What should we build a factory?

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This is a reality-the application of this method allows you to simulate all the processes of light industry enterprises, taking into account their characteristics.

His answer offered LLC "IIT Consulting" (Ivanovo). claiming that the construction of a simulation model of the factory will not take much more than a week. For example, one of my projects - the project of creating a so-called lean production, in which the specialists of "ITI Consulting" services of technological audit in the garment factories.

The main task of the engineer-technologist of sewing production is the restructuring of existing technological processes for new models and their optimization. In terms of frequent turnover of models, the range of tasks includes, in particular, assessment of the overall structure of the process and/or individual components, identification of priority directions of material flows, problem areas, analysis of the volume of products, equipment Park, depending on the range and planning solutions, the distribution of work between the performers. The structure of the production process of manufacturing a garment is a multi-threaded line, which is repeated execution of the same type of operations, but with changing values of input and output data. They depend on the number of simultaneously manufactured products, taking into account the size and growth gradation, the sequence of processing of cut parts (semi-finished products, finished products), as well as production conditions (type of equipment, processing methods, methods of forming parts, properties of material packages, etc.). In addition, the consistency of the structure of the production process depends on the schedule of individual sections (preparation and cutting of materials, workpiece parts, installation, wet-heat treatment, packaging) with different degrees of automation of processes and equipment loading.

In terms of frequent turnover of models, the range of tasks includes, in particular, assessment of the overall structure of the process and/or individual components, identification of priority directions of material flows, problem areas, analysis of the volume of products, equipment Park, depending on the range and planning solutions, the distribution of work between the performers. (poderzhka)

The main goal is to develop software to support engineering and management solutions that provide raw material savings of up to 5%, reduce the time of launching new products into production by at least 2 times, increase the intensity of labor, the efficiency of individual operations within 5...20%.



The main task to be solved in the framework of providing services for technological audit of enterprises is the development of methods and tools for computer-aided design of products and processes, monitoring of technological operations, optimization of conditions and methods of their implementation, ensuring improvement of quality and competitiveness of products of domestic light industry enterprises.

The developed software module uses the method of simulation modeling, which gives a number of advantages over performing experiments on a real system in real life: cost, time, repeatability, accuracy, visibility and versatility. The application of this method allows you to simulate all the processes of light industry enterprises, taking into account their characteristics (complexity of the process, taking into account transitions, existing equipment, manufactured range, changeability of models, moving the cut, p/f on the shop, etc.), to evaluate their effectiveness with the help of specially created software and mathematical models and choose the best option for further implementation. The created models will demonstrate production in real time and demonstrate how production will respond to various changes. Also, the use of simulation will allow to evaluate the work of production remotely, without interfering with the cyclicity of the process.

Module "Design of new and optimization of existing production". In contrast to traditional iterative and empirical methods for solving this group of problems, it is proposed not to use the expert knowledge of technologists, but to apply the developed methodology for providing such services using simulation tools, thus increasing the objectivity, speed, accuracy and degree of automation. In this case, there is a need to simulate the process of tailoring the product to obtain such characteristics as: loading of equipment and personnel, the average output for a certain period of time, the load of warehouses, the unit cost of moving semi-finished products, etc.

When using this module, 2d and 3d models of interactive production are designed (layout of the shop, production equipment, staff of workers, production process), indicating the scheme of movement of raw materials, semi-finished products, finished products and automatic formation of analytical graphs of the equipment and workers loading efficiency during the entire working time, conclusions about the presence of "bottlenecks" (overloaded and underloaded workplaces), downtime of equipment and workers, the calculated release of the product, the estimated processing time of each node and the product as a whole.

The interactivity of the model consists in the possibility of multiple modifications in order to determine the optimal variant of placement of jobs, transfer of semi-finished products, equipment loading, etc.The functional features of the module allow you to save the built logistics relationships, which allows you to quickly see and evaluate the results of changes.

Final results of the program:

- visualization of the process by solution options in the form of 2d and / or 3d models,

- comparative characteristics of indicators for solutions and graphics performance comparison,

- analysis, recommendations on solutions.

A distinctive feature is the use of simulation modeling, excluding the opinion of technical specialists of the analyzed enterprise. Thus, the company initially receives a third-party, not subjective opinion from stakeholders about the organization of the production process.

Three-dimensional model of the designed process can be used to discuss the project before the start of production, presentation of the workshop, etc.the use of visual objects from the database in the construction of 2D as close as possible to the reality of the model. The adapted functionality of the software module allows the specialist to carry out production planning in the shortest possible time, reducing business risks.

The benefit to the production:

- improving production performance with minimum investment of time and resources,

- reducing the cost of finished products by reducing production costs,
- risk reduction due to the possibility to evaluate the result without experiments on the existing production,
- recommendations for the acquisition of equipment that best suits the purpose, taking into account the peculiarities of production and existing equipment,

- obtaining reliable information to justify the need for investment for owners,
- reduction of dependence on the private opinion of technical specialists of the enterprise

Director of IIT Consulting LLC, Anna Gorelova

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