In any area of human activity, to achieve the desired result requires the implementation of clear steps towards achieving the goal. This is even more true in complex and multi-stage production processes.
Any mistake or deviation from the most rational operations in the manufacture or repair of products will lead to enormous losses of resources (temporary, material, financial). To reduce the number of errors in the maintenance staff, standardize activities (leading to predictability of the final results) and implement a unified technical policy, standard procedures and corresponding documentation for their implementation have been developed. Its content and further use are reflected in the technological instructions of the product.
Technological Design Approaches
In production, special approaches to the specialization and uniformity of technological elements (the so-called typing) are used, depending on various criteria of compliance and the content of the organization of implementation.
The depth and direction of the degree of detail makes it possible to distinguish between routing processes, operational and mixed. First, a description of the operations of the adopted technology occurs, that is, it shows how the product moves according to a given execution algorithm to workplaces specialized in performing specific operations. Operating rooms reveal the contents of interoperational transitions. Mixed processes use transition descriptions only for the most complex stages of production.
The ways of organizing various elements of technological processes (positions, equipment, workplaces) are differentiated into three main groups: single, standard and group.
A unit is formed for a product with one name, manufacturing method and size (car engine repair of a particular brand).
A typical process refers to objects with associated (common) features in terms of design and technology (for example, the manufacture of locksmith keys for different pipe diameters).
Group concerns arrays of different products, with dissimilar designs, but similar with the technological component (manufacturing using casting, pressing, rolling, etc.).
All considered varieties of processes are placed in the technological instructions for production.
Typing Benefits
These approaches to the formation and classification of processes allow:
- create a limited number of them (reducing the whole variety to an effectively controlled number);
- take into account the specific operating conditions at the design stages of various technologies;
- to carry out the most complete unification of equipment, tools and devices;
- constantly increase the level of mechanization (automation) of processes over time;
- reduce costs and losses during the technical preparation of production: analysis of structural elements, selection and justification of the features of technological support and comparative economic assessment aimed at obtaining an optimal and liquid product on the market;
- reduce the time for the development of technological instructions.
Development Algorithms
In a real production system, the primary organizational and technical task is to develop such a technology that is able to provide the necessary speed and quality of product manufacturing (with the least loss).
At the first stage, a thorough and thorough study of all design documentation and the parameters of the subsequent use of the product in operation is carried out (which will be reflected in the technological instruction of the process). In addition, it is necessary to take into account the estimated scale of production (to clarify the actual manufacturing program and the estimated production capacity), to take into account and analyze information about technological equipment and tools.
In general, the algorithm for developing a new technology can be represented in the form of a list:
- Analysis of the source data of the technology under consideration.
- Study of production features (determination of the coefficient of specialization or consolidation of operations).
- Selection of an existing similar process (to reduce design time).
- The choice of material, workpiece (component) and the method of its production.
- Determination of the position in the space of the subject of labor (analysis of the base).
- Creating a sequence of operations (route development).
- Choosing the necessary equipment.
- Detailing process operations.
- The choice of technological equipment.
- The rationing process.
- Billing elements.
- Definition of labor protection requirements.
- Registration of technological documentation.
- Calculation of the main production parameters.
- Production planning (determination of technical and economic parameters of the workshop).
More detailed information regarding the design stages can be obtained in the technological instructions in accordance with GOST.
Documentation Development
Technological algorithms are created in two forms: as the actions of workers in real production and in the form of formal algorithms of actions recorded in the form of relevant documents. The process is formed on the basis of a set of special forms (collections of technological instructions), which indicate certain performance requirements.
It consists of text and graphic parts. Layout and wiring diagrams, drawings, visual models with damage (failure) of products are indicated on sketch cards. The features of the technological tool, the sequence of operations, the details of the work are indicated in various types of information cards.
Technological instruction (TI)
It is a text document indicating the basic conditions for the manufacture of products or repairs taking into account available resources. An example scheme for recording information:
- The name of the process.
- Terms of preparatory operations.
- Disassembly conditions.
- Repair requirements with technical specifications.
- Information about testing finished products.
- Reference Information.
- Notes for further use.
Technological route (TM)
In the practice of production systems, the concept of technological routes is used. The main technological route is a diagram of the movement of manufacturing or repair facilities in the shops (sections) of the enterprise, indicating the location of equipment, parks of repaired products, etc.
When designing individual technological instructions (maintenance of the electric motor rotor, disassembling the hydraulic part of the pumping station), route maps are used. Their task is to provide a technical description of the movement of objects of labor by positions (jobs) in the process of performing production stages. A detailed study of operations in this case is not carried out. The magnitude of labor costs, type and amount of equipment, material costs are not indicated.
Production cards
There are several types. For example, KTPR, KTPD, OK (respectively, a repair, fault detection, operational card). Designed for a detailed step-by-step description of the implementation of the process elements, allowing to achieve the ultimate goal - the release of finished products (return to the object in good condition). For example, the process of painting the product will include all the necessary operations in the correct sequence, the time spent, the tool and the execution conditions are indicated.
Finally
The technological instruction is information support of any production. With the creation of modern digital technological systems, its role does not decrease at all. The developed routes, operational algorithms or picking lists represent an information stream, the level of organization of which affects the performance of all enterprise processes.