The development of science and technology in the modern world is based on the use of special design procedures and modernization of existing structures, progressive methods and approaches in production activities. Complex solutions that ensure the constant development of the design and technological base of industrial enterprises, as well as compliance with their rational economic use, are called technical preparation of production. It is based on innovative processes taking place in the context of scientific and engineering research (design and technological preparation of production).
Types of Research
Scientific research can significantly increase the level of competitive ability of developed products. From the point of view of the processes or phenomena to which they are directed, they are considered in the context of three main groups:
- Basic research - allows you to get new laws or patterns of behavior of objects and systems of the surrounding reality, with the aim of further use in the production and economic activities of people. Conducted by special (specialized) research organizations.
- Exploratory research - they are testing open patterns for production activities, which allows to increase the scientific and technical level and the overall efficiency of enterprises and civil sector facilities.
- Applied - in continuation of previous studies, they allow to solve specific scientific and engineering problems, create new technologies or designs.
Basic research, as a rule, is funded by government agencies, because quite often they have no market value. Search and applied are aimed at solving practical problems and are often financed by commercial enterprises. Scientific research on a specific problem, carried out according to a specific plan, is called a scientific topic (economic contractual).
As a rule, the design preparation of production includes certain types of research.
Stages of the implementation of a scientific topic
Economic-contractual, i.e. financed by individual enterprises, and scientific research are carried out according to a certain traditional scheme:
- development of technical specifications for the problem being solved and a feasibility study of the proposed topic;
- the choice of the direction of research, which is based on the study of existing solutions, research of patent information, as well as the development of general guidelines for implementation;
- conducting research (theoretical and experimental) to determine the theoretical position of the real data obtained from the experiment;
- general conclusions on the work done and the preparation of the report.
The results obtained are the basis for the subsequent stages of the design preparation of production. An industrial enterprise, which has in its organizational structure developed departments for the design and development of new technologies (chief designer, chief technologist), can independently conduct these studies. If necessary, there is the possibility of attracting external research organizations (institutes, venture firms), which makes it possible to increase the complexity of the work performed and accelerate the pace of the implementation of individual stages.
Conducted research (innovative processes) allows you to get three main types of innovations - discovery, invention and rationalization proposal. Their introduction into production and economic activity is an important element of the technical development of enterprises over time and is one of the key elements in the organization of design and technological preparation of production.
General organization issues
In the process of functioning, industrial enterprises need constant restoration of industrial buildings, technological equipment and infrastructure elements (traffic flows, utilities, communications, etc.) due to physical wear and tear. In addition, it is necessary to ensure the development of enterprise technology and equipment in order to meet the new economic conditions and the growing demands of consumers. Which is the main goal of the design preparation of production.
The actual level of the technical condition of the enterprise must be evaluated at predetermined time intervals, given a number of indicators of the production system. They are evaluated in the dynamics of change over time both at the enterprise itself and in related systems, which makes it possible to rationally correct them. It should be noted that monitoring the funds of the enterprise and maintaining them in working condition is the main task of the infrastructure enterprises of enterprises.
Development Assessment Parameters
As a rule, indicators are considered according to certain criteria:
- The level of technical equipment - how far the production workers are provided with the necessary funds (funds) and the necessary energy resources.
- The degree of technology novelty is the proportional distribution of processes in terms of labor intensity, the percentage of new technological processes and techniques, the average age of the elements of the technology used, the rationality of the use of materials and spare parts.
- Novelty and compliance of equipment characteristics - performance parameters, functionality, material consumption, reliability indicators (reliability, durability, maintainability and safety), average operating time, percentage of advanced equipment, percentage of equipment physically and mentally worn out.
- Indicators of mechanization (automation) - the number of mechanized labor operations; the percentage of products manufactured using automated devices (technologies).
The system of design preparation of production allows maintaining the value of these indicators within the established limits.
Directions of technical development
To solve the urgent tasks of maintaining and improving production systems in time, various mechanisms and procedures for influencing the elements of the enterprise are used. For their implementation, approaches to design preparation of production are attracted. These areas include:
- The construction of new facilities - the construction of an enterprise from scratch, the creation of a new production unit (workshop, site) in the manner prescribed by law.
- The expansion of the existing enterprise - the introduction of additional enterprise capacity through the creation of additional units or facilities; increasing the area of existing units in order to increase production indicators, the ability to increased product flows and economic efficiency.
- Reconstruction - a change in individual subsystems of an enterprise, improvement of technological and technical structures. It is carried out on the basis of replacing obsolete technological equipment, increasing the share of mechanized (automated) processes, eliminating the imbalance in the work of various enterprise subsystems (which helps to improve macroeconomic indicators of the enterprise).
- Re-equipment or re-equipment of the means of production - replacing obsolete equipment and tools with more advanced ones with improved performance.
- Modernization - individual improvements to elements of the production system (equipment, technology, organization and control) to match production and created products (elements, systems) to changing market conditions, standards or customer requirements.
In addition to these indicators, production systems are evaluated for environmental impact. Consider the extent of disposal of production waste, environmental pollution, the percentage of environmentally friendly products.
Organization of design preparation of production
Exploratory work in the field of designing promising designs is time-consuming, large-scale and demanding in terms of the use of material and financial resources, combining the results of the design of new products with subsequent experimental evaluation. They are carried out under the control of the OGK (department of the chief designer) or the design bureau (design bureau) of the technical department of the enterprise.
As a result of ongoing development, various parameters of production systems are improved - productivity and functionality are increased, cost is optimized, production time intervals are changed and conditions are created for the most rational work of production units.
An important role in organizing the design preparation of production is given to the design departments of the enterprise. A specific procedure for storing drawings, plans and diagrams is established. Mechanisms are being developed for the timely provision of production units. Strict design and technological discipline is supported.
Tasks of design preparation of production
The basic issues that are solved when designing simple and complex systems are:
- analysis of technical conditions for structural elements that are reflected in the features of manufacturing and repair;
- development of various projects for the products in question, aimed at improving the general design schemes;
- development of repair tolerances (increasing the interchangeability of parts and reducing production costs);
- improvement and modernization of the element base;
- unification of units (units, parts) to eliminate unreasonable overstatement of the number of standard sizes.
As you can see, the use of design preparation of production directly affects the level of losses during the subsequent operation of the facilities.
Order of conduct
The content of design studies is determined by the characteristic features of the object of study, its functional purpose and method of manufacture (repair). In general, several typical stages can be distinguished, the result of which will be the creation of normative and technical documentation. They are carried out according to ESKD. The complexity of the product and the scope of its further use has a direct impact on the content and number of stages. So, some of them, especially the preparatory stages, can be shortened, combined or completely absent.
Stages of design preparation of production:
- Preparation of technical specifications (abbreviated as TK). Drawing up a list of literature, analysis of special literature and regulatory documents - instructions, orders, explanations and recommendations. Analysis and subsequent coordination of the points of the task for the design of the structure. Development of the schedule of the proposed work in the form of an algorithmic model (Gantt charts or network charts). Accounting for future design costs. Preliminary calculation of the economic effect of the results of innovation.
- Development of a technical proposal (similar to TP). Full calculation of economic components. Consideration of design options and the selection of the most optimal. Correction of the total number of works and the duration of the implementation.
- The implementation of the preliminary design. Consideration of the schematic diagrams of new designs or processes, preliminary mathematical calculations, determination of the overall dimensions of the product in general drawings, production of a breadboard and its testing;
- Technical design. The most laborious and longest stage of research. Conducting basic calculations for structural strength, reliability and safety. Tests of the prototype (forced and / or accelerated). Design modernization based on calculated parameters. The most time-consuming, lengthy and expensive stage.
- Preparation of working documentation - creation of assembly drawings, detailing of the product, drawing up schematic and wiring diagrams. Creating duplicates and copies of documentation. Finalization.
The stages of design preparation of production allow us to complete the full cycle of development and implementation of project documentation.
Features of modern design
To meet the ever-increasing requirements for the element base of structures in terms of reliability and functionality of industrial products, in recent years, the design preparation of production uses computer-aided design systems. Given the increased complexity of individual projects (for example, the development of integrated circuits), the use of special machine methods is often the only possible way to create the desired product with the given parameters.
When automating design processes, the product is created on the basis of precise machine algorithms embedded in specialized software packages. At the same time, the influence of the human factor on the accuracy of calculations and the choice of the most suitable design option are reduced. Significantly reduced project execution time, testing and total costs at all stages of design.
At the same time, the design and engineering preparation of production has a number of advantages, which are expressed in such factors:
- significantly reduces the complexity and duration of the project;
- reduced payroll costs (due to state optimization);
- the quality level of the finished product increases;
- reliability indicators are normalized;
- accumulated time-tested solutions in industry databases;
- documentation is constantly monitored;
- mathematical modeling allows minimizing not optimal design options, etc.
Conclusion
The system of design preparation of production is a necessary link in the life cycle of any product. It is used with equal success both for creating industrial products and complex specialized systems. As the experience of recent years shows, the ever-increasing informatization of production processes puts forward new requirements for improving design systems.