home Preparation Creation and development of a new product (service). Organizational preparation of production and development of new types of products Planning of technical preparation of production

Creation and development of a new product (service). Organizational preparation of production and development of new types of products Planning of technical preparation of production

The creation of new products in industries is carried out in a certain sequence of phases of a single process of production preparation. This sequence includes:

Theoretical research of a fundamental and exploratory nature;

Applied research, during which the knowledge obtained at the first stage finds practical application;

Development work, during which the acquired knowledge and research conclusions are implemented in drawings and samples of new products;

Technological design and design and organizational work, during the implementation of which technological manufacturing methods and forms of organizing the production of new products are developed;

Technical equipment of a new production, consisting in the acquisition and manufacture of equipment, technological equipment and tools, as well as, if necessary, the reconstruction of enterprises and their divisions;

Mastering the production of new products, when product designs and methods for their manufacture created at previous stages are tested and introduced into production;

Industrial production, ensuring the release of new products in quality and in quantities that meet the needs of society;

Use of a newly created product in the field of operation; development and production of new types of products that embody the latest achievements of science and technology, meeting the highest requirements of consumers, competitive in the world market;

Providing appropriate technical and organizational conditions for a significant increase in labor productivity in the national economy;

Creation of new products that would have a high quality level with minimal production costs;

Reducing the duration of design, technological, organizational and other work included in the production preparation complex, and mastering the production of new products in a short time;

Cost savings associated with production preparation and development of new products.

Experimental design work (R&D) is a set of actions to create a new product in the form of a prototype and working documentation for subsequent industrial production and use of these products.

Development work is usually carried out, V three stages: preparatory, as well as development of design and working documentation.

At the preparatory stage, the need to create a new product and transfer it to service production is justified, the main technical and economic parameters of the product are agreed upon. Options for design and technological solutions are substantiated, a list of works is compiled, their volume, costs, performers, and deadlines are specified. The estimated cost of experimental and serial samples of the product and the deadline for their delivery to the customer are determined. The preparatory stage ends with the approval of the technical specifications containing the most important characteristics of the designed product.

When developing design documentation, the optimal option for manufacturing the product and its parts is selected, taking into account cost, efficiency and scale of production. General design and technological solutions are determined, tests are carried out, and the most complex and critical parts of the product are mocked up. Applications for the development and development of new materials, new components, etc. are substantiated. At this stage, a technical proposal, a preliminary design and a technological project are developed by drawing up the appropriate project documentation.

Development of working documentation is the final stage of designing a new product. A set of design documentation necessary for the material implementation of the designed product is being prepared. Drawings of parts, assembly units and assemblies are prepared, theoretical and experimental testing of circuit, design and technological solutions is carried out; New materials, semi-finished products, components are tested, and working documentation is developed. At this stage, special lists of parts, assemblies or graphics are compiled, reflecting the hierarchical structure of the creation of a new product. The listed documentation is submitted to the technical documentation department for reproduction and release into production. Then state tests are carried out, formalized by the relevant act.

Scientific and technical development is considered complete if the product has passed the test, been accepted by a departmental or interdepartmental commission and recommended for use in production.

In addition to ensuring a high scientific and technical level and competitiveness, the design of a new product must take into account the scale and conditions of its production, and focus on the lowest possible production costs. This problem is solved by design preparation for production.

9.7 Network planning and pre-production management

The use of network planning methods helps to reduce the time required to create new facilities by 15-20%, ensure the rational use of labor resources and equipment, i.e. improve the organization of production.

Network planning is a management method based on the use of the mathematical apparatus of graph theory and a systems approach to display and algorithmize complexes of interrelated work, actions or activities to achieve a clearly defined goal.

The main planning document in the network planning system is the network schedule.

Building a network diagram.

In the network model, events are indicated by circles, jobs - by arrows. The constructed graph must have one initial and one final event.

An event is an intermediate or final result of one or more activities. It does not have a duration in time, but indicates the beginning of some work and can simultaneously be the completion of others.

Work in a network diagram refers to any process that requires labor; waiting, requiring a certain amount of time; a dependency indicating that the start of a given job depends on the completion of the previous one. Graphically, the work is indicated by a solid arrow. An arrow that expresses only the dependence of one job on another is called a fictitious job and is indicated by a dotted line. It has a zero time rating.

Rice. 5 Example network graph

During the calculation of the network schedule, the following parameters are determined: duration of work and critical path; the earliest and latest dates for the occurrence of events and completion of work; all types of reserves for work and events that are not on the critical path.

Any sequence of activities connecting the initial event with the final event is called a path. The path with the longest duration of work is called critical and is depicted with bold arrows.

Activities on the critical path have no slack. Therefore, failure to meet deadlines for any work on the critical path leads to a delay in the overall deadline for completing the entire complex. Activities that are not on the critical path have a slack time.

Before determining the critical path, it is necessary to calculate the early and late dates for the completion of events, as well as the slack for each event. Events with zero float will indicate the passage of the critical path. The early date of an event characterizes the earliest possible date for the occurrence of an event. The duration of its completion is determined by the length of the longest segment of the path from the initial event to the one under consideration.

The time reserve for events shows by what maximum permissible period of time the completion of an event can be delayed without causing the danger of missing the deadline for the completion of the first event. If the reserve is fully used, the event will fall on the critical path.

If the deadlines for completing all work do not meet the guidelines, it is necessary to optimize the network. For these purposes, it is possible, firstly, to increase the number of performers, and secondly, to redistribute labor resources by switching some workers from jobs that have large reserves of time to performing jobs that are on the critical path.

The network model allows you to pose and solve two types of problems: computational - determining network parameters - and optimization. When solving optimization problems, a network schedule is found that satisfies a given criterion (for example, the minimum duration of a set of works) with restrictions imposed on some network parameters (number of performers, availability of equipment, materials, etc.).

Advantages of network graphs:

Provides the ability to depict connections between works

Determine the work on which the total duration of the work depends

Create conditions for predicting the progress of the project

Improves control by allowing you to focus on critical area work

When changing hourly chart parameters, there is no need to completely change it

Work performers take part in the scheduling process, thereby using their knowledge and experience

Mathematics and programming create conditions for the successful creation of network models

Provides the ability to depict a large number of interrelated works.

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

The period of mastering the production of new products is typical for conditions of mass and serial production. In single-unit 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 development of new products includes the following stages:

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

2. Introduction and debugging of new technological processes, mastering by workers of new technological operations, rational labor techniques and skills.

3. Technical development involves achieving the technical parameters of the product design, defined by standards and technical conditions.

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

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

The effectiveness of the process of updating manufactured 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 transition method depends on a number of factors:

– differences in the degree of novelty of products being developed and those being discontinued;

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

– type of production;

– level of unification and standardization of new products.

The methods of transition to the production of new products used in mechanical engineering differ primarily in the degree of combining the production time of replaced and mastered products and are divided 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 production of discontinued products. Depending on the break time between the end of the production of the “old” product and the beginning of the production of the “new”, discontinuous-sequential and continuous-sequential transition options are distinguished (Fig. 8.2 and 8.3).

Product output volume;

Planned volume of product output;

Time to develop new products;

Release schedule of the old product;

New product release schedule.

With a discontinuous-sequential transition option(Fig. 8.2) stopping production for a while is used for redevelopment and installation of equipment necessary for the production of a new product. With a continuous-sequential transition option(Fig. 8.3) the production of a new product begins immediately after the cessation of production of the old product, but this option requires the availability of reserve or additional space to prepare for the release of new products.

The disadvantage of the sequential transition method is the reduction in production volume to zero during the development of new products.

Parallel method characterized by the gradual replacement of discontinued products with newly developed ones, where, simultaneously with a reduction in the volume of production of old products, there is an increase in the output of new products (Fig. 8.4).

The duration of the combined time varies 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 batch production.

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

Parallel-serial method transition is quite widely used in mass production when developing new products that are significantly different in design from those being discontinued. At the same time, additional capacities (areas) are created at the enterprise, where the development of a new product begins - technological processes are worked out, personnel are trained, and the production of the first batches of new products is organized. During the same period, production of old products continues. After the completion of the initial period, a short stop is made both in the main production and in additional areas, during which the equipment is redesigned. In this case, the equipment of additional sections is transferred to the main production workshops. Upon completion of this work, the production of new products is organized at a faster pace (Fig. 8.5).

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 directions for reducing time and costs when switching to new product models in modern conditions is the introduction of flexible automated production, flexible production and automatic lines.

Mastering Production is a set of measures to prepare for the production of new products.

Dictionary of business terms. Akademik.ru. 2001.

See what “Production Mastery” is in other dictionaries:

Mastering production- one of the stages of putting products into production, including testing and testing the prepared technological process, and mastering practical techniques for manufacturing products with stable indicator values and in a given volume... ... Official terminology

DEVELOPMENT OF PRODUCTION- a set of measures to ensure the preparation of an enterprise (association) for the production of products it has not previously produced...

accounting of costs for preparation and development of production- Accounting for costs associated with preparing for the release of new products, improving the quality of manufactured products, etc. The costs of preparation and development of production, included in the cost of production, include: design costs and... ...

ACCOUNTING FOR THE COSTS OF PREPARATION AND DEVELOPMENT OF PRODUCTION- accounting for costs associated with preparing for the release of new products, improving the quality of manufactured products, etc. The costs of preparation and development of production, included in the cost of production, include: design costs and... ... Great Accounting Dictionary

expenses for preparation and development of production Technical Translator's Guide

COSTS FOR PREPARATION AND DEVELOPMENT OF PRODUCTION- goods (works, services): for the development of new enterprises, production facilities, workshops and (or) units (start-up costs); for the development or production of tools and equipment; for the preparation and development of new types of serial or mass-produced products... ... Great Accounting Dictionary

Costs for design, construction and development of the technological process for manufacturing a new product; redevelopment of placement, rearrangement and adjustment of equipment; production and testing of a prototype (batch of products); on the… … Economic dictionary

Costs for design, construction and development of the technological process for manufacturing a new product; re-planning of placement, rearrangement and readjustment of equipment; production and testing of a prototype (batch of products); on the… … Encyclopedic Dictionary of Economics and Law

COSTS FOR PREPARATION AND DEVELOPMENT OF PRODUCTION OF NEW TYPES OF PRODUCTS- costs of design, construction and development of the technological process for manufacturing a new product; redevelopment, rearrangement and adjustment of equipment; production and testing of a prototype (batch of products); for design... ... Large economic dictionary

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Development of the underground space of cities Scientific publication, Shulyaev O., Mozgacheva O., Pospehov V.. The book examines the history of the development of the underground space of cities, as well as the features of engineering geological surveys, design and execution of work during construction...
Economic risks of mining production, A. Petrosov. Methods for identification, accounting, analysis, qualitative and quantitative risk assessment, adapted to the conditions of the economics of mining production, have been systematized. Approaches, techniques and...

The essence, content and objectives of the process of creating and mastering new technology. The development of new types of equipment is carried out in the process of pre-production. The more complex the design of new equipment, the more time, labor and money is required to carry out this preparation. Not only the timing and cost of production, but also the technical level and uniformity of production of new equipment depend on the progressiveness of production preparation. The totality of work on the creation and development of new types of products and technological processes in production and the improvement of previously developed types of products and technological processes is called technical preparation of production (TPP), which is a special type of activity. It combines the production of scientific and technical information with its transformation into a material object - new technology.

Target TPP - creating a sample of new technology and organizing its development in production. The creation and development of new technology is carried out in a certain sequence of phases of a single process of technical preparation of production (content of the Chamber of Commerce and Industry): theoretical research of a fundamental and exploratory nature; applied research, during which the knowledge obtained at the first stage finds practical application; development work, during which the acquired knowledge and research conclusions are implemented in drawings and samples of new mechanisms and machines; technological design and design and organizational work, during the implementation of which technological manufacturing methods and forms of organizing the production of new products are developed; technical equipment of new production, consisting in the manufacture of equipment, technological equipment and tools, as well as, if necessary, the reconstruction of enterprises and their divisions; mastering the production of new products, when product designs and methods for their manufacture created at previous stages are tested and introduced into production; industrial production, ensuring the release of new products in quality and in quantities that meet market needs; use of the newly created product in the field of operation; studying the behavior of a newly created product in the field of operation and the development and implementation of new types of products that embody the latest achievements of science and technology that meet the requirements of consumers who are competitive in the world market.

The content of the TPP is determined by the scale of production for which the product is being developed, and its scientific and technical characteristics (novelty, complexity, manufacturing technology, etc.). The main tasks of the Chamber of Commerce and Industry, ways and methods of their implementation are given in Table. 7.4. The Chamber of Commerce and Industry of new technology includes a complex of various research, design, technological, organizational and planning activities. They are produced by research, design, technology and design institutes (research institutes) together with enterprises and joint-stock companies. According to the type and nature of the work, the CCI processes are divided into phases: research, development, technological, organizational and material (production and economic) (Fig. 7.6).

Organization of scientific research work. Modern production cannot successfully develop and improve without carrying out appropriate scientific research. Scientific research creates the prerequisites for the accelerated development of technology and opens up new potential sources for increasing social productivity. Scientific research works (R&D) include fundamental, exploratory and applied research.

Fundamental - research that studies objective phenomena and patterns, fundamentally new ways of transforming nature and society, productive forces, creating highly efficient equipment and technology, and using new energy sources. They are often carried out without taking into account the possible areas of application of the results obtained, although in their process it is possible to obtain side results of an applied nature. The results of fundamental research serve as the basis for the formation

The main tasks of technical preparation of production, ways and methods of their implementation

The task of the Chamber of Commerce and Industry	Ways to implement	Methods of implementation
1. Ensuring continuous technical progress in accordance with technical policy in the industry	1. Creation of perfect machine designs. 2. Design and implementation of advanced technology and production organization. 3. Integrated mechanization and automation of production processes	1. Forecasting the main directions of industry development. Organization of timely scientific and technical information (STI). 2. Constructive unification, standardization and aggregation. 3. Technological unification and typification of technological processes. 4. Collaboration of designers and technologists to create a technologically advanced design in production and operation
2. Creating conditions for organizing uniformly scheduled and economical production	1. Introduction of progressive forms of organization of production and labor. 2. Rational management and planning system and production accounting	1. Organization of all types of flow and flow-automated production and feasibility study of their feasibility. 2. Application of automated control systems
3. Reducing the duration, labor intensity and the cost of production preparation	1. Application of network planning and management. 2. Combination of design and technological work in time. 3. Scientific organization of work of designers, technologists and production personnel of experimental, instrumental and other workshops, laboratories and production preparation bodies	1. Development of optimal training schedules for each department. Control, adjustments and optimization of schedules. 2. Rational specialization of bureaus, groups and individual workers and timely STI. 3. Creation of a regulatory and reference facility, including the development of standards for design and technological work. 4. Mechanization of design and calculation work, reproduction, packaging, etc. 5. Application of a unified system of design and technological documentation (ESKD, ESTD and ESTPP)

Rice. 7.6.

a complex of scientific and technical problems of an applied nature in relation to the needs of specific areas of science, technology and production. These studies are carried out mainly in academic institutes and universities, but are not carried out at enterprises.

Search engines - research aimed at creating a scientific foundation for the purpose of its further use in applied research. They are performed when there are no ready-made scientific and technical solutions. They are aimed at finding optimal solutions to emerging scientific problems. Exploratory research aims to study the possibility of creating new technology, forms and methods of organizing production on the basis of previously completed fundamental research, newly discovered patterns, principles and phenomena. They are exploring fundamentally new directions in the design of technology for manufacturing special equipment and materials. Exploratory research is mainly carried out in industry research institutes, in some cases conducted by academic institutes and universities. Enterprises do not conduct exploratory research.

Applied - research aimed at solving scientific, technical, organizational and economic problems in order to obtain a specific result for its direct use in design developments. Applied research serves to determine the most advanced methods for developing new products, technological processes, and radically improving manufactured products, materials and methods for their development. These studies are carried out by large enterprises, industry research institutes and universities, which enter into business agreements with enterprises to carry out specific scientific work for the direct implementation of the results into production. Research carried out at enterprises conventionally includes developments on the creation of regulatory, technical, design and information documents that are subject to direct implementation in production (standard and guideline materials, organizational projects, reference books, scientific and information materials).

Organization of design preparation for production. Design pre-production (DPP) is a stage of the technical and technical development of new products, which is carried out following the implementation of research, design and experimental research of new work processes, materials, and kinematic diagrams. During the checkpoint, a transition is made from the creation of individual machines to the development of highly efficient systems of machines, equipment and devices that ensure mechanization and automation of all production processes. Particular attention is paid to the development of equipment for fundamentally new technological processes. The content and volume of the checkpoint is determined by the type and scale of production, as well as the design complexity of the product. The development of designs for new machines is carried out by the department of the chief designer (OGK) and design bureaus (KB) of the main manufacturing plants or research institutes and design organizations. The checkpoint begins with the development of technical specifications, which determines the technical and economic requirements for new products. Technical specifications can be received from the customer or developed by a design organization. It includes: the purpose of the product, indicating the operational and climatic conditions of its use; main technical parameters; adaptability to maintenance; durability in operation; requirements for safety, unification, aggregation, aesthetics, etc.

A technical proposal is attached to the draft technical specifications: development of a schematic diagram of the machine and its preliminary layout; determination of power, dimensions, type of drive, technical characteristics (limits of application).

The next stage of the checkpoint is a preliminary design: development of kinematic, electrical, hydraulic circuits of the machine and its layout, general drawings, prototyping, analysis of the patent purity of the design, determination of the cost and expected economic effect.

Then comes the stage technical project, which defines the main structural structure of the product and contains a set of drawings of general views and assembly drawings of components, as well as an explanatory note. It provides the service purpose of the product and technical conditions, analysis of the technical level of the product and comparison of the latter with the best world standards, competitiveness, calculations of the strength of units and components; specifications and technical conditions (TU), statements of purchased products, testing programs and methods, a patent form, and an economic justification for the design is provided. Based on the technical design, a working draft is developed: working drawings of components, parts for the manufacture of a prototype, then, taking into account the test results - working drawings for preparation of production. The latter contain the entire set of technical documentation for the production and operation of products of a new design.

As a result of the checkpoint, design documentation must be issued, including: specifications for the product; design drawings of all parts, assemblies and mechanisms; kinematic, electrical and other circuits; parts specifications; lists of parts and assemblies borrowed from other machines; standard, normalized and purchased materials; machine passport and instructions for its operation. As a result of the checkpoint, the product must fully meet a number of economic, operational, design, technological, organizational and production requirements (Table 7.5).

Organization of technological preparation of production. Technological preparation of production (TPP) is a set of interconnected processes that ensure the technological readiness of an enterprise to produce products of a given quality within a specified time frame, production volume and costs. The content and volume of the TPP are determined by the type of production, design and service purpose of the product (Table 7.6).

The technological readiness of an enterprise means the availability of a complete set of technological documentation and technological equipment necessary for the production of new products. The Chamber of Commerce and Industry has two directions for mastering the production of a new product and for improving technological processes not related to changes in the design of the product. Each direction has its own tasks, content and list of works, which depends primarily on the type of product and the purpose of the technological process. All design and technological work at the enterprise is carried out by the department of the chief technologist (CGT) and the department of the chief metallurgist (OGMet) together with the technological bureaus (technical parts) of the workshops. Apply three

Requirements for the product that must be met during the design pre-production process

Character requirements
Economic	Compliance of the achieved indicators with the tasks of the technical progress plan and the parametric series; ensuring growth in social labor productivity; reduction in unit cost (per unit of mass, power, productivity) compared to the base (replaced) product
Operational	High productivity, sufficient reliability, transportability, good storage, operational safety; environmental, aesthetic and ergonomic requirements
Design	Compliance of the selected design parameters with the conditions of its operation; choosing a rational scheme; increasing power and operating speeds; automation of regulation and management; unification of materials, parts, assembly units, etc.; replacement of mechanical connections with electrical, hydraulic, pneumatic ones; selection of the simplest shapes of parts
Technological	Compliance of the design with the optimal technological conditions for its manufacture; possibility of typification, mechanization and automation of production processes, provision of rational control methods
Organizationally production	Compliance of the design with the conditions of its manufacture, the possibility of specialization of production

forms organization of work on the Chamber of Commerce and Industry: decentralized, centralized and mixed. At enterprises of single and small-scale production, TPP is carried out decentralized. OGT, OGMet, OGS provide methodological guidance, carry out work on typifying technological processes and unifying equipment. All other work is done by the workshops' technological bureaus. At large-scale and mass production enterprises, TPP is usually carried out centrally- in OGT, OGMet, OGS. Shop bureaus are engaged in the implementation of developed technological processes. In medium-scale production it is more often used mixed form of organization of the Chamber of Commerce and Industry, in which workshop bureaus carry out the development

Table 7.6

Main functions and tasks of technological preparation of production

Main functions of the Chamber of Commerce and Industry	General tasks
Security manufacturability designs	Establishing standard methods and means for processing product designs for manufacturability, establishing basic indicators of product design manufacturability. Carrying out technological control of design documentation. Assessment of the level of manufacturability of product designs. Making necessary changes to the design of products and its documentation. Reducing the volume of work on technological processes by ensuring a high level of manufacturability of product design and the use of modern methods and means of performing relevant engineering work
Development technical processes	Development and standardization of standard technical processes for parts and assembly units for general machine-building applications. Organization of an industry-wide documentation fund for standard technical processes and centralized provision of industrial sectors with this documentation. Development, standardization and application of standard technical processes, technical processes using group processing methods and technological operations on parts and assembly units. Development and application of working technical processes for parts and assembly units, organization of factory documentation funds for standard technical processes, technical processes using group processing methods and technological operations
Design and manufacturing technological equipment	Comprehensive standardization of technological equipment for general machine-building applications. Carrying out work on the specialization of the design and production of technological equipment for industrial enterprises and industrial rental bases for technological equipment. Carrying out unification and standardization of technological equipment. Organization of the use of technological equipment, including unified and standard equipment, and the use of rental bases for these equipment. Design and manufacture of special technological equipment

Main functions of the Chamber of Commerce and Industry

General tasks

Organization and management of the Chamber of Commerce and Industry process

Long-term and annual planning, development and improvement of software for industries and enterprises in the industry.

Establishment of standard methods and technical means for organizing and managing the TPP process. Development and approval of methodological and regulatory materials for the development of standard structures and determination of the number of CCI services. Establishment of standard structures of technological services. Development of industry-specific methodological materials on the organization and management of the CCI process, taking into account the types of products and types of production. Development of industry-specific methodological materials on mechanization and automation of engineering, technical and management work for the Chamber of Commerce and Industry. Long-term, annual and current planning, development and improvement of technological processes at the enterprise. The use of modern methods for solving problems of technological preparation of production using means of mechanization of engineering, technical and management work. Organization and improvement of the structure of Chamber of Commerce and Industry services

operational technological processes. As part of the OGT and OGMet, specialized bureaus are organized according to types of processing: foundry, forging, thermal, coating, mechanical, assembly, etc.

Since for each production facility it is necessary to develop technological processes and manufacture equipment for various phases of production (procurement, processing and assembly), the TPP often turns out to be the most labor-intensive and time-consuming process. The volume of CCI increases from single to mass production: in single production - 25%; in serial - 50%; on a massive scale - 75% of all technical preparation of production.

Main stages of the Chamber of Commerce and Industry:

1) preliminary development of technical documentation (technological control);
2) development of inter-shop technological routes;
3) development of operational processes;
4) design of special equipment equipment;
5) implementation of technological planning;
6) calculation of material consumption rates and determination of the need for labor and material resources;
7) development and delivery of technical equipment to production workshops.

Before developing technical specifications, the documentation undergoes preliminary development - technological control of the drawings is carried out and they are tested for manufacturability, the scope of work, timing, costs, economic efficiency, and the possibility of providing material, labor and financial resources are determined.

The CCI itself begins with the development of inter-shop technological routes (workout), which establish the sequence of passage of blanks, parts, assembly units through production shops and the distribution of items between shops and sections. In single and small-scale production with universal equipment and tooling, highly qualified workers, the development of route technology is often sufficient for the manufacture of parts and assembly of products.

In medium-batch, large-batch, mass production types, the development of detailed operational technical plans (technological maps) is required.

The design of technological processes consists of drawing up a section layout; development of technologies (technological maps) by production stages (procurement, processing, assembly); selection of equipment, tools and devices; typification of technological processes; development of control processes; calculating time standards.

Process development is carried out on the basis of working drawings and sectioning, taking into account the production program, passport data of the equipment. Reference and guidance materials are also used. Developed by TP recorded (fixed) in technological maps, which must meet all the requirements of this type of production. Detailing TP is carried out mainly in mass production and to a lesser extent in individual production.

Technological maps must be adapted for processing their information on a computer and can have the following form:

1) route or planning and technological maps. They record the route of movement of a workpiece or assembly unit to work stations in a workshop or plant (a sequential list of basic operations indicating equipment, tools and devices, category and time standards). Purpose route technology: in single production - main document, in mass production - for planning and dispatch authorities;
2) technological maps manufacturing of blanks, parts or assemblies - TP structure (detailed characteristics of the tool, processing modes, type of work and time standard) - the main document of all productions;
3) operational instructions cards - for workers and adjusters. Contains all transitions, setup methods, processing modes, etc. - Mainly used in mass production.

Labor standards are carried out by technologists when designing technological processes. The forms of technological maps must provide for the possibility of their processing on a computer when drawing up a summary document of labor intensity for the manufacture of a machine, by workshop, by type of work, by profession, by equipment, etc. These data are the initial data for planning equipment load, for calculating the number of workers, determining the wage fund and other purposes.

In the Chamber of Commerce and Industry, its main share is occupied by the stage of design and manufacture of technological equipment.

The designer of technological equipment designs devices according to drawings of workpieces and process maps. First, the possibility of using existing (designed, previously manufactured) or standardized equipment is checked. If it is necessary to design new fixtures, then it is necessary to determine whether normalized parts or assemblies can be used for the fixture. If the number of units of equipment is large (in mass production), the order of its development and production is established: the first stage is to ensure the production of a prototype; the second stage is equipment, which, together with the first stage, constitutes a set under the condition of extensive (serial or mass) production. Here it is necessary to ensure a reduction in labor intensity and a reduction in product manufacturing cycles before the project. When mastering a new machine on a unit-by-unit basis, if there is a mastering schedule, the sequence is consistent with this schedule. It is more expedient to place orders for the production of equipment at specialized enterprises. At the same time, the workshops are loaded: tool, stamping and mechanical, model. The production time for tooling is established by OGT or OGMet according to the production preparation schedule. In mass production, there is often a need for non-standard equipment and various means of mechanization. This equipment is designed in the same way as fixtures (in the same order). It is advisable to entrust their production to specialized enterprises or to specialized workshops or a mechanical repair shop (RMS) within an enterprise. Then work is carried out to draw up a technological layout of equipment and workplaces, and to form areas. A feasibility study of technological processes and the selection of a method for switching to the production of a new product is carried out. Next, equipment requirements, calculation of material consumption rates and labor requirements, etc. are determined. Standards for material costs are developed on the basis of working drawings and shop drawings. Data on the cutting of materials for each part is entered into the specification and processed on a computer. As a result, reports are obtained by workshop - a summary rate of material consumption - for the preparation and substantiation of applications. The TTP ends with the completion of work on the verification, adjustment and implementation of technological transformers, equipment and accessories into production. Installation of equipment and its debugging are carried out for the specified accuracy and quality of production; training and staffing; testing and debugging of technology; adjustment of equipment and, finally, commissioning of the technological process into production. Checking and debugging of the TP is carried out in the same way as the design is checked on a prototype, i.e. TP is mastered on a pilot series (sample). The series size, for example for a car plant, is 200-250 cars. The pilot batch is produced only in the main production workshops. All changes in technological processes and equipment are recorded in technological protocols. The technological process is implemented and handed over to the workshop only after a suitable product that meets all technical requirements and conditions is obtained using the designed technology and equipment with the established labor intensity. A special act is signed on the delivery and acceptance of the developed technological process, according to which the workshop undertakes to comply with the adopted new technology according to the developed technological documentation.

Comparative technology-economic analysis of technological process options. The technologist must necessarily conduct a comparative analysis of TP options and select the most effective one that ensures the fulfillment of the technical specifications. To determine this option, it is necessary to calculate the costs of production for each existing option. In this case, there is no need to calculate all cost items. You can only compare the amount of costs that change when the TP changes, i.e. technological cost, which is calculated according to the formula where C y, C p - conditionally variable and conditionally fixed costs; TU - the number of products produced during the planned production period.

The technological cost of the entire production of products is determined by the formula WITH, A/"= S y I + S p N. Using data from different options, it is necessary to compare the technological cost of one product and the entire output for each option. When comparing two TP options, it is necessary to determine the critical production volume of the control unit at which the costs for both options are equal:

C, - C x, +

P, k"p2 s - s

Having determined the value of the critical production volume, it is necessary to compare it with the planned output of this product of the UU PL and select the most effective TP option. Option with smaller constant SPs and larger variables C y costs are more economical at L^ pl YU K the option with larger constant C„ and smaller variable C„ costs is more economical. If the introduction of a new TP option requires additional capital investments, then the comparison of options must be carried out based on the sum of total capital and current costs, reduced, for example, to a year.

Organizational preparation of production (OPP) and development of new types of products. The organization of production of new products involves the restructuring of the existing software and all its constituent elements. The development of new types of products requires not only the development of new technology and the use of new technological means, but also changes in forms and methods organization of production and labor, acquisition of new knowledge and skills by the personnel of the team, restructuring of material and technical supplies, etc.

Under these conditions, it is necessary to introduce a number of measures to restructure production to produce new products, i.e. implement OPP. The set of works included in the EPP is associated with solving problems of an internal and external nature, and the overall technical and economic indicators (TEI) of the enterprise, the level of organization of production and labor, and the material support of the new production depend on the quality of performance of these works. EPP is a set of processes and works aimed at developing and implementing a project for organizing the production of a new product, a system for organizing and remunerating labor, logistics of production, a regulatory framework for in-plant planning in order to create the necessary conditions for high-performance and accelerated development and release of new products required quality. AKI is divided into a number of stages:

The creation of a new product is a complex of interrelated works on the scientific, technical and economic justification of the concept of a new product, its design and production development. In Fig. Figure 2.3 shows the structure of a typical innovation process for creating a new product.

Fig.2.3. Structure of the innovation process of creating new products

There are four main phases of creating a new product:

1) research phase, or development of a product concept;

2) planning the creation of a product;

3) product design;

4) mastering the production of a new product and promoting it to the market.

On first phase information is collected and analyzed on the technical characteristics of products available on the market, scientific and technical capabilities and limitations in the development of the designed product, the demand for new products is predicted, the innovative potential of the enterprise and the impact of the product on the environment are assessed. The main methods of such analytical research are methods of innovative marketing and scientific and technical forecasting. The result of the first phase of creating a new product is a product concept containing the requirements for a new product, a feasibility study of the idea of creating it and conclusions about the economic feasibility and technical feasibility of creating a new product.

Second phase involves planning the creation of new products in two directions:

1) determining the prospects for the development of the product market;

2) drawing up a work program to create a new product.

During the planning process, the market capacity, investment requirements for the project and the financial consequences of introducing a new product to the market are established, all types of work to create new products are mutually linked and their rational sequence is established. In addition, product planning includes market testing, or trial sales, of new products to confirm or refute the validity of the new concept, as well as to clarify consumer preferences regarding the quality, price and functionality of the proposed product. The main form of product planning is a calendar schedule developed for each type of product, the creation and development of which is provided for by the enterprise development strategy.

The schedule ensures the correct distribution of the total amount of work across calendar periods, determination of the appropriate sequence of completion of the various stages of work, and uniform loading of the departments involved in the creation of a new product.

On third phase In the process of creating a new product, detailed engineering study of the new product is carried out. It includes the entire range of works on design and technological preparation of production: carrying out experimental design work, developing the technological process of a new product, designing and manufacturing means of technological equipment for the production process, etc. The main task of this phase is the preparation of working documentation for the industrial production and operation of a new product . At this stage, the product concept is translated into a working model - a working prototype, the testing of which makes it possible to make the necessary clarifications in the design documentation and eliminate shortcomings.

Fourth phase The creation of new products involves carrying out a set of works on the organizational preparation of production and the development of a new product.

Organizational preparation is aimed at developing and implementing a project for organizing the production process of manufacturing a new product, a system for organizing and remunerating labor, and material support in order to create the necessary conditions for the accelerated development of new products. The production of a new product begins with the release of an installation series, which is produced according to serial production documentation in order to confirm the readiness of production to produce products in specified volumes and with established requirements. As production is adjusted, product output increases. The end of development is the achievement of the design level of economic indicators of the new product and the planned sales volume.

When designing new equipment, it is important to take into account the environmental aspect and the need to design a new product from the consumer’s perspective.

The environmental aspect of the problems associated with the production and operation of a new product is reflected in the development of the concept of a “green” product. The formation of such a concept involves considering alternative options for implementing the idea of a new product in the first phase of its design.

When accepting the concept of a “green” product, it is necessary to provide for the solution of the following issues:

Reducing the costs of raw materials and packaging: eliminate or lighten packaging, use larger packaging, create multifunctional products;

Use of recycled materials;

Reducing the expenditure of scarce natural resources;

Improving the safety of products for the environment;

Increasing the life of the product;

Possibility of alteration, repair and disposal of goods.

Customer orientation in the design process is achieved through 1) direct consumer participation in the development of new products and 2) designing the product taking into account the requirements of the target consumer group.

Customer participation in development, or joint product design with the consumer, allows the user to see a new product, test it and improve it, if necessary, before mass production begins. Therefore, in a number of industries - instrument making, machine tool building, radio engineering - most of the ideas about fundamental innovations come from enterprises - consumers of products. These enterprises actively participate in the development and testing of new products, providing their own production facilities. Joint design allows you to establish stable partnerships with manufacturers. With close cooperation between the manufacturer and the customer, they share the commercial risk of innovation, and the uncertainty of the final results of their searches is reduced.

Designing a product taking into account the requirements of the target consumer group, or consistent satisfaction of consumer requirements, in foreign production management practice it is called “deployment of the quality function” ( Quality Function Deployment- QFD).

To solve this problem, a cross-functional team is created, including marketers, design engineers, technologists and production workers.

Consistently meeting consumer requirements begins with determining the characteristics and properties of the product that meet the needs and expectations of future buyers. During market research, consumer needs and preferences are determined. Their classification and subsequent ranking (determining the degree of significance) make it possible to accurately establish the requirements for the product and determine those qualities that are of greatest importance to the consumer and need improvement.

The main tool for identifying consumer needs is the quality matrix, or “quality house” (Fig. 2.4). With its help, consumer requirements are transformed into specific technological and engineering tasks. Thus, the quality matrix guides specialists involved in the design process to create products that would fully satisfy the needs of future consumers.

Fig.2.4. "House of Quality"

Expanded process QFD consists of four stages, each of which builds its own house of quality (Fig. 2.5): 1) development of a product quality plan; 2) structuring (deployment) of a product quality project (development of a quality plan for product components); 3) development of a process quality plan; 4) development of a product quality control plan.

Fig.2.5. Process diagram QFD

The process of creating new products is carried out on the basis of the implementation of a set of pre-production works.