transcript
2 Business portal "Management of production" has been successfully developing since 2010. It was created on the basis of the production management magazine of the same name (the first issue was published in 2008) due to its transfer to the Internet format. We currently only work in this format. In September 2011, a large strategic investor entered the project, which made it possible to start implementing a new concept for the development of the portal. Today, our portal provides its audience with a variety of sections and services. These are various sections in the Internet magazine, the Library, the News and the Forum. This is an opportunity to find the best shots using the Work section and not miss important events. After all, the section Events is at the service of the audience. We are also appreciated for the fact that we create a number of unique projects. Best Experience(or "best practice") is the core of our portal. Almost all exclusive interviews with professionals in various areas production management. Top managers of leading domestic and foreign companies share their management experience, talk about difficulties and successes completed projects. According to experts, this is what made the portal the most status specialized project on the Russian Internet. The key topics of the portal are: the development of production systems, modern technologies organization of production, modernization and technical re-equipment, strategic management, quality management, labor productivity, personnel management in production, cost reduction tools, management accounting and reporting, logistics of a manufacturing enterprise, maintenance and repair, information Technology and automation of production, innovation and R&D. The editors of the portal are a team of professionals with significant practical experience in manufacturing enterprises, in publishing, consulting and business education on industrial topics. Having our own Center for Research and Analytics allows us to conduct unique research projects, ratings, create analytical materials and practical guides. Presence in the portal team professional translators that specializes in production topics, provides an opportunity to provide the portal audience with relevant materials from foreign production sources (English, German and French), as well as interviews with the management of iconic foreign companies. The audience of the portal is made up of top managers famous companies(including Persons with whom we have published exclusive interviews), heads of the production unit, and managers of industrial companies, government officials (geography: Russia and the CIS countries Belarus, Ukraine, Kazakhstan). In 2011 and 2012, the business portal "Management of production" became the winner of the Competition of journalistic skills, organized by the Union of Machine Builders of Russia and the Union of Journalists of Russia.
3 Copyright Portal "Production Management". This analytical review or any part of it may not be distributed without the written permission of the Business Portal "Production Management" or replicated by any means. It is forbidden to transfer the review to third parties. Organizations that have purchased or received this report from the Business Portal "Production Management" are responsible for its non-distribution. All rights reserved. This analytical review has been prepared by the Center for Research and Analytics of the Business Portal "Production Management" for informational purposes only. The information contained herein has been obtained from sources believed by Production Management Portal to be reliable, but should not be construed, either directly or indirectly, as investment advice. All opinions and assessments contained in this material reflect the views of the authors as of the date of publication and are subject to change without notice. Business Portal "Production Management" is not responsible for any loss or damage resulting from the use by any third party of the information contained in this report, including published opinions or conclusions, as well as for the consequences caused by the incompleteness of the information provided. The information presented in this report was obtained from open sources or provided by the companies mentioned in the report. Legal address: , Moscow, Prospekt Mira d.52, str. 3, room III. for letters: , Moscow, PO Box 109. Website -
4 Information about the Business Portal "Management of Production" Welcome speech 5 1 Methodology of the rating 6 2 Results of the rating "100 best rationalization proposals in industry 2012" Structure and evaluation of the rating participants Winners of the rating "100 best rationalization proposals in industry 2012" 13 3 Status and trends of innovation in Russia What is the nature of the rationalization proposals received as part of the rating? What are rationalization proposals in Russia and in the world? What is the economic efficiency of innovation? Who is the source of innovation proposals? What is the system of motivation and bonuses for rationalization activities at the enterprises participating in the rating? 4 Conclusions
5 Opening remarks Dear ladies and gentlemen, the Center for Industrial Research of the Business Portal "Production Management" brings to your attention the first all-Russian rating "100 best rationalization proposals in industry 2012", aimed at assessing the existing in the domestic production environment innovation movement and providing both industrial companies, and the general public with up-to-date benchmarking data. The innovation movement has historically been strongly developed in our country, and today it is gaining momentum again. More and more companies are remembering Soviet traditions scientific organization work, many are guided by the modern experience of the world's leading companies, including the Toyota Corporation. This is also evidenced by the results of the study "Production Systems of Russia", according to which rationalization is the most common tool among enterprises that implement modern methods of optimizing production, about 180 companies out of 500 stated this. This prompted the Business Portal "Production Management" to launch the first in Russia unique rating "Top 100 Innovations in Industry 2012", designed to evaluate and stimulate the implementation this tool in our country. And we are happy to report that it was a success. The main goals of the rating were as follows: to promote the popularization of the innovation movement among Russian enterprises and their employees; make a snapshot of the situation by the nature of rationalization proposals at the end of 2012; determine which rationalization proposals are the most common and what they are aimed at; 5 to systematize the experience of market leaders in submitting rationalization proposals; evaluate the effectiveness of this tool for enterprises; understand the prospects for innovation in Russia. It can be argued that our experiment was a success. The first independent rating of rationalization proposals in the history of Russia took place. We plan to make it annual and look forward to your suggestions for its improvement.
6 I Rating methodology When preparing the rating, we planned that its results would be evaluated based on the effectiveness of rationalization proposals and the value of financial indicators achieved through their implementation. As the main criterion, on the basis of which the proposals were supposed to be ranked, the economic effect was conceived: both relative (percentage of cost reduction of the enterprise) and absolute (in thousands of rubles). This decision was explained by the desire to give enterprises of various sizes and specifics the opportunity to participate in the rating on an equal footing. Nevertheless, having considered the rationalization proposals submitted by the participating enterprises, we were forced to correct the methodology for their evaluation. At first glance, financial indicators are a universal measure of effectiveness, but after analyzing the questionnaires and discovering how different and dissimilar they are, we came to the conclusion that it makes no sense to compare them directly with each other. As evidenced by the data obtained, the concept of rationalization today includes a wide variety of proposals put forward on Russian enterprises: replacement of old equipment with new; use of new raw materials and materials; change in product design; standardization and regulation; optimization without financial result; 6 process optimization; use of secondary raw materials; mechanization of manual labor; exclusion of unnecessary operations, etc. For a more objective assessment, we decided to group them as follows within the first rating of the hundred best rationalization proposals: Group 1 rationalization proposals that have a pronounced economic effect and are aimed at optimizing processes and operations. Received from correct design(by filling in all items of the questionnaire, detailed description the essence of rationalization and a schematic (photo) image). This group included proposals that our experts identified as optimization aimed at optimizing various kinds, including, for example, optimizing the use of resources. That is, the first group is proposals, from our point of view, the closest to the world concept of "kaizen" (rationalization proposal). Naturally, when the rationalization proposal was described in detail and qualitatively in the questionnaire, the essence of optimization and its quantitative and qualitative results were explained, it was easier to evaluate it. Group 2 rationalization proposals that have a pronounced economic effect and are aimed at modernization and reengineering. The second group includes proposals that are characterized as modernization or technological (engineering) ones that are aimed at changing the elements of the working system.
7 system and process, for example, the use of new raw materials, the use of new equipment. It is not worth it now to enter into polemics and find out what is a real kaizen proposal and whether real rationalization is inherently reengineering, since there are a great many opinions on this matter. We believe that in conditions of depreciation of fixed assets and inefficiently organized work systems, in the presence of high potential For modernization, any proposal that allows enterprises to improve their processes or improve financial performance deserves to be called a rationalization. Thus, 36 rationalization proposals were included in the first group. Basically, they were ranked according to the parameter of economic effect, however, tracking quantitative indicators, we could not help but pay attention to the quality indicators. Therefore, particularly elegant and interesting solutions were also noted. The second group included 64 rationalization proposals, and in their evaluation the main criterion was the economic effect. When dividing into groups, such factors as the speed of implementation of proposals, positions held by their authors, non-financial effects, originality of the proposal, etc. were taken into account. 7
8 II Results of the rating “100 best rationalization proposals in industry 2012” Despite the short period for submitting questionnaires (2 months) and the decision to conduct the rating at the beginning of August, Russian industrial enterprises responded to our idea. More than 70 enterprises of various industries from various regions of Russia expressed their desire to take part in the rating of "100 best rationalization proposals in industry 2012". Unfortunately, due to the fact that such a competition is held for the first time, many enterprises failed to comply with all the requirements for the design and filling of questionnaires, and we were forced to exclude their candidacies. As a result, 17 enterprises were allowed to participate in the rating Structure and evaluation of the rating participants The finalists of the competition (17 enterprises) in total submitted more than 150 rationalization proposals for participation in the rating. It was extremely difficult for us to choose the top 100 among them, and we hope for the understanding of the participants. Applicants for the final were selected in such a way as to demonstrate the diversity of rationalization proposals of Russian industrial enterprises. As part of the "Production Systems 2013" rating, we plan to evaluate and compare the systems for submitting and implementing rationalization proposals, and we hope that the finalists of the rating "100 best rationalization proposals in industry 2012" will take part in it. But, despite this, we believe it is right to assess what kind of enterprises participated in the rating, how and what rationalization proposals they submitted, and what results this led to. Industry structure of participating enterprises was quite expected, although the absence of representatives of the Russian energy industry among them, who are traditionally strong in the field of rationalization and implementation of optimization solutions, was somewhat surprising. It should be noted that the absolute majority of the rating participants (90%) are large manufacturing enterprises with the number of employees from 700 to people and with revenues from 700 million to 110 billion rubles. 8 Fig. 1. Structure of participants by industry
9 As we can see in Fig. 1, mechanical engineering and metallurgy are in the lead, which indicates both a strong tradition of innovation that has not been lost over the past 20 years, and the presence of great potential for optimization in these industries. The reason for the latter largely lies in outdated technologies and fixed assets. Geographically, 12 regions were represented among the rating participants Russian Federation, which in principle demonstrates the sufficient prevalence of the movement of innovators. Table 1. Number of participants by region. Region Number of participants St. Petersburg, Leningrad Region 3 Republic of Tatarstan 2 Yaroslavl Region 2 Vologda Region 1 Republic of Buryatia 1 Republic of Bashkortostan 1 Nizhny Novgorod Region 1 Vladimir Region 1 Krasnodar region 1 Irkutsk Region 1 9 Sverdlovsk Region 1 Murmansk Region 1 Leningrad Region is the leading region together with the City of Peter. They are followed by the Republic of Tatarstan, where the development of Production systems is traditionally strong, and the Yaroslavl region. Unfortunately, a number of enterprises from various regions could not take part in the rating due to the employment of senior managers or their absence due to holidays. Otherwise, the picture of the regional prevalence of rationalization would probably be more complete. Separately, it should be noted that the development of innovation systems of participating enterprises takes place within the framework of the introduction of various concepts of production management (although we do not exclude that there is a common confusion with terminology for domestic practice). Most of the participating enterprises (more than 50%) are actively implementing the QMS (quality management system), the concept of "Lean Production" and the Production System. The age of the system for submitting and implementing rationalization proposals is also fundamental. After all, it depends on him how involved and trained the employees are, how well the submission and implementation of proposals are worked out, and how well the economists of the enterprise are able to calculate the economic effect obtained from the implementation of the proposal. Therefore, the questionnaire included the question of how long the system of rationalization has been functioning.
10 Table 2. List of enterprises finalists of the rating "100 best rationalization proposals in industry 2012" Enterprise - participant Age of the rationalization system, years 1 Apatit-Electromashservice 14 2 Armtel 2 3 BaselCement-Pikalevo 2 4 EVRAZ Nizhny Tagil Iron and Steel Works 75 5 Irkutskkabel 7 6 NPO Nauka 10 7 NPF Packer 6 8 OMZ-Special Steels Izhora Plant 2 9 OMK Almetyevsk Pipe Plant OMK Vyksa Metallurgical Plant PO ElAZ Russian Paints 4 13 Severstal Severstal-Metiz Selenginsky Pulp and Cardboard Mill AgroHolding Kuban 5 17 UEC Saturn gas turbines 41 In the course of the survey, a number of enterprises noted the continuity of the traditions of rationalization since the times of the USSR. Basically, these were large metallurgical and machine-building enterprises. More than half of the enterprises (11 participants) have been implementing rationalization proposals for no more than 10 years. And a particularly pleasant surprise was the participation in the rating of enterprises with very little experience (2 years), but despite this, they are ready to demonstrate that they have something to be proud of. There were four such participants. Now let's get to know our members better. Apatit-Electromashservice presented to our analysts a whole range of rationalization proposals, which, moreover, were perfectly executed: the financial effect was calculated both in equivalent per unit of production and in relation to total annual indicators. All proposals can be divided into two areas - improvement and optimization of operations and work processes at screw-cutting lathe and optimization of repair activities. Rationalization proposals of employees are quick and inexpensive to implement, their effect is clear, it is easy to calculate, both the presence of the “savvy” of employees and the high culture of designing the proposals themselves can be traced, which indicates a developed system of rationalization. Armtel presented only one proposal aimed at the processes of standardization,
11 lamentation and formalization of processes, and, nevertheless, it has already been implemented and brings a positive result to the enterprise. The Armtel rationalization system is at the very beginning of its development, and we are sure that participation in the competition will allow them to develop it to the international level. BaselCement-Pikalevo, the winner of the Production Systems 2012 rating in the Prospective Production System nomination, presented several proposals, some of which do not have a large financial effect, but they fully comply with the world standard of “kaizen proposals”, both in design, as well as in essence. In addition, they submitted proposals that demonstrated a good level of financial performance and a significant reduction in costs. The main directions of rationalization: optimization of existing processes and operations and optimization of repair activities. EVRAZ Nizhny Tagil Iron and Steel Works, a large metallurgical enterprise with rich traditions, presented a large number of rationalization proposals that are very serious financial results. At the same time, for the most part, they fall under the classical type of Soviet rationalization, that is, they belong to the field of activity of engineering and technical services to change and improve the elements of the working (technological) system, namely: replacement of equipment and raw materials, modernization, changes in product designs, etc. . Therefore, out of all rationalization proposals submitted by the enterprise, we could include only two proposals aimed at optimizing resources (for example, electricity) in the first group. At the same time, it is necessary to note the colossal potential of modernization, which the enterprise quite skillfully realizes. Irkutskcable, one of the leaders in the "Production Systems 2012" rating, also provided a large number of rationalization proposals for the rating. Some of them are modernization, some are optimization, and some are aimed at saving resources. Irkutskcable occupies a leading position in terms of the number of proposals that made it to the final, especially in the first group, not to mention the fact that it was he who got the fame of the best rationalization proposal of Russia this year. A reliable system for calculating the economic effect and production costs, a rationalization system covering everyone, from directors to ordinary employees, became, according to our experts, the key to the company's victories. NPO Nauka submitted quite a lot of rationalization proposals to the rating, but, unfortunately, most of them did not meet the basic selection criterion of having a recorded financial and economic effect. Despite this, a number of proposals have all the properties of optimization and are submitted by workers "from the machine", which is one of the most valuable characteristics of the rationalization system. Many proposals are aimed at changing designs, technologies, standardization and regulation. It should also be noted that best deals focused primarily on improvement and optimization at the level of operations, processes and product. NPF Packer provided three rationalization proposals, two of which meet the requirements for classical kaizen proposals, but, based on small production volumes, the financial effect obtained was small compared to the proposals of other participants. For a confident victory in the rating of "100 best rationalization proposals in industry 2012", the employees of the enterprise are recommended to draw up rationalization proposals in a more detailed and high-quality manner and develop rationalization aimed at optimizing processes and organizing flows. OMZ-Special Steels Izhora Plant, a metallurgical enterprise, like EVRAZ, has distinguished itself by a considerable number of economically effective rationalization proposals, which, nevertheless, are also of an engineering, modernization nature. Therefore, out of all the rationalization proposals in the first group, we could include only one proposal aimed at optimizing resources (rational use of 11
12 charge) and brought a serious economic effect to the enterprise. OMK Almetyevsk Pipe Plant submitted only two rationalization proposals, but one of them deservedly took second place in terms of efficiency and focus on process optimization (technological transitions). Detailed and high-quality description of the essence of the proposal, high economic effect (more than 1 million rubles), rapid implementation (in 1 month) all this testifies to the promising nature of OMK's system of rationalization proposals and its reliable traditions. OMK Vyksa Metallurgical Plant, like other metallurgists, presented several rationalization proposals, also related to the improvement of the elements of the working (technological) system, although they have an economic effect. This led to the fact that only one proposal could get into the first group, but OMK's rationalization proposal turned out to be the most effective in the second group. financially(58 million rubles of economic effect). Software ElAZ, which became the winner of the rating "Production Systems 2012" in the nomination "Intelligent Production System", submitted mainly rationalization proposals with a change in technologies and designs of a purely engineering nature and, due to small volumes of production (against the background of metallurgical giants), could not take a worthy high place among the finalists of the rating. But based on the success of ElAZ in the development of the Production System, we are sure that for the next competition it will present the most progressive kaizen proposals aimed at optimizing processes. Russian paints, an enterprise with good references and results in the implementation of the system of rationalization proposals, submitted three rationalization proposals of an engineering nature, and all of them have a good financial effect. But we were able to attribute only one to optimization, close to kaizen, due to the fact that it was associated with a revision of the entire product identification system at the enterprise. The proposals of the Severstal group of companies also had a more engineering character, which led to the inclusion of only one proposal in the first group, but there were several of them in the second group at once. Unfortunately, the participant did not provide the names of the plants that submitted and implemented the proposals, which caused additional difficulties. We hope that in the future the success of our colleagues in the market will encourage Severstal to prepare more carefully for such ratings. Unfortunately, Severstal-Metiz presented only two rationalization proposals, one of which on the recycling of the resource (neutralized water) could take its rightful place in the first group of proposals. The Selenginsky Pulp and Cardboard Mill, which has been developing an innovation system for only two years, has submitted a number of proposals from several (apparently pilot) production sites with classic elements of modernization and reengineering. An added advantage was that for each proposal the economic effect was calculated, but only one proposal could get into the first group. The rest competed with the proposals of metallurgists and machine builders. MC AgroHolding Kuban participation in the rating "100 best rationalization proposals in the industry 2012" of one of the largest agricultural holdings in the country has become a very positive sign, designed to show the way to rationalization for all agricultural enterprises and representatives of the agro-processing complex. Despite the specifics of the proposals and the difficulty of comparing them with metallurgists and machine builders, the rationalization proposals of the "Kubans" managed to take worthy places in our rating. We consider the path chosen by the employees of the management company AgroHolding Kuban to be extremely promising, especially in the context of Russia's dependence on food imports, and we call on all enterprises of the agro-industrial complex and Food Industry equal to the Kuban. 12
13 UK UEC Saturn Gas turbines this unique enterprise of the machine-building industry provided a number of proposals aimed at changing the design and technology, and only one of them was included in the first group, where, due to the economic effect, it took its rightful place. The rest competed with metallurgical enterprises in terms of economic efficiency Winners of the rating "100 best rationalization proposals in industry 2012" were also divided into two parts as follows: Table 3. Group 1 of the best rationalization proposals of Russia according to the criteria "compliance with international standards of rationalization", "qualitative description and design", "speed and ease of implementation" and "economic effect of implementation". Proposal Enterprise 1 Change in the process of marking cable drums Irkutskkabel 2 3 Adjustment of the welding stand of the mill during technological transitions Kaizen project "Organization of work on the restoration of machine parts in the ERC OMK Almetyevsk Pipe Plant Apatit-Elektromashservis 13 4 Production of a mobile hoist for the repair of pressure regulators BaselCement- Pikalevo 5 Fixture for continuous drilling on a screw-cutting lathe Apatit-Elektromashservis 6 Fixture for pressing double-row radial spherical roller bearings 3614 according to GOST into a part Apatit-Elektromashservis 7 Longitudinal stops for machining accuracy on a screw-cutting lathe Apatit-Elektromashservis 8 Fixture for fast centering of holes on a screw-cutting lathe Apatit-Elektromashservis 9 Structural change of the protective ring of the suction pipe of the pump brand 1GRT 1250/71 in order to improve operation and increase the turnaround time Pikalevo
14 Proposal Enterprise Change the operation algorithm of GP-7 in emergency situations(with one faulty lifting table) Use of non-liquid materials as a sublayer for power cables Modification of the GTA-6/8RM KVOU design in order to reduce transport dimensions and transportation costs Reuse of neutralized water for cooling drawing mills Severstal-metiz 16 Lead recycling Irkutskcable 17 Cleaning of metallurgical equipment (electric motors, electrical cabinets, contactors, etc.) by cryogenic blasting (cleaning with dry ice granules) Severstal 18 Rational use of charge. OMZ-Special Steels Izhora Plant 19 Organization of transportation of reel sets in containers Irkutskcable 20 Use of alternative packaging for transportation of cables in PVC insulation with a cross-section of conductive cores of 1.5-10 sq. m. mm Irkutskcable Use of underutilized steam energy for drying the cordel Irkutskcable Replace diesel fuel with an aqueous solution of Polyprom detergent G-D systems(rotating converters) Irkutskcable EVRAZ Nizhny Tagil Iron and Steel Works 24 Polyethylene recycling Irkutskcable 25 Optimization of box labels Russian paints Changing the scheme of waste line drainage from washing stations. The use of cardboard for sheathing products on reels 7 Changing the operation of manufacturing the “Plate” part APRS Selenginsky Pulp and Cardboard Plant Irkutskkabel Production Association ElAZ 29 Device for testing electrical equipment Agroholding Kuban 30 Hydrotesting of KCM. PACKER 31 Use of a gas-air burner to ignite the gas at the top when shutting down blast furnaces at PPR. EVRAZ Nizhny Tagil Iron and Steel Works
15 Proposal Enterprise Improving the design of the air distributor in adsorbers Measuring system of water level in the "warm tank" reservoir The design of the refrigerator cover and the method of its implementation during repair. Changing the method of marking the inscriptions on the "Hull" part according to clause 10 of the TT of the drawing Introduction of technological improvements in the "Clamp" part NPO SCIENCE NPO SCIENCE NPO SCIENCE NPO SCIENCE NPO SCIENCE technologies”, “reengineering” and “economic effect of implementation”. Offer Enterprise 37 Casting of wheel steel into semi-blank molds, combined with the head, the inner diameter of which is 507 mm., the height of the molds is 2870 mm. OMK Vyksa Metallurgical Plant 38 Matrix for the manufacture of TPG with a cross section of 240 square meters. mm with an angle of 120 degrees Irkutsk cable Use of high-carbon ferrochrome instead of medium-carbon in the smelting of chromium-containing steel grades in the EVRAZ converter shop Nizhny Tagil Iron and Steel Works 40 Obtaining an additional amount of blast-furnace additive 41 Increasing the production of krypton-xenon concentrate 42 Reducing the cost of fuel oil facilities EVRAZ EVRAZ Nizhny Tagil Iron and Steel Works Nizhny Tagil Iron and Steel Works EVRAZ Nizhny Tagil Iron and Steel Works 43 Shortening the production time for cable products Irkutskkabel 44 Change the design of the workpiece pusher OMK Vyksa Steel Works 45 Use of lime dust from gas cleaning and aspiration systems of the lime-dolomite shop in the charge of AGC-3 Severstal 46 Processing waste from the naphthalene distillation department EVRAZ Nizhny Tagil Iron and Steel Works plant 47 Change in the design of the fuel supply for the D049 engine from the GTES-2.5 UK UEC Saturn Gas turbines
16 Offer Enterprise Elimination of joint gaps between wide and narrow walls of CCM-4 mold without mechanical impact. Increasing the actual durability of narrow slabs of MNLZ-4 molds Changing the design of the annealing furnace of the galvanic galvanizing unit Changing the program of operation of the hydromechanical expander in the production of two-seam pipe Reducing the consumption coefficient per strip for the production of thrust brackets Applying new designs of self-supporting insulated wire to reduce production costs Change technological scheme pumping out scrap from the containerboard production workshop to the cooking and washing workshop. EVRAZ Nizhniy Tagil Iron and Steel Works Severstal-Metiz OMK Vyksa Steel Works EVRAZ Nizhniy Tagil Iron and Steel Works Irkutskcable Selenga Pulp and Cardboard Works 54 Reducing the cost of XLPE cables Irkutskcable 55 Putting into operation a sintering charge of waste woodworking wood chips Severstal 56 Restoring the working capacity of the Sictra AL5 drawing knife Drawing machine Irkut AL5 with critical wear in cutting coiled steel at APR-2 (manufactured in Korea) OMK Almetyevsk Pipe Plant Technology for loading iron ore materials into blast furnaces. Severstal 59 Reducing the level of rejects in the production of thrust brackets from 0.5% to 0.3% EVRAZ Nizhny Tagil Metallurgical Plant 60 Reducing steam consumption for hot water supply and heating systems of the administrative and industrial complex of the section for stripping cars of the hammer shop. Severstal 61 Replacement of filling material in the design of Irkutskkabel cables Application of an additional heat exchanger in the scheme of the condensate line of separators for continuous blowdown of medium-pressure boilers Replacement of the separating layer material in cables of the KVVGE, AKVVGE grades Use of MKRL tape instead of a refractory cord when casting ingots weighing up to 120 tons. Installing a VFD on the feed (network) pumps of steam boilers Application of digital processing of signals coming from the turbogenerator TK6-2RUKHLZ in the ACS GTA-6RM BazelCement-Pikalyovo Irkutskcable OMZ-Special Steels Izhora Plant Russian Paints UK UEC Saturn Gas turbines
17 Proposal Enterprise 67 Replacing the material for the separating layer Irkutskcable 68 Changing the design of the “Sections” of the BC and BC, which are part of the “Cyclone Blocks” for ground-based products UK UEC Saturn Gas turbines 69 Installation of a liquid meter to account for dilutions of the verstat Agroholding Kuban Division Sugar Reduction of time changeovers and the amount of waste when switching from section to section when twisting copper round TPG on Cortinovis 371 Increase in the yield of marketable products of solvent, BS-1 and inden-coumarone resin Change in the design of hot air distribution to the KVOU of GTA-6/8RM units Optimization of grain shipment from the elevator LV 3*175 of the production site 1 Modernization of the electric drive of the sulfate feeder of the soda recovery boiler 3. EVRAZ Irkutsk cable Nizhny Tagil Metallurgical Plant UK UEC Saturn Gas turbines Agroholding Kuban Ust-Labinsky KHP Selenginsky Pulp and Cardboard Plant 75 Increase in the output of marketable products of pitch distillate 76 Replacement of TGM-6 diesel locomotives with TGM- 4 EVRAZ Nizhny Tagil Iron and Steel Works EVRAZ Nizhny Tagil Iron and Steel Works One-time reduction in the cost of equipping shop 20 due to the involvement of the charge in shop 47. Installation of a device for removing premium milk from the milk pipeline milling machine FSS400 Use of metal packages made of galvanized iron from Metallopttorg LLC for smelting semi-finished products in EAF-120. Optimization of filtration of pentaphthalic lacquers in the lacquer dispensing department of shop 1 on one line. Reducing the consumption coefficient for smelting steel grade 10GN2MFA by the ESR method from cast electrodes in a mold with a diameter of 1700 mm. The use of polypropylene tape for fastening the flexible sheathing of drums Changing the scheme of pumping white strong liquor to the workshop for the production of wood-chemical products
18 Proposal Enterprise Replacing a part of metallic manganese Mp-95 with no cheaper ferromanganese FMP 78. Changing the manufacturing process of the part “Pump frame 9T TsN” Changing the design and manufacturing technology of the part “Bottom” of TsKB R B04, which is part of the “Special Sewerage Traps” of TsKB R and TsKB R Changing the technical process of forging with subsequent cutting on the USAY 1010 saw. Mechanized method of loading alumina at the complex treatment facilities. Change in the design of winches AR, APRS and APRS 60 / OMZ-Special Steels Izhora Plant Production Association ElAZ UK UEC Saturn Gas turbines OMZ-Special Steels Izhora Plant Selenginsky Pulp and Cardboard Plant Production Association ElAZ 91 reduced profit margin. OMZ-Special Steels Izhora Plant Fastening of bronze bushings in the working cylinders of the press 1250 tf. Changing the design of the piping of the oil-sulphurizing system B of the GPA-6 RM block-container unit V OMZ-Special Steels Izhora Plant UEC Management Company Saturn Gas turbines Use of business waste of the stop housing UPR 80 / ElAZ 96 Production Association Changing the design of the air duct section and installing reinforced slide gate valves for air flows Korenovskiy elevator 97 Optimization of the process of grain loading of floor storage warehouses at the production site 2 Agroholding Kuban Ust-Labinsky KHP 98 Changing the design of the travel gear drive and oil pump at the KSHP Agroholding Kuban Korenovskiy elevator 99 Production of a rolling and rolling device for the MTZ-80,82,82.1 tractor Agroholding Kuban 100 Replacement of the filter element in the oil system of the turbo expander unit DT 5/220. OMZ-Special Steels Izhora Plant It is not easy to choose a single winner among so many proposals. And after carefully analyzing each, our experts awarded the first place to Dobretsky S.I., OAO Irkutskkabel, who presented a completely new look at the process of marking drums with cable products. The implementation of this proposal made it possible to reduce the cost of marking drums, improve its appearance and eliminate unattractive
19 working places with harmful conditions labor: marker 15 units, painter 3 units. As a result, the implementation of the proposal brought 1.7 million rubles of economic effect. The second place was deservedly taken by the team of Khabirov F.A., Sandrevsky A.V., Matveev D.G. and Kulagin A.V. ("OMK Almetyevsk Pipe Plant") for the proposal to adjust the welding stand of the mill during technological transitions. This proposal was implemented in 3 days and brought a financial effect of 1.1 million rubles. The fact of saving the norm of time for the transition from one standard size to another was reduced by 16 minutes; there were 61 transitions on the base period; savings amounted to 16.3 hours; average performance mill increased by 31.37 tons/hour. As a result, additionally manufactured products amount to 511.33 tons. The third place (as well as places from 5 to 9 inclusive) was taken by Apatit-Electromashservice. Proposal for the organization of work on the restoration of machine parts in the ERC Finka A.O. is a classic proposal aimed at process optimization rather than the technology itself. Its implementation not only brought economic benefits, but also significantly improved the working conditions of the staff. It should be noted that the proposals of Apatit-Electromashservice were the best in terms of the quality of preparation and study and were closest to the kaizen standard. Although they did not bring a multimillion-dollar effect, like proposals to replace raw materials from other participants, they can really be called rationalization in the best sense of the word. I would especially like to note the turner of the 6th category of the Apatit-Elektromashservis enterprise Kuznetsov Andrey Nikolaevich, who put forward three proposals for rationalization for working on a screw-cutting lathe. The simplicity of their implementation, the elegance of the idea itself, as well as the clear and tangible effect both at the process and at the operational level, cause sincere pride in the ingenuity of the Russian production worker. The fourth place (as well as the 10th and 11th places) was taken by the proposals of BaselCement-Pikalevo. Like Apatit-Electromashservice, this enterprise has a high culture of preparing rationalization proposals. Kaizen proposal Grigoriev S.V. to make a mobile hoist to repair pressure regulators revolutionized the operation itself, freeing up two workers, reducing labor intensity and improving safety in just 9 days. Separately, I would like to highlight the rationalization proposal of the Irkutskkabel enterprise, which took 22nd place. It consisted in replacing diesel fuel with detergent. Someone will laugh and ask: “Where is the rationalization here?” But, apparently, diesel fuel has been used for mopping floors for more than one year, and no one was worried that it was unprofitable, harmful, and fire hazard. The problem was simply not noticed until Gorbachev V.I. and Shcherbo I.I. did not pay attention to it and did not submit a proposal to eliminate it. Their example is instructive for every production worker: look around, because the basis of rationalization is the constant desire to do better than it was, and the lack of inertia in thinking. No less progressive is the direction of increasing the efficiency of electricity consumption in production, a vivid example of which is the proposal of Bezdenezhnykh I. B. and Gulyashchev P.V. (“EVRAZ Nizhny Tagil Iron and Steel Works”) to reduce power consumption when switching the power supply to the automation systems of the PGR section and refrigerators from power voltage (380V 50Hz) instead of the G-D system (rotating converters). This proposal took 23rd place, which is not surprising, because the world's leading economies (Japan and Germany) have long been improving the efficiency of using all types of energy resources at enterprises, reducing their consumption and improving the structure of production costs. It should be noted Fattakhov R.A. and a group of his colleagues, authors of a number of interesting offers"Production Association ElAZ". In the proposals of his group one can see an unbanal 19
20th technological and engineering idea and serious experience gained over the years, which allowed them to take 28th place with the proposal "changing the operation of manufacturing the plate" APRS ". Simple solutions, fast implementations, focus on technological operations are the factors that, with proper development, high-quality proposals and a little more focus on optimizing processes rather than technologies, will allow this team and the enterprise itself to compete adequately in the fight for victory next year. The best rationalization proposal (engineering) for financial indicators, which took 37th place, was the proposal of OMK Vyksa Metallurgical Plant for casting wheel steel into seven-piece molds combined with profit, which was submitted by a group of engineers and technologists of the plant (first place among technological and engineering proposals). The effect of the implementation of this proposal amounted to 58.1 million rubles. In this case, one should not forget about economies of scale, but it doesn’t stop anyone from using the “Pareto analysis” and finding out which processes, operations and technologies the company spends the most resources on, and focusing its optimization efforts in these areas. Summing up the above, I would like to note that the total effect of the implementation of more than 150 proposals submitted for our consideration by 17 enterprises from different industries amounted to about 300 million rubles. 20
21 III Status and trends of innovation in Russia What is the nature of the innovation proposals received as part of the rating? One of the goals of the rating "100 best rationalization proposals in industry 2012" was to provide enterprises with the opportunity to see the whole picture that has developed with rationalization proposals in Russia, so that any manager can compare his system of rationalization proposals and its product with the results of our rating and make appropriate conclusions. When planning this rating, we took as a basis similar ones carried out in England, France, Austria, China, India, Malaysia, Taiwan, and assumed that our main task would be to distribute rationalization proposals (kaizen) by type, as is done all over the world: aimed at workplace(5S) aimed at repair and maintenance (TPM), aimed at logistics and movement (logistics), aimed at optimizing processes and operations, etc. Then, depending on the number of certain proposals, we had to form nominations or separate ratings for them, as, for example, in India, Taiwan and Malaysia, where the rating of proposals and TPM systems is the most popular. But having received the results of the survey, we found that the scheme familiar abroad does not work in Russia, and we divided all 150 rationalization proposals into the following types (see Fig. 2). 21 Fig. 2. Types of rationalization proposals of participating enterprises. The presented types of rationalization proposals, in fact, are the product of systems for the submission and implementation of rationalization proposals, that is, they indicate which
The system “passed” 22 proposals for implementation over the past 2 years. The creation of such a classification did not present any difficulties, since it does not even need additional explanations and studies. A cursory glance at the list of rationalization proposals, any reader will see that it is dominated by proposals with the name "Change in design" and "Replacement / Modernization", that is, classic rationalization proposals from the point of view of the NOT, which in total turned out to be more than 50%. After analyzing the information that is in the public domain, although enterprises are more likely to talk about the overall effect than about specific rationalization proposals, we were convinced that this classification and percentage correspond to the general market situation (with a deviation of no more than 5.5%). To understand how actively this situation is changing, we will be helped by the rating of the next year "100 best rationalization proposals in the industry 2013", and we hope that the current participants will wait for it and prepare for it with no less impatience than we do. We did not begin to divide optimization proposals into types, as is customary abroad, because they were not a large number only 8% of the total. On the other hand, a rather large percentage of rationalization proposals for the recycling of raw materials and materials is 12% of the total. This suggests that in the minds of managers and employees, the attitude “Russia is a country with innumerable and rich resources” began to change to “saving even 100 rubles will help the company to be competitive.” A high percentage of proposals aimed at optimizing resources (raw materials, materials, energy) of 13.3% of the total, on the one hand, is a very good trend, and on the other hand, it indicates that when designing, planning and organizing production (technological, working) systems at Russian enterprises are not able to reduce resource consumption. Surprising for us was the presence of such a type of rationalization proposals as the replacement of raw materials and materials 16.7% of the total. As a rule, these proposals are submitted by engineers, technologists, procurement specialists, department heads, and such a large percentage of the total number indicates both the existence of a high potential for modernization and optimization of production, and the need to closely monitor all global trends in technology development and the emergence of new types of raw materials and materials with new properties and qualities. Also, six proposals were not included in the classification, which we classified as “regulation, standardization, formalization”, since, although they bring an effect, they are not rationalization in their essence, but fall under the tasks of the QMS and process management in production. The fundamental issue is always the timing of the implementation of the rationalization proposal. On the one hand, this is a measure of the effectiveness of the system for introducing rationalization proposals, and on the other hand, an assessment of the complexity (value of fundamental changes in production) of the implementation of proposals. Taking into account the fact that up to 70% of rationalization proposals are aimed at modernizing and changing structures and technologies, the presence of such a large number of rationalization proposals with an implementation period of 3 months or more is not surprising. At the same time, 34% of rationalization proposals were implemented in less than a month, which indicates a high degree of readiness of enterprises for changes and a well-established system for implementing proposals. I would like to point out that within modern technique Kaizen Blitz says that "A proposal that cannot be implemented over the weekend is not worth considering." We were 22
23 are pleased to note that more than 10% of the rationalization proposals of the rating finalists meet this requirement! Rice. 3 The structure of rationalization proposals according to the timing of implementation. So, we can conclude that rationalization proposals in Russia have a clear focus, they: correct errors in technological processes; change the design of products (designed with errors); 23 initiate the replacement/repair of obsolete equipment or its components; change materials and raw materials for production to more efficient and modern ones; optimize the use of various types of resources (losses of energy, raw materials, materials); suggest efficient use of raw materials and materials in the production process for the second time; optimize processes, operations, technologies. A sample of 70 enterprises and more than 500 rationalization proposals (of which 17 enterprises and 150 proposals were admitted to the final) with an emphasis on innovation in mechanical engineering and metallurgy seems to us sufficient for formulating such conclusions. In order to leave no doubts, we do not have enough companies in the automotive and energy industries in the ranking. But we hope that, having become interested in the results of our rating and proceeding from the competitive Olympic principle, they will take part in the rating of “100 best rationalization proposals in the industry in 2013”. What are rationalization proposals in Russia and in the world? The results of the rating "100 best rationalization proposals in industry 2012" were surprising in many respects for us. After analyzing the potential
The business portal "Production Management" has been successfully developing since 2010. It was created on the basis of the production management magazine of the same name (the first issue was published in 2008) due to its transfer to
Rational proposals in the oil and gas industry download for free >>> Rational proposals in the oil and gas industry download for free Rational proposals in the oil and gas industry download for free
Analytical research "Production systems of Russia" CENTER FOR RESEARCH AND ANALYTICS PRODUCTION SYSTEMS OF RUSSIA ANALYTICAL STUDY Moscow, 2012 Business portal "Management of production"
Overview of the market for copper pipes in the CIS 3rd edition Moscow August, 2017 Demo version With purchase conditions full version The report can be found on the website page at: http://www.infomine.ru/research/4/526
State Autonomous Institution “Center for Energy Saving Technologies of the Republic of Tatarstan under the Cabinet of Ministers of the Republic of Tatarstan” Tools for increasing the competitiveness of an enterprise. Increasing labor productivity. Martynov Evgeny Vasilyevich 1 Implementation of the policy of increasing
STATE STANDARD OF THE UNION OF THE SSR UNIFIED SYSTEM OF TECHNOLOGICAL PREPARATION OF PRODUCTION REGULATION OF THE CONSUMPTION OF MATERIALS MAIN PROVISIONS GOST 14.322-83 STATE COMMITTEE OF THE USSR ON STANDARDS Moscow
GOST 14.322-83 M E F G O S U D A R S T V E N N Y S T A N D A R T REGULATION OF THE CONSUMPTION OF MATERIALS MAIN PROVISIONS Official publication Moscow Standartinform issuance of certificates UDC 658.513:002:006.354
CONVERTER EQUIPMENT FOR THE METALLURGICAL INDUSTRY
Automation of production in the machine-building industry (on the example of JSC "Plant Dagdiesel") Magomedova K.M. Dagestan State University Makhachkala, Russia Automation of production in the
THE MECHANISM AND EXPERIENCE OF REGIONAL ENGINEERING CENTERS (RCC) FOR THE DEVELOPMENT OF MANUFACTURING ENTERPRISES OF SMEs PAVEL ALEKSANDROVICH DEREVYANKO EXPERT OF THE ENGINEERING BRANCH DIVISION BUSINESS RUSSIA, DIRECTOR OF PRODUCTION
The practice of creating an efficient production system at Novomet-Perm modern equipment for oil production, carrying out
ENGINEERING AND TRANSPORT UDC 658.5.5:658.588 A.N. Saveliev, S.S. Severyanov, M.I. Tarasov Siberian State Industrial University
EXPERIENCE IN IMPLEMENTING THE TOYOTA PRODUCTION SYSTEM IN RUSSIAN COMPANIES Yushmanova Among the main concepts on the basis of which a continuous
Energy efficiency of the implementation of the project of the station for the collection, cooling and use of steam condensate in OJSC Kazanorgsintez Brief summary of the project 1. Name of the project: Station for the collection, cooling
Overview of the status and development projects of the ferrous metallurgy of Russia and Kazakhstan 13th edition Moscow November 2018 Demo version The conditions for purchasing the full version of the report can be found on the page
INNOVATIVE TYPE OF DEVELOPMENT OF ECONOMIC SYSTEMS AND INNOVATIVE MANAGEMENT V.A. Sheremetiev In economic theory, two main types of development of economic systems are distinguished: extensive and intensive.
Cost estimate life cycle equipment Economic efficiency in the long term MU ETechnologie White Paper Life Cycle Cost Estimation. How to determine
UDC 338.45:621 A.V.Aleksandrov INCREASING THE EFFICIENCY OF MATERIAL CONSUMPTION AS A STRATEGIC WAY OF THE DEVELOPMENT OF THE MACHINE-BUILDING COMPLEX Mogilev State Technical University Mogilev, Belarus
"Construction of the Blast Furnace Complex 7" EVRAZ Nizhny Tagil Metallurgical Plant JSC April 017 EVRAZ NTMK one of the leaders in Russian metallurgy EVRAZ NTMK JSC The world's largest enterprise
[analysis and risks] A small hit parade of the main mistakes that analysts make when working out investment projects for capital investments is considered. The main mistakes that occur during the development of investment
Option 1. Determine average annual cost and indicators of the movement of fixed production assets for the following data: Funds at the beginning of the year 15,500 thousand rubles. It is planned to introduce OPF in the amount of 5900 thousand rubles,
A. S. Dobretsky (graduate) Siberian-American Faculty of Management of the Baikal international business school Irkutsk State University IMPROVEMENT AND DEVELOPMENT OF QMS USING TOOLS
2 The program is drawn up according to the working curriculum of the secondary vocational education mid-level specialist in the specialty 15.02.01 "Installation and technical operation industrial equipment"
Bearings for railway equipment
Siemens Service new opportunities for your company siemens.com/industry-services Answers for industry. Technology-driven service to increase competitiveness. Minimum Downtime
The goal of the national project is to ensure by 2024: ANO "Federal Competence Center in the Sphere of Labor" (FCC) was established on December 18, 2017 by decision of the Presidium of the Council under the President of the Russian Federation for Strategic
SKF Off-Road Solutions SKF Product Benefits Use SKF Solutions for Your Equipment Comprehensive systems approach Every engineer understands that all components in a machine are interconnected.
UDC 62.3 Automated systems control and metering of electricity at substations of the energy system Demidov E.V. Scientific director- KALENTIONOK E.V., Ph.D., Associate Professor
Learning the basics of lean manufacturing Metrowagonmash 2012 The market determines the price. (why everyone is switching to lean manufacturing) Previously, price minus cost equaled profit:
CHEMICAL INDUSTRY OF RUSSIA 1,182 Chemical enterprises 2/5 chemical production needs modernization 2/3 of equipment and technologies for the chemical industry are supplied from abroad 638 thousand people work
Methods for cleaning water-based cutting fluids Clean cutting fluids are more profitable than you think
July 17, 2017 Magnitogorsk Operating results MMK Group for the 2nd quarter and 6 months of 2017 MMK Group: Key indicators MMK Group steel 3,182 3,066 3.8 6,248 6,208 0.6 Marketable products of the Group
The efficiency of production maintenance management at an enterprise as a factor in the economic sustainability of an enterprise Karapukhin S.I., student of the VF GOU MGIU Barmashova LV, director of the VF GOU MGIU, Ph.D. Effective
2013 LLC "Samara Avtodetal" is one of the business units Industrial Group SSEZ is a recognized leader among the foundry enterprises of the metallurgical industry of the Volga Federal
COMPLEX SOLUTION OF BUSINESS PROBLEMS IN TRADE DEAR COLLEAGUES! Despite the unfavorable macroeconomic situation, the B2B trading industry continues to develop. According to Federal Service state
UDC 325658 MAIN PROPOSALS TO IMPROVE LABOR REGULATION AT MACHINE-BUILDING ENTERPRISES D. I. Dolgov (Ph.
BUINSKY ELEVATOR Improvements in energy efficiency Energy savings 0 8 kWh Reduction of greenhouse gas emissions 86t CO Monetary savings Additional benefits Total investment Medium
Professiogram Machine operator with numerical program management Structure General characteristics ... 2 Types of economic activity ... 2 Occurring names ... 2 Related professions ... 2 Means of labor ... 2
Plan: Topic 2. Essence, structure and dynamics of cost 1. The role of cost in increasing the competitiveness of products, increasing sales and profits 2. Systematization of cost indicators
Large vertical column pumps The most energy efficient pumps on the world market Higher Efficiency - More Savings Large pumps are known to consume a significant amount of electricity. That's why
Modernization Second life for pumping equipment Time for modernization The modernization program has been developing successfully over the past years. New environmental regulations, increased competition in the industry
C.M. Voronin (Academy of Management under the President of the Republic of Belarus) PRODUCT AND PROCESS INNOVATION modern economy
Leaders 2020: Next Generation Leaders Importance of Leadership for SMBs What are the Key Features ideal company era digital economy? She is flexible. Its employees are motivated and
Mitigating Data Center Network Modernization Risk Cisco Data Center Migration Services helps enterprises and carriers improve business agility and end-user experience by reducing
Project Approved by order of the Ministry of Labor and social protection Russian Federation PROFESSIONAL STANDARD SPECIALIST IN TENOLOGIES OF MEAN ASSEMBLY PRODUCTION 2 PROFESSIONAL STANDARD SPECIALIST
OJSC ZELENODOLSKY PLANT IM. A.M. GORKY From production audits to real projects to improve productivity Table of criteria for production audit Parameters to be checked Evaluation criteria
The electrician of the 5th category of the Teploozersky district of the contact network of the Obluchenskaya power supply distance, Alexander Andreyanov, was awarded a personalized watch of the head of the Far Eastern railway. His device for removing broken strings outside the size of the contact wire won the industry review competition "The Idea of Russian Railways" - 2012. Now they are talking about an insulated bar with wire cutters not only in the Far East, but throughout the entire road network.
The contact network consists of many elements - strings. If one of them breaks off and hangs in an oversized area, this impedes the movement of the rolling stock. To eliminate the cliff, earlier it was necessary to take "windows". And they, in turn, waited until 5:00.
“Once we had a conversation with the chief engineer of the EC-1, Ivan Sergeevich Tolstokulakov, that the situation needs to be changed,” Alexander Andreyanov said. – In principle, we invented together with him. I first made one, then improved it so that the device worked flawlessly. It took me about a month to do everything.
This is practically all that we managed to learn from Alexander Vasilyevich himself. As his colleagues said, he does not like to brag and talk a lot.
- Alexander Vasilyevich is a man of action. His hands are golden, - this is how the head of the EChK Vitaly Yakimov described the worker. – This is not his first rationalization proposal and invention. To start working on one, it will take a month to prepare: he will think everything over, consult with chief engineer Ivan Sergeevich. Until Alexander Vasilyevich decides that the device is ready for operation, it is better not to ask him about it and not to hurry.
Information sheets on a device for removing broken strings outside the size of the contact wire were distributed over the network. A request has already been received from the Sverdlovsk road.
Everything ingenious is simple. In appearance, the device resembles powerful scissors that cut through the wire. They are attached to a long bar (it allows you to work under voltage). During operation, it must be held with both hands, - Ivan Tolstokulakov gave a description of the invention. - The cost of its manufacture is only 3 thousand 838 rubles 28 kopecks, including labor costs. And the annual economic effect is 90 thousand 533 rubles.
The technical department of the distance explained that at the time of filing documents for the awarding of Alexander Andreyanov, the annual effect was calculated only for one unit and without taking into account train work(stopping a train, delaying trains, reducing sectional speed, passing a section with a lowered pantograph, etc.). In fact, the economic effect of the application of this development over the entire distance will be much higher.
“This device has already been introduced at six distances and is working without failures,” said Ludmila Sunmina, lead engineer of the ECH-1 technical department. - Before the introduction of this simple device, when using an emergency window for one damage, the total costs sometimes exceeded 100 thousand rubles.
Previously, in order for a train to pass a place with oversized strings, it was necessary to make a stop in order to lower the pantograph. And, of course, it was necessary to warn the driver about this in time.
To remove oversized wires, the team had to go to the "windows". It included at least 4 people, including signalmen. Now "windows" for this type of work are not needed. The device allows to eliminate oversized strings by a team of two people. At the same time, trains can run with raised pantographs.
Today, all divisions of the distance are equipped with such "scissors". They are made in workshops according to the drawings of Alexander Andreyanov.
4.2. rationalization proposals, an integral part of enterprise activities
Rationalization movement in Tatneft exists almost from the very beginning of the company. Even today the management encourages its employees to creative work of thought in every possible way. Not the last role in this is played by the planned approach - every year the departments of departments are given the number of rationalization proposals that need to be introduced into production. And I must say that OGPD Bavlyneft consistently not only fulfills, but also exceeds this plan.
The importance of innovation cannot be overestimated. This gives development to the production process, improves working conditions, increases its safety, is reflected in the rating of the shop and affects the material and moral encouragement of employees. The economic effect of rationalization findings is also important. According to rough estimates, rationalization proposals made it possible to save about 400 thousand rubles. At the same time, not all successful ideas introduced into production can be calculated in monetary terms, since some of them are aimed at improving working conditions.
4.3. Economic efficiency from the introduction of otm, gtm
Every year, oil and gas producing enterprises develop and approve measures for an energy-efficient economy. One of such measures is the introduction of pumps with a shortened suspension (reducing the depth of descents of downhole pumps) at production wells.
I Some of the wells operating with high dynamic levels are in operation at NGDU "Bavlyneft". Reducing the pump suspension depths in these wells leads to a decrease in energy costs for lifting the fluid, and optimal operation of downhole pumping equipment is achieved.
The layout is designed to increase the overhaul period of sucker rod pumping equipment for oil production from oil wells, and contributes to an increase in oil production.
The performance of wells before the introduction of pumps with a short suspension was taken as the basis for comparison.
Table 4.2.
Introduction of pumps with a short suspension
|
The name of indicators |
Basic option |
New option |
Deviation |
|||
|
Scope of implementation | ||||||
|
Suspension drop depth | ||||||
|
Trip time | ||||||
|
Electricity consumption | ||||||
|
Electricity costs |
thousand rubles/year | |||||
|
Specific amount of ORS in wells | ||||||
As a result of the introduction of pumps with a shortened suspension, there were changes in indicators: the depth of suspension descent was reduced by 11%, which amounted to 120 m, and the duration of tripping operations decreased by 5%, which amounted to 1 hour. Electricity costs decreased by 8.4 thousand rubles / year, which amounted to 4683.3 kW / h, that is, by 8.7%. The volume of implementation has remained unchanged, and the technology of testing wells of the existing stock, equipped with pumps with a shortened suspension, is being carried out without the involvement of drilling teams.
Table 4.3.
Calculation of the economic effect of introducing pumps with a short suspension
|
The name of indicators |
Meaning |
||
|
PRS costs | |||
|
Resuscitation costs | |||
|
Savings in operating costs | |||
|
income tax | |||
|
income tax | |||
|
Net profit | |||
|
Duration of work | |||
|
Main and additional wage, with social security contributions |
The results of the calculations show that the savings in operating costs amount to 741.7 thousand rubles and the net profit is 593.4 thousand rubles.
Thus, the economic effect is achieved through:
reducing the cost of energy consumption;
reducing the height of the liquid.
With the help of this method, the enterprise performs the tasks set in the field of resource saving cost savings and the economic effect is achieved.
II Application of a variable heating mode, with a decrease in temperature at night and weekends in the buildings of the enterprise:
automatic regulation of thermal energy consumption is established, which significantly increases the efficiency of its use;
comfortable conditions inside the premises and uniform distribution of heat energy throughout the building are provided;
the temperature of the return network water is maintained according to the schedule;
the modes of heat supply of buildings are selected and adjusted;
any temperature regime is set and maintained, for example, the temperature in the building is lowered in order to save money during off-hours or on weekends;
excessive heating is excluded in the autumn-spring periods;
the hydraulic regime of the heat supply system is improved.
For comparison, we take automatic control of heat energy consumption and the usual mode of heat supply to buildings according to the temperature schedule (table 4.4).
Table 4.4
|
The name of indicators |
Unit measurements |
Option basic normal heating mode |
Option new automatic regulation |
Saving |
|||
|
Thermal energy | |||||||
|
Net profit | |||||||
III Replacement of transformers with more power for less
Oversized transformers are installed at oil production facilities. Replacing them with a lower power will reduce transformer no-load losses and reduce power consumption.
Depending on the load, the power losses of power transformers are about 4% of the rated power. Replacing power transformers 100 kW with 63 kW, and 63 kW with 25 kW will reduce power losses.
25 kW transformers are installed instead of 63 kW transformers, which then replace 100 kW transformers, the released 100 kW transformers are transferred to the reserve fund or installed at newly commissioned facilities, or sold (table 4.5).
Table 4.5
Technical - economic advantages
|
The name of indicators |
Unit measurements |
Basic variant |
Option new |
Saving |
|
Replacement of transformers | ||||
|
100kVA transformer power is released | ||||
|
Transformer cost. 25kVA - 5pcs. | ||||
|
Electricity | ||||
|
Electricity | ||||
|
Replacement costs | ||||
|
Increase in depreciation costs | ||||
|
Reduced operating costs | ||||
|
Net profit |
thousand roubles. |
Table 4.6
Analysis of energy saving measures aimed at saving electricity
|
Name of events |
Energy saving |
Economic |
||
|
The use of a variable heating mode, lowering the temperature at night and on weekends in the building of the enterprise | ||||
|
Replacing transformers with more power for less | ||||
An analysis of these two energy saving measures aimed at saving electricity (table 4.6) shows the progress achieved in terms of money. They total more than 1.7 million rubles. With the help of these measures, the enterprise fulfills the tasks set in the field of energy saving. Thus, an economic effect is achieved.
A team of authors from Tulenergo, a branch of PJSC IDGC of Center and Volga Region, proposed using a set of measuring rods to measure the parameters of the phase-zero circuit on a 0.4 kV power line without lifting to the support and turning off the voltage.
The initiators of the creation and application in practice of such measuring rods were the employees of the Odoevsky district of electrical networks (RES) of the production department "Suvorovskie Electricity of the net"- Dispatcher Andrey Svistunov and site foreman Alexander Telyatnikov, as well as the head of the operation service of the Tulenergo branch Irina Makarova.
According to Andrey Svistunov, an experienced power engineer who has worked in an electric grid company for more than 16 years, the rationalization idea arose from the need to improve the process of measuring the parameters of the phase-zero circuit on a 0.4 kV overhead line. This is a rather lengthy procedure, which is carried out in strict accordance with regulatory requirements, with the power line turned off to connect the instrument's test leads and then turned on for measurements. At the same time, it is necessary to interrupt the power supply to consumers, a lot of time is spent on the preparation of various documentation, preparation of the workplace and subsequent activities.
The rational proposal of the Tula power engineers allows measuring the parameters of the "phase-zero" circuit without interruptions in the power supply to consumers. At the same time, the time spent is reduced by 3.6 times. Most importantly, it increases the safety of work. Now they can be carried out by operational and maintenance personnel in the order of current operation.
Alexander Telyatnikov, who has been working in the Odoevsky Distribution Zone since 2002, says that the measuring rods are prefabricated, up to 8 m long, and have clamps that provide good contact with the wires of the overhead line. The measuring wires of the rods are connected to the clamps, on the other hand, the wires are provided with connectors that are suitable for connecting to a measuring instrument. The length of the wires allows you to connect them to the device while on the ground.
Now this development, along with other rationalization proposals of the teams of authors from the Tulenergo branch of PJSC IDGC of Center and Volga Region, which have already proven their effectiveness in practice, will be widely used in the work of the Tula power grid complex and other regions to fulfill the priority task of ensuring reliable power supply consumers.
What could be rationalization proposals?
What is expressed from the effectiveness?
How to choose a formula for calculating economic efficiency?
It is possible to reduce the cost of production by optimizing the costs of the enterprise. One of the methods to improve work efficiency industrial enterprise— rational use of resources and reduction of waste and losses during the production process. In order to motivate employees to look for options to reduce waste, enterprises develop and implement provisions on rationalization.
The economic efficiency of rationalization activities at the enterprise is expressed in increasing output, improving product quality, reducing losses from manufacturing defects and waste, reducing production cycle, saving material and energy resources, reducing the cost of production, increasing labor productivity and facilitating it. When calculating real savings from the implementation of proposals, only those cost items for the production of products that really change as a result of implementation are taken into account this proposal. All costs associated with the implementation of the proposal are deducted from the savings.
In order to motivate employees to search for such solutions, it is necessary to develop and implement a provision on rationalization at the enterprise.
Rationalization proposal is a proposal of a production and technical nature that directly improves manufacturing process by more efficient use of equipment, materials or labor of workers, but not significantly changing the design or technological processes of production.
It is necessary to distinguish rationalization proposals in the field of organizing production from rationalization proposals in the field of organizing enterprise management, economy, etc.
In the first case, the author of the adopted rationalization proposal receives a remuneration, the amount of which, as a rule, depends on the amount of annual savings received from the application of the proposal; in the second - a bonus in the amount established by the head of the enterprise or institution.
In the second case, it is only necessary to evaluate whether the proposal is rationalization or not. And in the first, economists must calculate the economic effect of the rationalization proposal.
The choice of formula for calculating the economic effect depends on the type of rationalization proposal.
Enterprise economists most often calculate the economic effect of the first type of technical solutions using the formula:
E \u003d (Z 1 - 3 2) × A 2 \u003d [(C 1 - C 2) - E × (K 2 - K 1)] × A 2, (1)
where E is the annual economic effect, rub.;
З 1 , 3 2 - the reduced costs of a unit of production (work) produced before and after the implementation of the rationalization proposal;
C 1 , C 2 - the cost of a unit of production (work) for changing cost items before and after the start of using the invention or rationalization proposal;
E is the coefficient of reduction of capital investments;
K 1, K 2 - specific capital investments V production assets before and after the start of using the rationalization proposal, in rubles;
A 2 - the annual volume of production (work) with the help of rationalization proposals, in natural units.
Consider the procedure for calculating the economic effect on the example of rationalization proposals for reducing industrial waste.
In this direction, there are 2 types of rationalization proposals:
- to reduce recyclable waste and their rational use;
- on the use of non-returnable waste.
We are interested in a rationalization proposal to reduce the cost of production as a result of the reduction of returnable waste and their more rational use. In this case, the economic effect is the difference in the cost of the main product, during the production of which waste was generated, for those cost items that are affected by the rationalization proposal. This takes into account the prices established for the sale of waste.
And since returnable waste is minus, the cost of the main product can be calculated using the formula:
C o \u003d N m × (C m + R t) - O m × C o, (2)
where WITH o - the cost of a unit of main products, rub.;
N m - consumption of the main material, raw materials per unit of production;
Р t - transport and procurement costs for the delivery of a unit of material, raw materials to the enterprise, rub.;
C m - Wholesale price per unit of material, raw materials, rub.;
About m - waste material, raw materials per unit of production;
P o - the price for the sale of a unit of waste, rub.
Substitute formula 2 into formula 1:
E \u003d [(N m1 × (C m1 + R t1) - O m1 × C o1 - N m2 × (C m2 + R t2) + O m2 × C o2) - E × (K 2 - K 1)] × A 2. (3)
If P t1 \u003d R t2, C m1 \u003d C m2, C o1 \u003d C o2, etc., the formula for calculating the economic effect will look like this:
E \u003d [(C m1 + R t1) × (N m1 - N m2) - C o1 × (O m1 - O m2) - E × (K 2 - K 1)] × A 2. (4)
In order to calculate the economic effect of the rationalization proposal on the use of non-returnable waste instead of high-grade materials for the production of products, the cost of manufacturing products from high-grade materials is compared with the cost of manufacturing products from non-returnable waste. In this case, only changing cost items are taken into account.
In this case, formula 4 can be used. Provided that O m1 \u003d O m2, the formula will take the form:
E \u003d [(C m1 + R t1) × (N m1 - N m2) - E × (K 2 - K 1)] × A 2. (5)
Table 1
Calculation of the economic effect of a rationalization proposal that changes production waste
|
No. p / p |
Indicators |
Unit |
Before use |
After use |
|
Output |
||||
|
unit cost |
||||
|
Including |
||||
|
consumption of basic material per unit of production |
||||
|
wholesale price of material for 1 kg |
||||
|
transportation and procurement costs per 1 kg |
||||
|
waste per unit of production |
||||
|
unit price of waste |
||||
|
58 800,00 |
||||
R. V. Kazantsev,
financial director of LLC UK "Teplodar"
