PRODUCTION SYSTEM

The production is based on application of innovative technologies and modern automated equipment ensuring high quality of products.

Arkadiy Bardov

Director of the electric equipment plant

Total production area comprises 14.000 m2, of them assembly production areas occupy 6.800 m2, production capacity is 3.000 cabinets per year. At the production manufacturing of the whole spectrum of distribution units and management systems is organized in the sphere of power supply. The structure, dimensions of the devices are adapted if there is a need of their placing within a constricted space for a reconstruction or modernization project. The construction development of the product “for the project” is carried out within the shortest terms with application of CAD-system (system of construction software). The products compatible with both Russian and foreign component parts. It makes it possible not only to provide for reliable power supply, but also to fully satisfy individual requirements of each customer. NIPOM constantly improves the issued product, increases its functionality and quality.

The enterprise actively applies modern technologies during the whole life cycle of the product.

Products Development

When designing the products and building technological processes the enterprise actively applies parallel engineering providing for almost simultaneous implementation of all stages of the products development. Active application of typical technological processes allows for making production preparation automated covering 80% in total (the development in semiautomatic mode) by way of indicating the process number and its temporary attributes (manual input). As a result, based on the obtained data the system itself develops and forms a technological process. The remaining 20% are developed for a certain product, and criteria of labour norms are calculated automatically based on construction data. The system of technological design is built on the basis of addressing the databases which are unified both for construction engineers and for process engineers.

In such case expenses for technological design are reduced on account of the use of construction developments (without their copying) and addition of “missing” data necessary for the system of production planning.

Engineering Centre

Reference data for engineering centre experts is requirement specification from the Customer (mandatory component) and results of preliminary technological working-out. Development of CDD (Construction and Design Documents) starts from working-out of electrotechnical part of documents in ECAD (means of electrotechnical CAD-system development). The program contains the base of basic and auxiliary electrotechnical products (switches, contactors) and functions in connection with additional software modules of own development. Based on technical specifications electrician creates a tree structure of the product in ECAD with the help of SW module “Product Structure”. Position denomination is assigned automatically (a basic part is indicated in the database for the electric component in advance, for instance, “QF”, and then the system adds the number –“QF1” etc. – circuit number for communication lines). The developer can correct them manually if it is required by technical specification.

For comfort of the development separate electric components in the list are united in groups, clarifying messages are added, addresses for circuits are assigned in the circuit which go beyond a functional unit.

Based on a chief circuit (ECAD) the developer makes the rest of the circuit set – single linear circuit of intercabinet connections. Physically the developer only places necessary symbols (which are already included into each electric component); signs, addresses, names of circuits, which are inherited from ER (Electronic Record) and are changed together with it applying GOST 2.053 terms.

Documents actually prepared by the developer are technical documents for a construction engineer. Based on the received data the product is configured in PDM-system (system of engineering data management) with the use of the developed construction blocks containing also process data. If necessary, new facilities are created to which corresponding drawings are attached. The material is requested by CAD-system out of MAA (“Materials and Assortment” reference book representing a single base of materials applied in the course of the product manufacturing), out of it the product name is also filled out.

As a result, the final structure looks like this (example): “Part (support), part (bus), part (panel) – assembly unit (bus set N) – assembly unit (bus partition set) – assembly unit (parts cabinet outgoing lines 1) – assembly unit (parts cabinet outgoing lines 1) – assembly unit (input and partitioning cabinet)”. Each facility of “assembly unit” type is added by two documents: assembly drawing and specifications. Specifications and other business documents are formed based on the tree structure of PDM-system by a specialized SW of own development.

After re-work of the structure and inclusion of all necessary documents and parts the construction developer adds to each assembly unit a necessary fixture, materials for electric installation (if necessary) and other purchased products, indicates the rate of disposal and quantity.
All these things exist inside of PDM-system in the form of facilities with corresponding types. The materials and other purchased products are recorded both in MAA base and in PDM-system and are connected with each other. At that facilities in MAA database are basic and are temporarily used by other complex parts – systems of PDM and CAD.

Introduction of changes into already approved structure of the product is carried out via the mechanism of PDM-system versions. The developer (construction engineer or electrician) creates a new variant of the functional part where changes are necessary, at that all indentures of the preceding version are copied to the new version. After that with the help of a separate SW two versions are compared, the result of comparison is a table of changes which is exported into the card of ERP system (the system of enterprise resources management) and is sent to the Archives for approval. After approval of the new version the table of changes is exported into ERP system for correction of the process of purchase and/or production.

Production Technology

At the enterprise the whole production cycle of distribution units manufacturing is localized. Compact placement of the production allowed to build optimum material flows inside of the enterprise which positively influenced all spheres of production activity:

Warehousing Facilities

Use of Kaizen materials provided for reduction of time for completing the orders by 48%, and application of modern logistics solutions at reduction of warehousing areas twice allowed for increasing the capacity of warehouse by 2.5 times.

Blank Production

Application of value engineering allowed for reducing production areas and freeing the equipment. Standardization of preparation operations provided for application of modern equipment with NPC (Numerical Program Control), and automation connected the racks of digital program control with a single engineering data base.

At present the operators work is carried out without paper drawings reducing not only expenditures on support of production process but also reducing the amount of faulty goods due to untimely replacement of drawings. The operator gets access to a single system of engineering data (construction and technological documents), and due to separation of access rights he or she may receive information but has no authority to make changes to it. Operators acting on-line get access to drawings relevant at the moment (approved for implementation). Using the system of two monitors they can simultaneously see the drawings and make changes (software controlled) into NPC system.
Application of SMED instruments allowed for increasing productivity by 5% and covering the expenses in 3.5 months.

Application of Powder Coverings

In 2008 semi-automatic line of powder dyeing is launched, which provides for constantly growing production volumes. Application of modern technologies enables to receive a stable covering the thickness of which is recorded daily. Control over fulfilment of technological requirements in carried out in the automatic mode. Besides that, harmful nature of dyeing is reduced significantly.

Technology of powder dyeing is based on application of:

  • polyether coverings for outdoor use as due to them maximum resistance to the effect of ultraviolet rays is reached;
  • epoxypolyether coverings for indoor use as they are symbiosis of the properties of epoxy and polyether coverings and provide in the same manner for resistance to UV and to aggressive media.

1. Surface Preparation
This operation is a significant factor providing for endurance of the covering, and corresponds to all requirements of GOST for powder covering. Preparation of the surface includes the following stages:

  • Degreasing of the surface (for removal of conservation cover from the surface of sheet metal) – on account of placement of nozzles, spreading at certain angles in three planes and high pressure of the supplied degreased solution;
  • Combined with the degreasing stage – application of an additional layer to the metal surface in the form of a phosphate film;
  • Washing-out by filtered municipal water;
  • Washing by demineralized water for removal of salt residues from the metal surface.

This technology provides for a long-term corrosion stability of basic metal in case of insignificant damage and short-term protection in case of significant damage.

The unit of surface preparation is equipped with the system of working processes regeneration allowing for using solutions several times. This reduces self-cost of coverings application and reduces ecological loading.

2. Drying

Before application of powder covering on the part surface drying takes place till full removal of moisture from the sheet surface.

3. Application of Powder Covering

It is carried out in a two-side chamber equipped with a system of recuperation of the powder dye which allows reducing application expenses. The coverings application system can work both in electrostatic mode and in tribostatic mode ensuring a high quality of application. The programmable system of controlling the filling units allows reducing the human factor influence.

4. Forming the Covering

This is actual baking of the powder on metal surface, as a result of which a protective film is formed. As this process requires a certain temperature mode, the chamber of the covering forming has a system of ventilation for the uniform distribution of temperature on the product surface and the system of electronic control of temperature mode. This system represents a temperature gauge combined with a timer providing for exposure of parts to the set temperature in accordance with the technology within the required time. Buzzer generates signals of ending of the process which prevents from overexposure of the part to the treatment inside of a furnace and reduces the time spend on servicing of this process.

The site actively applies 5S instruments, as a result of that the carrier may distinctly determine in accordance with the applied system of the identification the fact of readiness of some parts for transfer to assembly sites for these or those products.

Assembly Production

Application of 5S and KANBAN allowed for receiving the productivity growth by 16% in the first 4 months after their implementation on account of reduction in losses. At present the enterprise carries out the transition from a traditional technology of post assembly of products to the technology of stream assembly of products which is, as pilot projects show, the technology allowing for reducing the assembly production cycle by 4 times. Application of modern equipment and instruments ensures high quality manufacturing of products and minimizes a human factor. The enterprise has also patented technologies of its own development, for instance, the technology of radial pressing out of cable ends ensures guaranteed high quality pressing out of cable ends regardless of manufacturers of cable ends and the cable.

Testing and Adjustment

Quality control carried out at all production limits is proved before the packing at the dedicated site of testing and adjustment. Employees of this site are trained in special centres and are provided with modern calibrated equipment and instruments. For reduction of time of adjustment at the site special stands of own development are applied. Modern IT infrastructure enables online recording and resolution of issues.

Workplaces of the adjustment staff are equipped with PCs and provide access to a single system of engineering data reducing not only losses in the course of search for relevant documents, but also reducing distraction of engineering staff by receiving additional advice.
Application of “one topic lessons” extends the circle of the involved personnel into the process of improvement and the products quality.

Synchronization of programs, testing methods and adjustment with general technical requirements of the customers provides for maximum satisfaction of the customer’s needs.

Handover of the Equipment to the Customer

Multistep control is applied at the plant:
1. Self-control
2. Control at different stages of technological conversions
3. Testing and adjustment of the equipment
4. Acceptance by QCD (Quality Control Department)
5. Handover of the equipment.

In the course of testing and adjustment working capacity of the products is fully checked up to automated operations. If the testing programme provides for this, technological working-out of products from the point of view of failure analysis is carried out. Mandatory check is products’ inspection for EIC (Electrical Installation Code).

Service

In order to provide for maximum comfort of our clients the enterprise has a service desk which can offer technical assistance to our customers both at the distance and with a practical trip to the customer’s site. Experts of this desk undergo periodical training both in external training centres and inside of the enterprise.

Supporting processes

Natural symbiosis of modern management systems allowed for increasing the production efficiency significantly. Application of quality management system ensured transparency of processes and allowed for reducing expenses for servicing document flow and increasing the products quality. Implementation of ecological management system allowed for finding an additional source of income from the enterprise’s wastes. Use of Kaizen instruments ensured productivity growth during three years by 2 times. Automated power consumption management system provided for forecasting of power use at the enterprise and annual economy of 3-5% during 4 years. The system of planning is built based on the product of ERP class which provided for reduction of manufacturing terms by 25% in average.

The results of production system implementation in 2011 – 2013:

Increase of productivity

+45%

Release of production areas

16%

Release of warehousing areas

25%

Reduction of stock

18%

Reduction of Lead Time of basic products

30%

Reduction of reclamations

23%

55% efficiency of the production.

In accordance with express audit results of international Kaizen Institute the efficiency level of NIPOM production system comprises 55%, at the same time this indicator of Russian industrial enterprises comprises in average 20-30%.

3rd place among Russian enterprises

In 2013 NIPOM company took part in the rating of production systems, in which the enterprise’s production system took the 3rd place among Russian enterprises from the point of view of work places organization based on 5S system.