2024 Author: Howard Calhoun | [email protected]. Last modified: 2023-12-17 10:16
In any machine assembly shop, the foreman plays the role of the chief specialist who oversees production. To date, this site can work according to three principles for the production of parts. It can be mass, serial or single production.
Serial production
If the machine assembly shop operates as a mass production site, this means that batches of parts and series of products will be manufactured here, which will be regularly repeated after a certain period of time. A feature of mass production in this workshop is its multi-product range. A characteristic feature of this parameter is the repeated execution of the same operation at the workplace. As for the products that a workshop of this type can produce, this includes studs, cylinder covers and bushings, lever pushers, parts belonging to the connecting rod group.
All the parts that a serial machine shop produces can be used to assemble devices such as internal combustion engines, machine tools formetal cutting, compressors, pumps. It is worth paying attention to such a technological feature of this section as the nomenclature, the size of the manufactured parts, the laboriousness of manufacturing each part. Depending on all these parameters, mass production in the machine assembly shop is divided into small-scale, medium-scale, large-scale production.
Other types of workshop productions
If we talk, for example, about small-scale production, then in terms of its technological parameters it very much resembles a single production. As for the equipment, universal types are used, as well as a normal working universal measuring tool. By resorting to this type of product manufacturing, the machine shop can produce suspensions, crankshafts, cylinder blocks, oil pumps and fuel pumps.
As for single production, it is multi-product, like serial production. Using this method of organizing a section of a mechanical assembly shop, it is possible to manufacture parts and assemblies for marine diesel engines. A distinctive feature of this type of production is a large range of products with a small volume of production. In workshops of this type, both universal and special equipment is used. If we talk about the necessary qualifications of workers, then it must be at least average in order to work in such conditions.
The last type is the mass production of any products. Everything is quite simple here. A characteristic feature of such a scheme of work is the releasethe same type of product according to the same drawings, for a long period of time. As for the performance of any operations at the workplace, then one or two procedures are performed on each of them. As equipment, special and specialized machines are used. The main preference is given to high-speed machines.
Workshop staff
As for the structure or composition, the composition includes 21 sections. The mechanical assembly shop also consists of such additional shops as assembly and testing and blanking and pressing. Specialization based on the unification of the creation of specialized workshops was adopted as the basis for organizing the workflow.
The technological process in the mechanical assembly shop includes 114 production lines and mechanized sections. It also uses seven fully automatic lines. Among them, there are automatic cylinder head processing lines, for example.
Machine shop equipment includes a minimum of 2469 metal cutting equipment. Up to 650 foreign-made machines can also be used to process manufactured base parts.
Workshop organization principle
Today, two principles for organizing this type of workshop are used.
The first option is independent mechanical and assembly shops. The second variant of the organization is the united mechanical assembly sections. In addition, the organization isfeatures such as nodal, technical, mixed.
If we talk about the first sign, then its essence lies in the fact that each section of the workshop is assigned a certain number of parts that belong to the same type or are used to create one node. In this case, the organization applies subject specialization. Depending on the design of the product, as well as on the specialization of processing in the workshop, a nodal assembly is also provided. It is important to note here that if one plant has more than one mechanical assembly shop, then it is mandatory to introduce a general assembly section into the structure. This principle of organizing production is possible only if the amount of work is able to fully load the existing equipment.
The second option is the arrangement of the site on a technological basis. All produced parts are combined into groups. One group combines those products and components that are similar in size, and also have a similar manufacturing process. Applying this method of organization is relevant only if the plant is engaged in small-scale or single-piece production of parts and assemblies. In other words, in the event that it is not possible to fully load the existing equipment.
The last option is a mixed type. Everything is quite simple here. This means that some of the workshops work on a nodal basis, while the other part, for example, forging and foundry, work on a technological basis. The majority of all industrial enterprises in all sectors operate precisely in this way.principle.
Signs of varieties of workshops
Today, there are four features that are the main ones for determining whether a workshop belongs to one of the types.
- The first and main one is, of course, serial production.
- The method of manufacturing parts and assemblies also plays an important role.
- The number of machines installed and in operation is also important.
- Indirect, but still very important feature is the maximum mass of machined parts.
If we talk about serial production, then it is determined by the coefficient Kc. The serialization coefficient is a numerical characteristic of the number of operations that are performed at the same workplace. Thus, small-scale production is characterized by a Kc value of 20-40. Serial and medium series plots have a coefficient of 5-20. Large-scale ones have a coefficient of only 3-5. The most large-scale production, that is, mass production, differs in Ks by 1-3.
Product production methods
When planning a machine shop, it is important to consider how the product is made. Currently, two methods are used - this is in-line and non-in-line production.
The flow method is a form of production organization, which implies that all operations will be performed within a strictly established and agreed time between all workshops. In addition, all procedures must be repeated after a certaintime interval with an exact time interval between them. As for the workplaces in this case, they all belong to a specialized type, and they are located in such a way as to correspond to the course of the technological process. The use of this form of organization of production contributes to the fact that all the principles that bring the efficiency of the workshop to the maximum level are embodied. Naturally, the in-line form of organization has become most widespread in large-scale and mass production. In small-scale or single production form is also used, but very rarely.
It is worth paying attention to the fact that such a structure of the machine assembly shop will help to simplify the work with the material flow and its management as much as possible. This is facilitated by the fact that there is a high elaboration of the issue in terms of the orderliness of the movement of objects of labor in space and time. It is also important to add that this layout of the machine assembly shop is confidently moving towards full automation of the process. Automatic lines are introduced, machine tools with numerical software, lines that contain equipment with program control, frequent use of microprocessor technology.
Non-threaded organization
If we talk about the use of this type of organization of production, then most often it is observed in single, small-scale and medium-scale production of parts and assemblies. It differs in that the movement of objects of labor in space is disordered, but you canpredict their movement in time. This is also the greatest difficulty in organizing a non-flow form of production, if compared with a flow one. It is necessary to put in order the chaotic movement of objects of labor in space. It is necessary to bring all production flows into a single technological route, where the same type of units and parts will be manufactured.
The scheme of technological processes plays an important role. It is a document that indicates the sequence of passage of one part through all the shops, and inside the shops - through all technological operations. In addition, it is necessary to indicate on the diagram all the data on equipment, equipment and material standards.
Classification of workshops by machine type
Mechanical assembly shop of a machine-building plant, for example, like any other, can be of small, medium or large type. This classification depends on the type of machines it uses.
Small or light workshop is characterized by equipment weight up to 0.2 tons. On average, the weight of the machines increases to two tons. Heavy types of workshops are divided into three groups, as well as especially heavy ones. The first group is distinguished by the weight of machines up to 30 tons. The second group - 75 tons, the third group - 250 tons. An especially heavy type of workshop contains equipment weighing up to 500 tons.
In this case, the maximum mass of the part to be processed plays an important role. If we are talking about light engineering, for example, then the large weight of the part limits the uselifting vehicles.
When designing a mechanical assembly shop for medium mechanical engineering, it is necessary to use devices such as overhead cranes, pneumatic hoists, conveyors. When setting up a workshop for heavy engineering, it is necessary to have overhead cranes with a lifting capacity of 30 to 250 tons.
Shop sections
Any mechanical assembly department should include such sections as production, auxiliary. In addition, it is also necessary to have amenity and service premises. The power supply of the mechanical assembly shop is carried out using devices installed just in the service premises.
As for the production sites, they are intended to accommodate the main equipment for the manufacture of parts and assemblies. All sections combine jobs. In this case, jobs are understood as the primary building unit of the plant, on which the technological operation is performed. PM, which are interconnected by a vehicle, for example, a conveyor, can be combined into one section. Such small areas are organized according to two features: a subject feature for mass or large-scale production and a technological feature for small, single and medium-scale production of parts and assemblies.
The workshop also has auxiliary sections. The main purpose of their existence is to ensure the efficiency of production sites.
Functions of shop floor
In order for this department of the enterprise to be able to normally performits main function is the production of parts and assemblies, it is necessary that the services attached to this site work in normal mode.
This workshop has a technical bureau, a planning and distribution bureau, an accounting department, a mechanic service, etc. The functions of the technical bureau are as follows.
Firstly, they are engaged in the calculation of the load of equipment for the month, quarter and annual plan. Secondly, the same bureau is engaged in the introduction into production of technological processes that are developed by the CDP and OGM. One of the important tasks of this bureau is to control the observance of technological discipline in the workshop. He organizes all the necessary documentation for the operation of the workshop, as well as its further maintenance. Engaged in the organization of work on the basis of available technical information. It performs a rather important function, which consists in the introduction of organizational and technical measures, as well as plans for new mechanization.
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