of products

Organization of preparation for production of new products. Mastering production Methods for mastering new types of products

Mastering production- this is the initial period of industrial production new products, during which the planned technical economic indicators... The period of mastering production begins with the manufacture of a prototype of a new product and ends with the start of its serial production. During the period of development, the design and technological refinement of the new product and the debugging of the technology of its production continue.

The period of mastering the production of new products is typical for the conditions of mass and serial production. In one-off production, the development period is practically absent, since the release of new products is carried out in units or in small batches.

The period of mastering new products includes the following stages:

1. Debugging and fine-tuning of a new product design. During this period, significant amount design and technological changes that require not only making adjustments to the design documentation, but also to technological processes.

2. Implementation and debugging of new technological processes, the development by workers of new technological operations, rational work methods and skills.

3. Technical development provides for the achievement of the technical parameters of the product design, determined by the standards and specifications.

4. Production development is the achievement of the planned production volumes for a given quality and sustainability of production.

5. Economic development is the achievement of the planned economic indicators in terms of cost, profit and profitability of the production of new products.

The effectiveness of the process of renewing products at machine-building enterprises is largely determined by the rationality of the chosen method of transition to the production of new products.

The choice of the transition method depends on a number of factors:

- differences in the degree of novelty of the products being mastered and removed from production;

- the degree of preparedness of the enterprise for the development of new products;

- type of production;

- the level of unification and standardization of new products.

The methods of transition to the release of new products used in mechanical engineering differ, first of all, in the degree of overlapping of the time of release of replaced and mastered products and are subdivided into three types: sequential, parallel and parallel-sequential.

Sequential method- the transition is characterized by the fact that the production of new products begins after the complete cessation of the release of products removed from production. Depending on the time of the break between the end of the release of the "old" product and the beginning of the release of the "new", there are discontinuous-sequential and continuous-sequential transition options (Fig. 9.3.2. And 9.3.3.).

Product release volume;

Planned volume of production;

Time to master new products;

Old product release schedule;

New product release schedule.

With a discontinuous-sequential transition(Figure 9.3.2.) a temporary stop in production is used for redevelopment and installation of equipment necessary for the release of a new product. With a continuous-sequential transition(Figure 9.3.3.) The release of a new product begins immediately after the termination of the release of the old product, but this option requires spare or additional space to prepare for the release of a new product.

The disadvantage of the sequential transition method is the reduction in production to zero during the period of mastering the release of new products.

Parallel method characterized by the gradual replacement of products removed from production by newly developed ones, where, simultaneously with a reduction in the volume of production of old products, an increase in the output of new products occurs (Figure 9.3.4.).

The duration of the overlapping time is different and depends on the degree of preparedness of the enterprise for the release of a new product. This method is most often used in mechanical engineering both in mass and serial production.

The main advantage of the parallel method of transition over the sequential method is the preservation or slight decrease in the total volume of production.

Parallel serial method transition is widely used in mass production in the development of new products that differ significantly in design from those removed from production. At the same time, additional capacities (sections) are created at the enterprise, where the development of a new product begins - technological processes are worked out, qualification training personnel, the release of the first batches of new products is organized. During the same period, the production of old products continues. After the end of the initial period, a short stop is made both in the main production and in additional areas, during which equipment redevelopment is carried out. In this case, the equipment of additional sections is transferred to the shops of the main production. Upon completion of these works, the release of new products is organized at a faster pace (Figure 9.3.5.).

The disadvantage of this method is also the loss in total output during the development of new products, although in smaller volumes than with the sequential method.

One of the main areas of time and cost reduction when switching to new product models in modern conditions is the introduction of flexible automated production, flexible flow and automatic lines.

Lecture 10. Planning of innovative processes in the enterprise

Topic 10.1. Types and content of production preparation plans

Planning of technical preparation of production

Business success in the marketplace is achieved when they act proactively anticipating and preparing for the future, rather than reacting with hindsight. Preparing for the future is done through planning. Planning is done on data marketing research, which answer the question: what kind of products need to be produced.

Planning includes the establishment of the scope of work, determination of the labor intensity of work, determination of the required number and composition of workers, distribution of work by divisions and performers, preparation of cost estimates for preparation, determination of the timing of work, coordination and regulation of work and control over the progress of their implementation, achieving a uniform loading of divisions and performers.

The following types of plans are drawn up:

promising,

general,

calendars - schedules and

operational.

Promising plans are drawn up for five years or longer. They give a list of new products to be developed for the future, predicted indicators of product quality, preparation time and consolidated costs.

General plans are developed for each type of new product for the entire period of its preparation, indicating the stages and works, the complexity of the cycles of technical training, the timing of each stage and cycle and the project as a whole.

Calendar plans-schedules are drawn up for the year by stages, performers.

Operational plans are drawn up for the current period quarter, month, day.

Initial data for the development of plans:

list of new types of products to be developed

established terms of development;

volumetric standards - the number of original parts, drawings, documents, the number of equipment, etc.

labor standards, standards for the duration of cycles and stages.

Planning innovation processes consists in drawing up calendar plans performance of work, determining the necessary labor, material and financial resources on carrying out research and design work.

The main tasks of planning scientific and technical developments:

mutual coordination of all work on the creation of new technology and the establishment of a rational sequence of stages;

determination of the total duration of work and ensuring their completion on time;

the best use of production resources.

The planning of the technical preparation of production is based on the calculations of the labor intensity and duration of the individual stages and stages of work.

When planning scientific and technical developments, the normative method is determined using the existing standards for the labor intensity of work for all stages and stages, the duration of individual stages and the entire development in calendar days, the cost estimate.

There are the following types of standards:

- labor intensity (the number of standard hours for one specification of a part, assembly unit);

- the duration of the cycles (the number of standard hours for the development stage, the stage of technical preparation of production);

- costs (rubles / specification).

The standards may differ by stages and stages of work, by categories of novelty and groups of complexity of the designed products. To classify products into a group of complexity and a category of novelty, industry classifiers are drawn up. The use of the normative method has become widespread in the development of design and technological documentation for a designed product. In the absence of standards for individual work, the labor intensity should be determined by expert or experimental statistical methods.

Labor intensity of work by stages terms of reference, technical proposal and draft design determined according to the norms for the product as a whole, depending on the category of novelty (A, B, C, D) and the complexity group (I, II, III, IV) of the product.

For the stages of the technical design and working documentation, the labor intensity is determined by the formula:

where, is the number of names of original parts and assembly units of the -th category of novelty and the -th group of complexity;

Labor intensity standards for the development of one original part and assembly unit of the -th category of novelty and the -th group of complexity, standard hour.

Based on the established labor intensity for each stage, the duration of the stage cycle in calendar days is determined:

, (10.1.2.)

where is the complexity of the th stage, hour;

- coefficient taking into account additional time for approval, amendments to technical documentation and other work not provided for by the standards;

- coefficient of conversion of working days to calendar days:

where, - the number of calendar and working days in the planning period;

The number of employees engaged in the implementation of the -th stage;

Length of the working day (shift), hour;

The rate of fulfillment of norms for workers with piecework wages.

The required number of employees can be determined by the formula:

where is the actual time fund of one employee for the planning period, hours.

Determination of the total duration of work depends on the organization of work based on sequential or parallel-sequential execution of stages and stages.

The sequential method of organizing work is that each subsequent stage begins after the complete completion of the previous one. In this case, the total duration of work in calendar days is determined by the formula:

, (10.1.5.)

where is the duration of the th stage in days;

The number of stages in development.

The duration of the entire development can be reduced either by reducing the duration of individual stages, or by partially overlapping the time of their execution, that is, using a parallel-sequential method of organizing work.

The total duration of work with the parallel-serial method is determined by the formula:

, (10.1.6.)

where is the minimum value of the duration of adjacent stages, performed in parallel;

Coefficient that takes into account the parallel (simultaneous) execution of adjacent stages .

The costs associated with research and development work (R&D) are included in the calculation of the economic efficiency of new equipment in the amount capital investments under the general title "before production costs».

Total amount for the implementation of a specific development is called the estimated cost of R&D. It is calculated according to the following cost items.

1. Materials, purchased products and semi-finished products, necessary for scientific research, manufacture of product models. They are priced at current wholesale prices, including transportation and procurement costs, which amount to 5-10% of the cost of materials.

2. Special equipment for scientific and experimental work... The purchase of such equipment is made at the expense of the estimated cost of R&D in cases where it is used to develop only this topic.

Special equipment for the development of several topics can be purchased at the expense of capital investments and credited to the fixed assets of the organization. Its cost is taken into account in the estimated cost of R&D in the form of depreciation deductions according to the formula.

Concept, stages of industrial development of products

Mastering of production is the initial period of industrial production of new products, during which the achievement of the planned design technical and economic indicators (design production of new products per unit of time and the corresponding design labor intensity and unit cost) is ensured. The allocation of this period is advisable only for conditions of mass and serial types production, which is characterized by the stability of the range of products manufactured by the enterprise over a certain period of time; in one-off production, the development period is practically absent, since the renewal of the nomenclature is associated with the release of each new one-off product.

During this period, a significant number of design and technological changes are received, which not only require adjustments to the technical documentation, but also changes in already mastered technological operations, technological equipment, and sometimes processes in general. The scope of these changes can be significant.

During the period of development, many workers, especially those employed in the main shops of enterprises of mass production, have to re-master technological operations, serviced equipment, technological equipment, i.e. to acquire professional skills in the changed production and technical conditions.

In the process of mastering the release of new types of products, the following stages are distinguished: technical, production and economic development.

Start t technical development it is considered that the production unit receives technical documentation and a prototype of the product simultaneously with the task of starting it industrial manufacturing, and the end is the achievement of technical design parameters, certain standards or technical specifications.

Production development is carried out in the process of setting up production and ends in conditions when all production units of the enterprise ensure the fulfillment of the established volumes of output at a given quality and the necessary sustainable production. During the period of production development, "bottlenecks" are eliminated, workers fully master labor operations, and the load of equipment and labor is stabilized.

Economic development of the production of new products presupposes the achievement of the main design economic indicators of the production of products. As a rule, the production costs of the first products are several times higher than the costs of mass-produced products. Subsequently, there is a sharp decrease in these costs. However, over time, the rate of decline slows down and then becomes insignificant.

Dynamics of production costs during the development of new products

Dynamics of production costs during the development period is determined by a number of factors, including the level of preparedness of the enterprise for the development of new products. This level reflects the degree of completion of various types of work on the preparation of production, the ability of the enterprise to ensure the design output of products and can be characterized by a number of indicators. The most significant of them is the readiness factor of fixed assets. With small values of the availability factor (0.2 .... 03), the first products have an increased labor intensity and cost, the development period is stretched in time for months, or even years. With values of the coefficient close to one, it is already possible at the beginning of the development period to reach the level of production costs close to the design one, and the development period itself is minimized. Enterprises that manufacture competitive products prefer to start production at high availability rates. This strategy ensures obvious benefits due to the reduction of the development period, however, it requires the attraction of significant investments by the time of the start of production. Moreover, with such a strategy, the degree of economic risk is high, since the real volume of sales may be lower than the potential output of products.

The main characteristics of the development process - the duration of this period, the dynamism of costs - also largely depend on the degree of preparedness of the enterprise to provide a deployed serial or mass production... With a high degree of readiness of special equipment and tooling for the beginning of the expanded production of products, it is possible to significantly reduce the development period, to ensure a relatively small excess of the labor intensity of the first industrial products in comparison with the design labor intensity.

Organization of the transition to the release of new products

There are two main forms of transition to the release of new products: with a stop and without a stop in production. In each of these forms, sequential, parallel and parallel-serial methods are distinguished.

Sequential transition method characterized by the fact that the production of new products begins after the complete cessation of the release of products removed from production.

Allocate discontinuously - sequential and continuously - sequential versions of this method. With the discontinuous-sequential method, after the termination of the production of an old product, redevelopment and installation work is performed at the same production facilities technological equipment and Vehicle, and upon their completion, the development of the production of a new product begins. The duration of these works determines the value of the stopping time of production - D T, during which there is no release of both new ones, since the losses in the total output are the highest here. They cannot be compensated for a long time, which does not allow the use of the discontinuous-sequential method in the practice of mastering new products.

The continuous-sequential version of the sequential method is characterized by the fact that the release of the product being mastered begins immediately after the termination of the release of the product being discontinued, i.e. D T= 0. Although this leads to losses in the total output of products, they can be minimized due to the high rates of increase in the output of the product being mastered. This requires a high degree of completeness of work on the technological preparation of the production of a new product to the beginning of its development.

Parallel transition method characterized by the fact that simultaneously with a reduction in the production of old products, there is an increase in the output of new ones. The length of time for combining the release of discontinued products and newly developed products can be different. This method is most often used in mechanical engineering both in mass and serial production.

Its main advantage in comparison with the sequential method is that it is possible to significantly reduce the losses in the total output of products during the development of a new product.

At parallel-serial transition method additional capacities are created at the enterprise, at which the development of a new product begins. Technological processes are being refined, qualification training of personnel is being carried out, the release of the first batches of new products is organized. During this initial period of development, the main production continues to produce items to be replaced. After the completion of the initial development period, there is a short-term shutdown both in the main production and in the additional sections, during which the equipment is re-planned: the equipment of the additional sections is transferred to the shops of the main production. Upon completion of these works, the release of new products is organized in the main production.

After completing all the preparatory stages and starting the production of new products, the design volume of output is not reached immediately. This requires some time, which is commonly called the development period. Its duration is significantly influenced by the quality of all stages of technical preparation of production and various production, organizational and economic conditions at the enterprise.

The period of mastering new products is a combination of various different works, in the process of which the structures and technology are checked and tested to the established technical requirements, new forms of production organization are being mastered. During this period, the planned production volumes, the planned economic indicators and the technical and economic parameters of the products (cost, quality, etc.) are achieved.

To identify and eliminate design and technological shortcomings in the future product, the projected structure and technological process are experimentally are verified by making a prototype under production conditions, and then by trial runs ui.

The following tasks are solved by making a prototype:

Comprehensive operational tests of a prototype product in accordance with specified specifications;

Appropriate testing of the most critical units and parts;

Verification and refinement of structural elements of parts and assemblies that could not be accurately established by preliminary calculation;

Identification and elimination of structural defects, verification of the accuracy of the operation of individual mechanisms and the product as a whole, complete coordination of all drawings;

Determination of technological deficiencies in the design and making appropriate changes to the drawings in order to improve the manufacturability of the product;

Experimental verification and establishment of more rational methods for manufacturing the most complex parts and assemblies.

Unlike a prototype, a prototype batch (series) of products should be manufactured under normal conditions of serial or mass production, typical for a particular enterprise. The purpose of making a pilot batch is as follows:

Provide proper quality processing and assembly of the product in full compliance with the specified specifications;

Verify and adjust the "technological process, designed for serial production;

Reveal and eliminate defects in technological equipment;

To identify and eliminate additional and fitting work that arose during the manufacture of parts, during the assembly and testing of a trial batch.

In order to identify and eliminate shortcomings and discrepancies in the drawings and technological processes in the manufacture of a pilot batch, it is advisable to carry out control assemblies, which are as follows. After fitting the parts, assembling them and carrying out the necessary tests, the product or its individual units are disassembled, accurate measurements of the parts are performed, and the actual dimensions of their mating and coordination are established. These dimensions are compared with those specified in the drawings. In case of deviations, their reasons are found out and the necessary corrections are made to the technical documentation. Then the product is subjected to repeated control assembly, during which the quality of the joints is carefully controlled and the timing of all assembly operations is carried out, determining the time spent on assembly in the absence of additional and fitting work.

Control assemblies are the final stage technological verification of the product before launching it into serial production.

To speed up the development of a new product, it is advisable to divide the totality of changes to which the drawings and technological processes should undergo based on the results of the manufacture of a prototype and a trial batch of products, into three main groups:

Changes to ensure the required quality of the product, to prevent defects and deformation during assembly of the product;

Changes aimed at increasing labor productivity, reducing labor intensity, reducing the production cycle, etc .;

Changes that provide for further modification of the products being mastered or fundamental improvements in the methods of their production.

Changes in the first group are made to the technical documentation immediately, that is, before the product is launched into serial production. Changes in the second group are carried out within the shortest technically possible time frame. Changes in the third group are transferred to the design department for use in the order of planned modification of manufactured products.

Simultaneously with the implementation of the technical and production stages of the development of new products, the design level of the main economic indicators is reached. It is known from practice that the costs of producing new products in the initial period of their development significantly exceed the costs provided for in the feasibility study of the transition to the release of new products. Some time after the start of development, as a result of the introduction of various organizational, technical and economic measures, costs are reduced, and the quality of new products increases (Fig. 28, 29). As a rule, the tendency to reduce production costs and improve quality when mastering the production of new products is stable, and the volume of output in this case is the most important factor.

Methods for the transition to production... In addition to the factors considered, the duration of the development period is also influenced by the form of transition to the production of new products. There are two main forms of transition: with a stop and without a stop in production. Moreover, in each of these forms, sequential, parallel and parallel-serial methods are distinguished.

The choice of the transition method significantly depends on the following factors:

the technical level of the product being mastered, its difference from the product being removed from production;

technological complexity of the new product;

availability of reserve production areas and capacities.

Sequential method transition is characterized by the fact that the production of new products begins after the complete cessation of the release of products removed from production. There are two variants of this method: discontinuous-sequential and continuous-sequential.

At discontinuous method, after the termination of the release of the old product A, at the same production facilities, work is first performed on redevelopment and installation of technological equipment, and after their completion, the development of the production of a new product B begins (Fig. 30, a). The duration of these works determines the time of stopping production. ∆Т during which neither the old nor the new product is produced. In terms of economic indicators, this is the least effective transition option, since during the time ∆Т the highest losses are observed in the total output.

At continuous sequential using the transition method, the release of the mastered product begins immediately after the termination of the release of the product being discontinued, i.e. at the same time ∆Т= 0 (Fig. 30, b). In this case, there are also losses in the total output of products, however, they can be reduced due to a sharp reduction in the development period.

Parallel method transition is characterized by the fact that simultaneously with a decrease in the volume of production of old products, the volume of production of new products increases (Fig. 31). This method is most commonly used in mechanical engineering. Its main advantage over the sequential method is that it can significantly reduce the loss of free capacity and production space. It is there that the development of a new product begins: technological processes are worked out, qualification training of personnel is carried out, the release of the first batches of new products is organized.

Parallel-serial the method of transition to the release of new products assumes the availability of products at the enterprise when a new product is mastered. In this initial period of development, the production of products to be replaced continues on the premises of the main production (Fig. 32). After the completion of the initial development period, a short-term shutdown occurs both in the main production and in additional areas ( ∆Т), equipment from additional sections is also transferred here. After the completion of which, the redevelopment of the main production areas is carried out; These works in the main production are organized by the release of new products.

The parallel-sequential method is widely used in the conditions of mass production in the development of new products that differ significantly in design from the removed ones, and allows to ensure high rates of increase in the release of new products after a short-term stoppage of the main production.

Market conditions predetermine the accelerated process of creating and mastering new products. All stages of the life cycle must be carried out quickly, with minimal waste of money and time, in order to stay ahead of competitors in the struggle for the sales market.

Before the development of new products, technological preparation of production (TPP) is carried out, which is a set of interrelated processes that ensure the technological readiness of the enterprise for production required quality at deadlines, production volume and costs. The content of the CCI and the amount of work depends on the type of production, design and purpose of the product. The work is regulated by the state standards ESTPP, which determines the procedure for organizing and managing the CCI, provides for the development and widespread use of progressive technological processes, the use of unified technological equipment and equipment, means of mechanization and automation of production processes, engineering, technical and organizational and managerial work.
Mastering the production of new products called manufacturing process their manufacture, during which the necessary debugging of technology, organization and planning of production takes place in order to release new products in a given volume, the required quality and achieve design economic indicators.
When determining the essence and content of the development of new products, one should proceed from the position that development is a production process, the initial stage in the release of new products.
The essence of the process of mastering new products reflects the deep connections and relationships that arise in the initial period of production of new product models.

Mastering content is an ordered set of elements and phenomena that form the production process during this period.
Should distinguish between technical, production and economic development.
Under technical mastering the production process is understood, during which the production reaches the design level of the technical indicators of new products.
The design technical parameters of the new model must be achieved in pilot production during the preparation of production for the serial, mass production of the new reduction.
However, technical development is sometimes carried out in batch production. As a result, the consumer receives products of low quality that do not meet technical specifications.
Production development begins with the release of the first serial samples and ends with the production reaching its design capacity in terms of the number of machines produced. During this period, additional equipment of production takes place for an increasing volume of production.
New equipment is being introduced, new complexes of special tooling are being put into production, cooperative ties with suppliers of materials and components and with consumers of an increasing volume of products are being refined, consolidated.
The skills of performing operations by the main workers are strengthened, technical and organizational knowledge and work experience of engineering and technical workers are replenished.
Economic development new products are characterized by a gradual decrease in the increased costs of labor, material and financial resources caused by the development, a decrease in the cost of production, an increase in labor productivity, profitability, and production efficiency. The economic development ends with the production reaching the design level in terms of the main economic indicators. In practice, you can focus on the dynamics of the labor intensity and cost of the product.
Economic development, like industrial development, begins with the release of the first products. Economic indicators reflect the state and development of the production process, prove the degree of readiness of the enterprise to start mastering the new model.
The higher the initial values of labor intensity, the cost of production, the greater the steepness of the development curve and, naturally, the longer the development period, the lower the quality of R&D, the worse the enterprise prepared for the transition to the release of a new model.

Development can be considered complete only when production and economic indicators have reached the design level. The first indicator characterizing the dynamics of economic development should be considered the labor intensity of products. It gives an idea about the acquisition of the necessary skills by workers, about the sufficient equipment of workplaces.
The economic development is convincingly characterized by the indicator of the cost of new products. Reaching the design cost indicates the end of the development of the production of the model.
additional information about economic development gives an indicator of the profitability of new products.
The dynamics of the level of profitability during the development period should be monitored and analyzed.

There are two types of mastering the release of new products.. First view- mastering the release of a research product (testing a product in a pilot production - Airborne Forces). Second view- development of industrial production of new products (industrial development). It consists in the sequential deployment of serial or mass production of new products. The types of development differ in goals, objectives, time and place.

6.1. The structure of the cycle of creating and mastering new products. The life cycle of a product (product) and the place in it of scientific and technical preparation of production

One of the main factors for the success of an enterprise in market conditions is the continuous updating of goods and production technology, in other words - creation, development, testing in market conditions, mastering the production of new products.

New products, based on new ideas, research and technical advances, provide concrete market success. The concept of the "R&D - production" cycle implies a close relationship between scientific research and their industrial development. The full range of work on the creation and development of new products is shown in Figure 6.1.

The place of scientific and technical preparation of production in the life cycle of goods is shown in Fig. 6.2.

Rice. 6.1. A set of works on the creation and development of new products

Rice. 6.2. The life cycle of a product and the place in it of scientific and technical preparation of production

All work included in the production preparation system (PPS) is unthinkable without information support and economic development. Economic development should be carried out at each stage of the SPP. This is all the more important because with results that significantly exceed the initial estimates and require an increase in pre-planned costs, it is possible to abandon the idea of creating a new product and prevent losses to the company.

Business development and analysis are more important in the early stages of product development (R&D). It is at these stages that the foundations of the economy and efficiency of a new product are laid. The influence of the pre-production system on the formation of the final effect of the development, production and operation of a new product is shown in Fig. 6.3.

Rice. 6.3. The influence of the pre-production system on the formation of the final effect of the development and use of a new product

The successful implementation of such a complex problem as the creation and development of a new product is impossible without the use of a systematic approach, which is based on a comprehensive solution of the tasks and tasks included in the problem, provides for setting a goal, requires identifying the content of input and output information flows, establishing optimization criteria, forecasting, modeling.

Optimization criteria systems for creating and mastering a new product are established depending on the goals and objectives of the company. They, in particular, can be:

The technical level of the product;
- terms of creation and development;
- increase in production volumes;
- an increase in the product range;
- reduction of costs in the preparation of production and in production;
- reduction of costs during the operation of the product.

An approximate structuring of the problem of creating and mastering new goods is shown in Fig. 6.4.

Rice. 6.4. Approximate structuring of the problem of creating and mastering new goods

6.2. Reducing the time required to create and master new products. Tasks and methods

In the ever-increasing volatility of market conditions, the timing of the creation and development of new products are extremely important (and, as a rule, decisive) in the activities of the company. The delay in bringing a new product to the market in comparison with competitors makes the efforts and costs for its creation and development useless, i.e. leads to irreparable losses, sometimes leading to bankruptcy.

Therefore, reducing the time required for the creation and development of new goods (NPP + TNPP + OP) is a central task, which is achieved by reducing the duration of the SPP stages and increasing the degree of their parallelism. The main tasks and methods of reducing the time required for the creation and development of new goods are given in table. 6.1.

Table 6.1

Tasks and methods of reducing the time for creating and mastering new goods

Main tasks shortening the time creation and development new goods	Methods	Content
1. Reducing the number of changes made after transferring results from the previous link to the next	Engineering and technical	Computer-aided design (CAD) systems Automated systems technical preparation of production (ASTP)
2. Determination of the rational degree parallelism of phases, stages and stages of SPP	Planning and coordination	Planning and coordination Network planning system Modeling Automated control systems (ACS for creating and mastering new goods)
3. Ensuring a minimum amount of time when performance of work and loss of time during transmission results of work from the previous stage to the next	Organizational	- standardization; - unification; - typification of technological and organizational solutions; - timely production of fixed assets (equipment, tools, tooling); - mechanization and automation of labor of production preparation services; - automation of normative economic and other calculations; - functional cost analysis and economic development; - preliminary testing of new products in pilot production; - the use of GPS

6.3. Planning the creation and development of new products. Network planning and management

The process of creating and mastering new products, like any other complex process, consisting of many stages and stages performed by various departments of the company, must be carefully coordinated and linked in time.

Requirements for planning and control systems:

Assessment of the current situation;
- forecasting the development of events;
- development of options for solutions and selection the best option actions for the preparation of production;
- control of work performance, their coordination and regulation.

The production preparation schedule as an element of the planning and management system and at the same time as a model of the cycle of creating and mastering new goods should reflect those that are significant in relation to the achievement of the final goals of the work (stages, phases, etc.). He should also take into account the possible states of the complex of relevant works, the timing of their implementation, possible violations of these terms and the consequences of violations.

Simplest planning methods involve the use of models such as strip charts (Fig. 6.5).

Rice. 6.5. Enlarged ribbon chart of ROC

Line charts are still used today for relatively simple objects of pre-production planning. However, they have a number of significant disadvantages:

They do not show the relationship of individual works, which makes it difficult to assess the significance of each individual work for the achievement of intermediate and final goals;
- do not reflect the dynamism of developments;
- do not allow to periodically make adjustments to the schedule due to changes in the timing of work;
- do not give clear points of alignment and conjugation of adjacent stages;
- do not allow the use of a mathematically sound calculation of the implementation of the planned complex of works;
- do not provide an opportunity to optimize the use of available resources and the timing of the development in general.

Network planning and management

Planning and managing a work package is a complex and often controversial task.

The assessment of the time and cost parameters of the functioning of the system, carried out within the framework of this task, can be made by different methods. Among the existing ones, the method of network planning and management (NMS) has proven itself well.

The main planning document in the STS system is the network schedule (network model or network), which is an information-dynamic model, which reflects the relationships and results of all work necessary to achieve ultimate goal development.

The simplest single-purpose network model on a small set of works is shown in Fig. 6.6.

Rice. 6.6. An example of a network diagram for a small work package

The network model is depicted as a network diagram (network), consisting of arrows and circles.

The arrows on the network represent individual works, and the circles represent events. The expected time of work is indicated above the arrows.

The stages of development and management of work progress using a network schedule have the following sequence of basic operations:

1) drawing up a list of all actions and intermediate results (events) when performing a set of works and their graphic reflection;
2) estimating the time it takes to complete each job, and then calculating the network schedule to determine the time frame for achieving the goal;
3) optimization of the calculated timing and necessary costs;
4) operational management of the progress of work by periodically monitoring and analyzing the information received on the execution of tasks and the development of corrective decisions.

WORK is any processes (actions) leading to the achievement of certain results (events). The concept of "work" can have the following meanings:

a) actual work - work that requires an investment of time and resources;
b) waiting - a process that only requires time (drying, aging, relaxation, etc.);
c) fictitious work, or dependence, is an image of a logical connection between works (depicted by a dashed arrow, over which time is not put down or zero is put down).

EVENTS (except for the original) are the results of the work performed. The event is not a process and has no duration. The onset of an event corresponds to the moment of the beginning or the end of work (the moment of the formation of a certain state of the system).

An event in the network model can have the following meanings:

a) initiating event - the beginning of a set of works;
b) the final event - the achievement of the ultimate goal of the work package;
c) an intermediate event or just an event - the result of one or more of the work included in it;
d) boundary event - an event that is common to two or more primary or private networks.

A work event can have the following meanings:

1) the initial event, which is immediately followed by the given work;
2) the final event immediately preceded by the given work.

A PATH is any sequence of network activities in which the end event of each work in this sequence coincides with the start event of the next work.

The path (L) from the starting to the ending event is called complete.

The path from the original to this intermediate event is called the path that precedes this event.

The path connecting any two events i and j, of which neither is the source or the final, is called the path between these events.

Network model parameters

The main parameters of the network model include:

a) critical path;
b) time reserves of events;
c) time reserves of tracks and works.

The critical path is the longest path of the network schedule (L cr.).

Changing the duration of any work on the critical path changes the timing of the ending event accordingly.

When planning a set of works, the critical path allows you to find the timing of the onset of the final event. In the process of managing the course of a complex of works, the attention of managers is focused on the main direction - on the works of the critical path. This allows the most expedient and efficient control of a limited number of works affecting the development period, as well as better use of available resources.

Event time reserve- this is such a period of time for which the onset of this event can be delayed without violating the deadlines for completing the complex of works as a whole. The time reserve of an event is defined as the difference between the late T pi and the early T pi timing of the event:

Late due date T ni is such a period of occurrence of the event, exceeding which will cause a similar delay in the onset of the final event, that is, if the event occurred at the moment T ni, it fell into the critical zone and the subsequent work should be under the same control as the work of the critical path.

The earliest possible date the occurrence of the event T pi is the time required to complete all work preceding this event. This time is found by choosing the maximum value from the duration of all paths leading to the given event.

The rule for determining T p and T p for any network event:

T p and T p of the event are determined by the maximum of the paths L max passing through this event, and T p is equal to the duration of the maximum of the paths preceding this event, and T p is the difference between the duration of the critical path Lcr and the maximum of the paths following the given event , that is

;

where C and - the initial event;
С з - the final event.

Zero slack for events... For these events, the allowed time is the shortest expected. The initial (C and) and final (C c) events also have a zero time reserve.

Thus, the most simple and convenient way identifying the critical path is the identification of all sequential events with zero slack.

Time reserve for paths and works

Full travel time reserve R ( L i) is the difference between the length of the critical path t ( L cr) and the length of the considered path t ( L i):

R (L i) = t (L cr) - t (L i).

It shows how much the total duration of all works belonging to the path can be increased. L i, that is, the maximum permissible increase in the duration of this path. The full travel time reserve can be distributed among the individual jobs on the way.

Full reserve of operating time R nij is the maximum period of time by which the duration of this work can be increased without changing the duration of the critical path:

where t ij- duration of work;
ij - the initial and final event of this work;
T ni and T pi - respectively, late and early dates of occurrence of events j and i.

Dependent runtime reserve

Since the reserve travel time L i can be used to increase the cycle of work on this path, we can say that any of the work of the path L i in its section, which does not coincide with the critical path, it has a reserve of time. But this reserve has a peculiarity:

if we use it partially or entirely to increase the cycle t (i, j) of some work (i, j), then the reserve of time for other jobs decreases accordingly L i... Therefore, such a reserve of the time of the path on which it is located is called the dependent reserve of the operating time (i, j) and is denoted by.

Independent runtime reserve

In addition to the dependent slack, individual jobs may have an independent slack, denoted by. It is formed when the work cycles (i, j) are less than the difference between the earliest possible timing of the event j immediately following this work and the latest of the admissible timing of the event i immediately preceding it:

Free reserve of work time () is the difference between the early dates of occurrence of events i and j minus the duration of work t (i, j):

Free reserve of work time - the maximum period of time by which the duration can be increased or its start can be postponed without changing the early dates of subsequent work, provided that the initial event of this work occurred at its early date.

Possibilities for shifting dates the beginning and end of each work is determined using the early and late dates of the occurrence of events between which this work is performed:

Early start date of work;
- late date getting started ;
- early completion date ;
- late completion of work.

Analysis and optimization of the network model

The originally developed network model is usually not the best in terms of turnaround time and resource utilization. Therefore, the original network model is analyzed and optimized for one of its parameters.

The analysis allows us to assess the appropriateness of the structure of the model, to determine the degree of complexity of each work, the workload of the work performers at all stages of the work complex.

The relative complexity of meeting the deadlines for performing work on non-critical routes is characterized by the coefficient of work intensity:

where is the duration of the maximum path passing through this work;
- the duration of the segment of this path, which coincides with the critical path;
- the duration of the critical path.

The higher the stress coefficient, the more difficult it is to complete the work on time.

Using the concept of "travel time reserve", it can be defined as follows:

It should be borne in mind that the reserve time R (L i) of the path L i can be distributed between individual jobs on the specified path, only within the dependent time reserves of these jobs.

The value of the stress coefficient for different works in the network lies within 0Ј<1.

For all jobs, the critical path is equal to one. The value of the stress factor helps, when setting the planned deadlines for the performance of work, to assess how freely you can have the available reserves of time. This coefficient gives the performers of work an idea of the degree of urgency of work and allows you to determine the priority of their implementation, if they are not determined by the technological links of work.

To analyze the network model, the coefficient of freedom (i, j) is used, which shows the degree of freedom or independence of work cycles that have a free reserve of time, and also shows how many times the duration of work t (i, j) can be increased without affecting the timing all events and other works of the network:

Moreover, (i, j)> 1 always. If (i, j) Ј 1, then this indicates the absence of independent reserve time for work (i, j).

Optimization of network models according to one of its parameters can be carried out graphically or analytically. Solving the problem of optimizing a network model, usually calculate the minimum duration of a set of works with restrictions on the resources used.

Optimization of the network model, carried out by the analytical method, lies in the fact that it is based on the regularity in which the execution time of any work (t) is directly proportional to its volume (Q) and inversely proportional to the number of performers (m) employed in this work:

The time required to complete the entire complex of works is determined as the sum of the durations of the component works:

However, the total time calculated in this way will not be minimal, even if the number of performers corresponds to the complexity of the stages.

The minimum time for a complex of sequentially performed works and other types of fragments of network models can be found by the method of conditionally equivalent labor intensity.

The conventionally equivalent labor intensity is understood as the amount of labor costs at which the number of performers of an equivalent specialty is distributed among the constituent works, provides the least time for their execution.

The conditionally equivalent labor intensity is determined by the formula:

where is the labor intensity of the previous and subsequent work.

The minimum work execution time will be ensured with the following distribution of workers by stages:

, ,

where - total working at certain stages.

Graphical method for optimizing the network model - "time-cost"

The "time-cost" method is to establish an optimal balance between the duration and cost of work.

Determination of the costs and resources required to complete each job is done after the development of the network schedule.

Thus, material and labor resources are planned based on general structure a network created by predicting temporal estimates.

Rice. 6.7. Time-cost graph

To build graphs "time-costs" (Fig. 6.7) for each job are set:

The minimum possible cash costs for the performance of the work (subject to the performance of the work in the normal time);
- the minimum possible time to complete the work at the maximum cost.

In defining the first pair of estimates, the emphasis is on maximizing cost savings, and in defining the second, on maximizing time savings.

It is possible to approximately determine the amount of additional costs required to shorten the work execution time, or to solve the inverse problem using a graph with an approximating straight line. The amount of additional cash costs required to complete the work in a reduced time will be

For each type of work, its own graph is calculated and built, characterized by the slope of the approximating straight line.

Using a linear cost-time relationship for each type of work, you can calculate the rate of increase in costs per unit of time:

The economic efficiency from the implementation of the STS is determined primarily by the possibilities of reducing the overall cycle of work and reducing costs due to a more rational use of labor, material and monetary resources.

Reducing the duration of the complex of works provides a reduction in the payback period of investments, an earlier launch of goods on the market, which contributes to the competitive success of the company.