Today, the average age of equipment at Russian machine-building enterprises is more than 20 years, the share of equipment older than 20 years exceeds 40% (Rosstat data for 2008).

It is obvious that there is an urgent need for the modernization of fixed assets, the implementation of which is hampered by the existing problems of the industry: the steady aging and deterioration of the quality of engineering and production personnel, an outdated educational base, an insufficient level of innovative development of Russian mechanical engineering and others.

The result of numerous examples of implemented technical re-equipment programs is new, but inefficiently operating equipment that does not significantly increase profits.

Thus, what is needed is not just modernization, but effective modernization, which increases the profitability of machine-building enterprises and increases the level of innovativeness of products and their consumer properties.

POSSIBLE EFFECTS WHEN MODERNIZING RUSSIAN MACHINERY ENTERPRISES

Speaking about the modernization of machine-building enterprises, it is interesting, first of all, to find out what might change during its implementation? What opportunities do Russian machine-building enterprises now have in this regard?

To answer this question, it is necessary to take into account that effective modernization implies not just the replacement of technological equipment, but also a change in the principles and approaches in the organization and management of production.

Thus, the potential effects of modernization can be divided into two components:

Effects of replacing technological equipment,

Effects of changing principles and approaches in the organization and management of production.

Effects of replacing process equipment

The replacement of technological equipment at machine-building enterprises is primarily carried out with the aim of reducing the production time of parts, saving costs on raw materials and electricity, freeing up personnel and production space.

The results of the projects and analytical work carried out allow the authors of the article to assert that the potential effects for machine-building enterprises with an outdated fleet of equipment (more than 20 years old) have the following values ​​(see figure).

Effects of changing principles and approaches in organizing and managing production

Replacing equipment with a more productive one in itself will not give tangible effects, since the production time of individual parts is a small part of the production cycle. To achieve tangible effects, modernization must be accompanied by the introduction of modern principles and approaches in the organization and management of production. It is necessary to use methods of fast-response production, theory of constraints, synchronized production, Toyota Production System methodology and others.

The effects of using these methods depend on the specifics of the enterprise and the state of its production system. It is difficult to express them quantitatively and bring them to an average. We can only say that in most cases they exceed the effects of simply replacing equipment, since they affect the enterprise as a whole.

According to the authors and other Russian and foreign experts, any modernization of machine-building enterprises must combine the effective replacement of old equipment with the introduction of modern principles and approaches in the organization and management of production.

WHAT IS INTERFERING?

The planned significant effects from modernization of production in practice are often more modest in nature (the authors even know of cases when the results of modernization were worse than when working on old equipment).

What are the main difficulties that Russian machine-building enterprises experience when carrying out modernization?

One of the main ones, according to the authors, is the provision of qualified personnel when implementing modernization projects. The reason for the lack of effectiveness of many projects is a lack of resources: the enterprise personnel are not strong enough to effectively update the equipment fleet. As a result, modernization is carried out over an extended period of time, which reduces the effect of its implementation.

Also, sometimes our own specialists may not keep up with new technological solutions, modern principles and approaches in organizing and managing production. In this regard, there is a risk of choosing outdated and less efficient technological equipment, as well as methods for organizing modernized production.

Another of the main difficulties of modernization is the ineffective budgeting system of some machine-building enterprises. This mainly applies to large state holdings. Quite often nowadays, the task of subsidiaries and organizational units to spend the money allocated to them before the end of the budget period is mandatory. This dominance of calendar deadlines over real needs significantly reduces the efficiency of expenses. Technical specifications for the purchase of technological equipment are not worked out in detail and are focused on budget development; purchases of equipment and tools are carried out “for future use” (“What if there is no money later?”). Ultimately, this leads to budget overruns due to purchases that do not reflect real needs.

WHAT TO DO?

To carry out effective modernization, enterprises need to pay special attention to training human resources to implement modernization projects. These should be highly professional specialists who “keep their finger on the pulse” of new technological solutions, modern principles and approaches in organizing and managing production. If it is inappropriate to maintain such a staff - with a small number of modernization projects - or provided that your own human resources are sometimes insufficient, it would be advisable to attract independent professional companies that can assist in the implementation of equipment fleet renewal projects.

Involving such companies for express analysis of technical re-equipment programs (as a technological auditor) will also have a positive effect, as it will allow you to obtain an independent opinion on the effectiveness of the solutions being developed. This will minimize the risks of choosing the wrong equipment.

Here it would be appropriate to draw an analogy with conducting regular accounting audits of organizations, the purpose of which is to provide objective financial information to management. Auditors check the accuracy of accounting and identify tax risks. It is not clear why, in most cases, machine-building enterprises do not spend funds on carrying out Making the wrong decision when forming the composition of production assets can lead to significantly greater monetary losses than tax payments!

As for the problems of the budgeting system, it seems appropriate to apply the principles of budget formation focused on achieving the final result, as well as increasing the horizons of budget planning.

At the industry level, it is important to create a specialized association that unites companies that conduct independent technological audits and implement modernization projects. At the same time, it is important to pay attention to the interaction of such an association with government bodies to provide assistance in the implementation of government programs aimed at the development of Russian mechanical engineering.

One of the proposed joint programs of the association and the state in terms of industry development may be a program for the creation and implementation of industry standards developed taking into account the best world experience and practices, including requirements for the production system of both state and commercial engineering enterprises. Another very popular program could be the creation of a center specializing in training personnel who carry out modernization and conduct technological audits (the authors know examples of similar industry programs abroad that were implemented due to the urgent need to reduce the cost of production of industrial enterprises and stimulate industry development).

In custody We would like to draw the attention of the management of Russian machine-building enterprises to the fact that sometimes modernization may not bring the desired effect due to the previously stated reasons.

In some cases, it will be advisable to involve independent professional companies in modernization projects and conduct technological audits of developed technical re-equipment programs. Sometimes it is difficult to notice a speck in your eye, and it is better to attract a person (and in some cases, a doctor) who can look from the outside, give his opinion and help.

Machine tool industry

The market for machine tool products in Russia last year amounted to 98.2 billion rubles.
According to the Federal State Statistics Service, industry enterprises in 2015 were able to maintain positive dynamics and increase the share of domestic products in the domestic market (from 13% before 22% ) .
In physical terms, the growth in production of metalworking equipment amounted to 5,3 % (With 5 756 before 6 059 PC.). At the same time, due to structural changes in product output towards increasing the production of more knowledge-intensive, high-tech equipment, the production of machine tools with numerical control has increased. The growth was about 60% (With 347 before 542 PC.).
According to the enterprises of the “Machine Tools” association, the output of machine tools amounted to 1873 PC. or 172,8% to the level of 2014.
Some enterprises of the Association showed more than 2-fold growth compared to 2014 (ZAO Stankotekh, Kolomna - 273% , LLC NPO "Stankostroenie" Sterlitamak - 243% ).
In 2015, state support was provided to the following machine tool enterprises:

• OJSC "Tyazhmekhpress" - RUB 3,496,120.26; JSC "ZAREM" - RUB 3,863,609.80; PJSC "Siblitmash" - RUB 2,563,758.92; STAN Group LLC - RUB 17,148,241.33;
• The Industrial Development Fund supported 4 projects in the machine tool industry with a total volume of RUB 1.4 billion(JSC Interskol-Alabuga, LLC Virial, OJSC Tyazhpressmash, LLC NPO Stankostroenie).

Heavy engineering

At the end of 2015, the volume of the heavy engineering market was RUB 235.5 billion or 114% by 2014. Domestic production in the industry increased by 29% and reached 115.5 billion rubles.
In physical terms, the volume of output for the main types of products in 2015 was:

• steelmaking equipment and foundry machines - 27.2 thousand tons. (158,4% by 2014);
• rental equipment - 456 t. (85,1% by 2014);
• continuous lifts and conveyors for underground work - 315 pcs. (68,9% by 2014);
• electric overhead cranes - 1690 pcs. (71,3% by 2014).

Power engineering and cable industry

According to preliminary estimates, the volume of the power engineering market in 2015 was RUB 117.2 billion, which is lower than the level of 2014 by 4,95% , the volume of the electrical industry market in 2015 compared to the previous year decreased by 7,43% and compiled RUB 137 billion, and the cable industry increased by 1% – RUB 236.3 billion At the same time, according to the Federal State Statistics Service, the volume of domestic production in 2015 compared to the previous year in the power engineering industry increased by 5,2% , cable industry - on 14,9% . At the same time, the volume of exports in the power engineering industry increased by 62,5% , in the electrical industry - on 5,56% .

• As part of the Eastern Economic Forum, the state corporation “Bank for Development and Foreign Economic Affairs (Vnesheconombank)” and OJSC “Power Machines” entered into an agreement on the joint implementation of export projects and programs in the countries of the Asia-Pacific region (APR). The document is aimed at strengthening the competitiveness of the Russian economy, increasing its diversification, and ensuring access of Russian companies and the goods and services they produce to the world market.
• OJSC Power Machines entered into agreements with the Directorate for the Unified Order of Equipment for Nuclear Power Plants (JSC DEZ, part of the Rosatom State Corporation) for the supply of complete equipment for turbine units at 122 billion rubles., the manufacturer will design, manufacture and supply six sets of turbine room equipment for three nuclear power plants - Bushehr (Iran), Kudankulam (India), Kursk NPP - 2 (Russia). The equipment for Kursk NPP-2 will include low-speed steam turbines (the plant’s own development); high-speed steam turbines will be installed at the other two stations. The development of a low-speed turbine unit will allow Power Machines to enter the market of low-speed high-power turbines.
• OJSC Power Machines manufactured and completed shipment of a hydrogenerator with a capacity of 80 MW, manufactured for the Nizhne-Bureyskaya hydroelectric power station under construction.
• At JSC "Optical Fiber Systems" (Saransk), with the participation of Deputy Chairman of the Government of the Russian Federation A. Dvorkovich, the launch of the 1st stage of the plant for the production of optical fiber took place ( 2.4 million km. per year) for the production of fiber optic cable. The creation of such an industrial production, practically the first in Russia, will make it possible to reduce the dependence of cable factories on imported optical fiber and expand the range of modern types of fiber-optic cables.
• In the field of renewable energy sources, over 45 MW installed capacity of generating facilities with a high level of localization – 70% : Sakmara solar photovoltaic station. A.A. Vlazneva - 25 MW; Buribayevskaya solar power plant - 10 MW; Bugulchanskaya solar power plant - 5 MW; Kosh-Agach solar power plant-2 - 5 MW; Novokarachaevskaya Small Hydroelectric Power Station – 1.2 MW.
• For the first time, high-speed controlled reactors of domestic production (manufactured by Aidis LLC) were put into commercial operation at a voltage substation 220 kV"Svetlaya" of intersystem electrical systems (IES) of Siberia.
• In 2015, CJSC ZETO (Velikiye Luki) began implementing a large-scale project for the development and production of SF6 equipment. It is planned to develop industrial production of the following SF6 equipment: GIS - 110 kV; tank switches 110 kV; column switches 220 kV; current transformers 220 , 330 And 500 kV; voltage transformers 220 kV.

Oil and gas engineering

• According to preliminary estimates, the volume of the oil and gas equipment market in 2015 was 476 billion rubles., which is higher than the level of 2014 by 5,7% .
• According to data from the Federal State Statistics Service, the volume of domestic production increased by 10,7% , the volume of exports of oil and gas equipment increased by 17,65% .
• In 2015, three meetings of the Interdepartmental Working Group on reducing the dependence of the Russian fuel and energy complex on equipment imports, as well as on the development of oil and gas engineering in the Russian Federation (March 24, July 3 and November 23) were held. On June 19, 2015, at the St. Petersburg International Economic Forum, the Minister of Industry and Trade of Russia D.V. Manturov and Chairman of the Management Board of OJSC Gazprom A.B. Miller signed the Program for Import Substitution of Industrial Products used for the needs of PJSC Gazprom, its subsidiaries and dependent companies. This program was developed in order to concentrate the company’s investment resources on the development of strategic industries, minimize the impact of unfavorable foreign economic and foreign policy conditions on the domestic mechanical engineering industry, as well as synchronize the investment program of PJSC Gazprom with the capabilities of Russian manufacturers.
• On October 26, 2015, a memorandum of understanding was signed between the Ministry of Industry and Trade of the Russian Federation and PJSC Gazprom for implementation on the basis of OJSC Tomsk Electromechanical Plant named after. V.V. Vakhrushev" investment project using the mechanism of a special investment contract to organize serial production of domestic anti-surge and control valves and electric drives for them. Also on November 23, 2015, at a meeting of the Interdepartmental Working Group in Ufa, Bashkortostan, a memorandum of intent was signed to conclude a special investment contract between Gazprom Neft PJSC, the GMS group, the Oryol region and the Russian Ministry of Industry and Trade for the localization of the production of import-substituting pumps for oil refining (including Apollo pumps according to API standards), as well as high-power pumps for the transport of oil/petroleum products.
• In 2015, the Russian Ministry of Industry and Trade prepared proposals for adjusting the state program “Development of shipbuilding and equipment for the development of offshore fields for 2016-2030”, within the framework of which in 2016-2017 it is planned to support R&D in 6 offshore areas related to seismic exploration and underwater wellhead equipment, in the amount 1.35 billion rubles.
• On June 25, a new multi-product research and production complex was launched on the territory of PJSC Cryogenmash. As part of the modernization program, the latest equipment has been installed and mastered: roll forming, welding, forging, rolling, shot blasting, metal cutting, painting, robotic complexes, an automated line for preparing parts for welding, etc.

• As part of Resolution No. 1312 to subsidize the costs of R&D in priority areas of civil industry as part of the implementation of complex investment projects, the Ministry of Industry and Trade of Russia in 2015 supported investment projects in 8 technological areas for a total amount RUB 285 million, including PJSC Cryogenmash (“LNG production plants”), LLC Tekon Membrane Technologies (“membrane plants”), LLC NPF Plant “Izmeron” (“well equipment”), LLC Bezhetsk Experimental Plant " and LLC "Kamyshin Drilling Tools Plant" in the direction of "Drilling Equipment".
• As part of Resolution No. 3 on providing subsidies from the federal budget to Russian organizations to compensate for part of the costs of paying interest on loans received from Russian credit institutions in 2014–2016, the project of Cryogenmash OJSC (OMZ PJSC) was supported for the implementation of new comprehensive investment projects. , who received a subsidy in the amount 42.282 million rubles.
• As part of Government Decree No. 214, in 2015, 8 oil and gas engineering enterprises received RUB 312.8 million to compensate for the costs of paying interest on loans to replenish working capital (Novomet-Perm JSC, Kazankompressormash OJSC, Volgogradneftemash OJSC, Blagoveshchensk Valve Plant PJSC, Pervomaiskhimmash OJSC, Dmitrovogradkhimmash OJSC, Izhora OJSC factories", LLC "Corporation Uraltekhnostroy").
• In 2015, the Industrial Development Fund reviewed applications for 31 projects from 29 enterprises and approved 6 projects, highlighting RUB 1.8 billion(FPC Cosmos-Neft-Gas LLC, Giprogazoochistka JSC (GGO), Tyazhpressmash JSC, HMS Livgidromash JSC, Concern Central Research Institute Elektropribor JSC, NPO Regulator JSC) for their implementation.
  The Ministry of Industry and Trade of Russia received information from oil and gas engineering enterprises about their intentions to submit applications in 2016 from the companies LLC NPP BURINTEKH, Ruselprom, NPF Baltic Manufactura, LLC ZERS, OJSC Volgogradneftemash, OJSC Kazankom-pressormash, Uralmash NGO Holding LLC.

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Technical re-equipment of an enterprise is one of the urgent tasks that companies in the mechanical engineering sector face today. And the main thing here is to find a professional, experienced contractor who can give not only a comprehensive assessment of the state of production, but also offer modern solutions that increase its efficiency. One of the latest such projects was implemented by Pumori-engineering invest, a company specializing in comprehensive technical re-equipment. The customer is a machine-building enterprise where it is necessary to modernize one of the machine shops to ensure efficient production of a given range of products.

BASED ON TECHNICAL AUDIT

The work began with a technological audit of existing production. Specialists from the technical service of Pumori-Engineering Invest conducted an examination, paying attention to the technologies and equipment used at the enterprise, the production planning and management system, product quality control, etc.

At the same time, design and technological documentation for manufactured parts and assembly units (ADU) were studied. The customer presented drawings of about one and a half thousand DSE of various types and categories of complexity. For their production, the company uses modern and already outdated equipment of the following types: turning, milling, turning-milling, cylindrical grinding, surface grinding and electrical discharge. Based on the results of the technical audit, a concept for modernizing production, primarily in the technological field, was formed.

Illustration of the technological layout of the modernized workshop

(other production is located in the vacant areas)

NON-STANDARD APPROACH

The second stage of technical re-equipment is the development of promising technologies for processing parts, selection of modern high-performance equipment, calculation of its quantity, development of technological layout of the workshop and calculation of economic indicators of the project.

When working with a large number of DFUs, the standard approach is considered to be one in which individual DFUs are combined into groups according to design and technological characteristics. In each group, a representative part is highlighted. For its production, a transitional technological process with the necessary equipment is developed and labor intensity is regulated. For the remaining parts of the group, so-called reduction coefficients are assigned - their use makes it possible to give a fairly accurate assessment of the labor intensity of manufacturing each part.

However, the complexity of this project was that due to the diversity in the design of parts, materials used, accuracy and other parameters, using a standard approach would have to form a huge number of groups with a relatively small number of parts in each. As a result, the time spent on developing the entire range of DSU would be significant, while the project duration is limited by the customer. Therefore, Pumori-engineering invest specialists have developed an improved methodology. It made it possible to combine parts into groups only by type of processing, and assign reduction coefficients based on the following parameters:

• volume of machining;
• type of workpiece;
• precision and roughness;
• presence of heat treatment, etc.;

This approach significantly reduced the number of teams, which speeded up the project without compromising its quality.

Illustration of the technological layout of the modernized workshop

WORK FOR RESULTS

Based on the developed technological processes and the calculated labor intensity, a list was generated, the required quantity was determined, taking into account the restrictions specified by the customer: annual working time, maximum load factor, interchangeability of machines. Technical requirements have been developed for the equipment, according to which specific machine models are recommended. The technological layout of the workshop was developed taking into account the results of analysis and optimization of material flows.

Today, the customer of the project for technological modernization of production, together with Pumori-engineering invest, is implementing the proposed solutions. It is planned that by the end of 2018 the project will be fully completed. Without waiting for the final stage, we can confidently state: the solutions proposed by the contracting company are already increasing production efficiency.

Simulation of a workshop in a virtual environment

Nikita Gaisin, Head of Engineering Projects Department

Review of the current state of the bearing sub-industry of the Russian Federation. Products of the bearing sub-industry have their special significance and role in the country’s economy. Modernization of production and development of the bearing sub-industry. The complete elimination of finishing operations from the technological process, as well as a significant reduction in the volume of manual and adjustment operations, makes it possible to reduce the labor intensity of bearing manufacturing and, as a result, reduce personnel.

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