ORGANIZATION

INCREASING MAINTENANCE V.

AND

THE

ECONOMICS

EFFICIENCY

OF

PRODUCTION

OF

THE

INDUSTRY I. S h i r o n i n

UDC 658.588.9:331o015.13

In i n c r e a s i n g the efficiency of the national economy, bringing out the r e s o u r c e s of the machinebuilding industry is of g r e a t i m p o r t a n c e . The m o s t i m p o r t a n t of t h e s e r e s o u r c e s is an i m p r o v e m e n t in the a u x i l i a r y s e r v i c e s of an e n t e r p r i s e , including maintenance s e r v i c e s . The use of existing r e s o u r c e s in the maintenance industry and the organization of a u x i l i a r y work p e r m i t a c o n s i d e r a b l e i n c r e a s e in the r e s o u r c e s of the industry without the n e c e s s i t y for capital expenditures. The p a r t i c i p a t i o n of maintenance s e r v i c e s in i n c r e a s i n g the efficiency of production must be effected b y reducing l o s s e s in the m a i n industry, due to the maintenance of equipment and expenditures for c a r r y ing out maintenance work, i . e . , the b a s i c p r o b l e m consists in the complete and high-quality a s s u r a n c e of the s e r v i c i n g of the e n t e r p r i s e s in different kinds of maintenance w o r k and s e r v i c e s , with the lowest p o s sible e x p e n d i t u r e s . An a n a l y s i s of the laws and t r e n d s of the development of the m a i n and maintenance i n d u s t r i e s in machine building, as well as an evaluation of the existing f o r m s of maintenance work, has p e r m i t t e d the Ministry of C h e m i c a l and P e t r o l e u m Machine Building to w o r k out a p r o g r a m for the technical and e c o nomic development of the maintenance industry, a i m e d at i n c r e a s i n g the technical level of maintenance w o r k in the e n t e r p r i s e s of the b r a n c h . A significant place in. this p r o g r a m is occupied by questions of the i n d u s t r i a l i z a t i o n of m a i n t e n a n c e , c a r r i e d out d i r e c t l y in the maintenance facilities of the e n t e r p r i s e s , using the equipment, of the b e s t use of the c a p a c i t i e s of maintenance and m e c h a n i c a l units, al~t in i m p r o v e m e n t of the s y s t e m for the control of m a i n t e n a n c e s e r v i c e s . Among the m e a s u r e s i m p l e m e n t e d by the Ministry of C h e m i c a l and P e t r o l e u m Machine Buitding~ the m o s t i m p o r t a n t is the i n t r a b r a n c h s p e c i a l i z a t i o n of the f a b r i c a t i o n of s c a r c e s p a r e p a r t s and maintenance equipment by s p e c i a l i z a t i o n of a n u m b e r of the maintenance and m e c h a n i c a l units of the e n t e r p r i s e s , and an i m p r o v e m e n t in the u s e of the existing equipment in t h e m . At the p r e s e n t t i m e , the c e n t r a l i z e d supply of the e n t e r p r i s e s of the b r a n c h with s p a r e p a r t s for m e t a l - c u t t i n g equipment is being done only on a limited s c a l e . The f a b r i c a t i o n in each plant of individual, or of s m a l l batches of lacking s p a r e p a r t s for its own needs leads to a n i n c r e a s e in the l a b o r consumption and the cost of t h e i r fabrication. It is well known, for e x a m p l e , that the labor consumption for the f a b r i c a t i o n of s p a r e p a r t s in machine-building plants is 7-11 t i m e s l e s s than in the maintenance and m e c h a n i c a l units of the e n t e r p r i s e s . At the s a m e t i m e , it m u s t be noted that many of the e n t e r p r i s e s of the b r a n c h have r a t h e r well equipped maintenance and m e c h a n i c a l units, whose c a p a c i t i e s c a n be used for the organization of the s p e c i a ! i z e d (within the limits of the branch) f a b r i c a t i o n of the lacking s p a r e p a r t s and maintenance equipment. The b a s i s for the choice of n o m e n c l a t u r e and the n u m b e r of s p a r e p a r t s which lend t h e m s e l v e s to c e n t r a l i z e d product, in working out the p r o g r a m the following c r i t e r i a w e r e used: the a o m e n c ! a t u r e of the p a r t s for c e r ~ r a l i z e d f a b r i c a t i o n must be lacking, i . e . , they a r e not made, or a r e m a d e in insufficient quant i t i e s by the e n t e r p r i s e s of the Ministry of Machine Building and the I n s t r u m e n t Industry; the r e q u i r e d s p a r e p a r t s must be f a b r i c a t e d in batches whose size wilI p e r m i t achieving a c o n s i d e r a b l e lowering of the l a b o r consumption due to the u s e of efficient technology and of i m p r o v e d equipment; the s i z e of a batch of s p a r e p a r t s m u s t be d e t e r m i n e d on the b a s i s of optimal l a b o r consump,+Aons; the l a b o r consumption for the f a b r i c a t i o n of the p a r t s in the e n t e r p r i s e s of the b r a n c h must a p p r o a c h the labor consumption for f a b r i c a tion of the p a r t s in the machine-building plants; the n o r m s for the use of s p a r e p a r t s p e r 100 machines T r a n s l a t e d f r o m Khimicheskoe i Neftyanoe Mashinostroenie, No. 4, pp. 30-32, Aprils 1976. 9 9 76 Plenum Publishing Corporation, 22 7 West 17th Street, New York, N. Y. 10011. No part o f this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, microfilming, recording or otherwise, without written permission o f the publisher. A copy o f this article is available from the publisher for $15.00.

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m u s t not exceed the s t a n d a r d s developed by the Central Design and Construction Office for the Automation and Modernization of Existing Metal-Working Equipment (Ts PKTBA M) V/O "Soyuzstankoremont" and others. The a r t i c l e s which w e r e found suitable for c e n t r a l i z e d production w e r e c o n s i d e r e d in a c c o r d a n c e with the following c r i t e r i a : in what e n t e r p r i s e will they have the l e a s t cost; which e n t e r p r i s e has the m i n i m a l t r a n s p o r t e x p e n s e s , e n s u r e s the b e s t quality in the f a b r i c a t i o n of the a r t i c l e s , and is the b e s t equipped; which e n t e r p r i s e has the m o s t highly skilled c a d r e s and p r o s p e c t s in this r e g a r d ; where is the coefficient of the u s e of the m e t a l the g r e a t e s t . On the b a s i s of e c o n o m i c evaluations of the efficiency of the organization of the c e n t r a l i z e d f a b r i c a tion of lacking s p a r e p a r t s in the e n t e r p r i s e s of the branch, an a n a l y s i s was made of the following s t r u c t u r i n g data: s y s t e m a t i z a t i o n and c l a s s i f i c a t i o n of the equipment of the m o s t widely used models, which need a d e t e r m i n e d n o m e n c l a t u r e of s p a r e p a r t s ; the balance of the needs of and the capacity of the s p a r e p a r t s industry (taking account of d e l i v e r i e s by the A d m i n i s t r a t i o n of Material and Technological Supply of the Gossnab SSSR); grouping of whole n o m e n c l a t u r e of the p a r t s in a c c o r d a n c e with s t r u c t u r a l and technological c r i t e r i a ; d i s c l o s u r e of the existing r e s o u r c e s of the c a p a c i t i e s of the maintenance and m e c h a n i c a l units of the e n t e r p r i s e s of the b r a n c h ; s p e c i a l i z a t i o n of the maintenance and m e c h a n i c a l units and d i s t r i bution of the n o m e n c l a t u r e of the s p a r e p a r t s . The r e s u l t s of the a n a l y s i s have made it possible to d e t e r mine that, in the e n t e r p r i s e s of the branch, the following n o m e n c l a t u r e of s p a r e p a r t s and pieces a r e suitable for c e n t r a l i z e d f a b r i c a t i o n (by s t r u c t u r a l and technological g r o u p s ) : slotted shafts, shaft g e a r s , clutches, r a c k s , w o r m s c r e w s , lead s c r e w s , one-, two-, and t h r e e - r i m g e a r s , conical g e a r s , and o t h e r s . The calculation of the r e s o u r c e s of the capacity of the maintenance and m e c h a n i c a l units m u s t be made taking account of the p r o s p e c t s for the development of the e n t e r p r i s e and of the need, under t h e s e c i r c u m s t a n c e s , for c o m p l e t e l y satisfying the demand for maintenance work. In the calculation, it is n e c e s s a r y to exclude the loading of the maintenance and m e c h a n i c a l units with w o r k on the f a b r i c a t i o n of s p a r e p a r t s for the needs of the plant itself, since the machine hours for c a r r y i n g out capital, m o d e r a t e , and s m a l l m a i n t e n a n c e a r e designated p r e c i s e l y for the f a b r i c a t i o n of the r e q u i r e d interchangeable p a r t s . It is i m p o s s i b l e to a g a i n include this w o r k in the calculation of the load. In calculations of the load of the maintenance and m e c h a n i c a l units, p r o v i s i o n m u s t be made for nonmaintenance w o r k , connected with periods of r e c o n s t r u c t i o n of the e n t e r p r i s e s , in an amount up to 25%. It m u s t be noted that, with a calculation of t h e i r r e s o u r c e s , s o m e e n t e r p r i s e s do not take account of the additional p o s s i b i l i t i e s which a r i s e due to the c e n t r a l i z e d acquisition by the e n t e r p r i s e s of the whole r e q u i r e d n u m b e r of p a r t s for a d e t e r m i n e d n o m e n c l a t u r e of equipment. In this c a s e , they a l s o do not t a k e account of r e s o u r c e s existing in the maintenance units of the b a s e s , where the equipment is cons i d e r a b l y l e s s loaded than in the m a i n t e n a n c e and m e c h a n i c a l units. Calculation of the cost of s p a r e p a r t s for m e t a l - c u t t i n g machines c e n t r a l l y f a b r i c a t e d by the m a i n tenanee and m e c h a n i c a l unit must be c a r r i e d out taking account of the magnitude of the indirect expendit u r e s for operation and maintenance of the equipment, unit and g e n e r a l plant, using the data for each ent e r p r i s e . An a n a l y s i s showed that the actual indirect expenditures in a maintenance and m e c h a n i c a l unit a r e less t h a n in the plant as a whole; the g e n e r a l - p l a n t expenditures include a l s o expenditures not connected with capital maintenance work. In view of the fact that the principal p a r t of the s p a r e p a r t s a r e n e c e s s a r y to the e n t e r p r i s e s of the b r a n c h for c a r r y i n g out capital and m o d e r a t e - s i z e maintenance, then, t o prevent too much of an i n c r e a s e for t h e s e , the calculation of the cost m u s t be made s t a r t i n g f r o m the i n d i r e c t expenditures of the maintenance units and the o v e r a l l plant expenditures, c o r r e c t e d for expendit u r e s not connected with production work, connected with capital maintenance. In a c o m p a r i s o n of the calculation of the cost of s p a r e p a r t s , the following limitations m u s t be t a k e n into consideration: the labor consumption, the m e t a l consumption, and the c a t e g o r y of the work m u s t be t a k e n in a c c o r d a n c e with the s t a n d a r d s of the Ministry of the Machine-Building and InStrument Industry; the p e r c e n t a g e s of bonus payments f r o m the wage fund, additional wages, deductions for social insurance, must not exceed the m e a n values a c c o r d i n g to the Ministry of Chemical and P e t r o l e u m Machine Building. Thus, the f a b r i c a t i o n of lacking s p a r e p a r t s for the e n t e r p r i s e s of the b r a n c h by the best use of t h e i r existing maintenance units p e r m i t s solving a n u m b e r of p r o b l e m s of maintenance s e r v i c e s . In the f i r s t place, h e r e account is t a k e n of the specific s p e c i a l c h a r a c t e r i s t i c s of the industry of the branch, having an effect on the c h a r a c t e r of the w e a r of the p a r t s and s u b a s s e m b l i e s of the equipment. In the second place, s p e c i a l i z a t i o n of the maintenance and m e c h a n i c a l units in the f a b r i c a t i o n of a limited n o m e n c l a t u r e

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of s p a r e p a r t s p e r m i t s organizing the m a s s production of p a r t s of one type, which e n s u r e s a high quality of t h e i r f a b r i c a t i o n and p r o m o t e s the attainment of the r e q u i r e d economic indices. In the third place, s m a l l e n t e r p r i s e s a r e f r e e d f r o m the f a b r i c a t i o n of s p a r e p a r t s for t h e m s e l v e s , since the organization of this kind of production in s m a l l plants r e p r e s e n t s definite t e c h n i c a l difficulties and is economically unp r o f i t a b l e . In the fourth place, the scheduled production of s p a r e p a r t s g u a r a n t e e s the s a t i s f a c t i o n of the needs of the e n t e r p r i s e s , and, consequently, d e c r e a s e s t h e i r need for s t o r a g e of s p a r e s . F o r e x a m p l e , in 1971-1975, the e n t e r p r i s e s of the b r a n c h d e c r e a s e d t h e i r r e q u e s t s for lacking s p a r e p a r t s , although the amount of equipment and the volume of maintenance i n c r e a s e d c o n s i d e r a b l y during this period of t i m e . F o r only one y e a r , the saving f r o m the i m p l e m e n t a t i o n of p r o p o s a l s for the c e n t r a l i z e d f a b r i c a t i o n of s p a r e p a r t s in the e n t e r p r i s e s of the b r a n c h was m o r e than 400 thousand r u b l e s . The s p e c i a l i z a t i o n of the maintenance and m e c h a n i c a l units, ensuring a division of labor, can be r e g a r d e d as one m e a s u r e for the s p e c i a l i z a t i o n and c e n t r a l i z a t i o n of maintenance, since, under the cor~litions stipulated by the m i n i s t r i e s , it is p o s s i b l e to e n s u r e a b r o a d e r c o o p e r a t i o n in the p e r f o r m a n c e of maintenance work, on the b a s i s of the c r e a t i n g of leading maintenance and m e c h a n i c a l units. The organization of leading maintenance and m e c h a n i c a l units is p a r t i c u l a r l y i m p o r t a n t in connection with the o r g a n i z a tion, in the b r a n c h , of All-Union Industrial Combines, including s c i e n t i f i c - i n d u s t r i a l and industrial c o m b i n e s , and individual e n t e r p r i s e s . The Ia~est, and r e l a t i v e l y b e s t , c o m p l e x maintenance and m e c h a n i c a l units m u s t be s e p a r a t e d out as leading units. T o c r e a t e the possibility of c a r r y i n g out maintenance w o r k not only for the leading e n t e r p r i s e of s c i e n t i f i c - i n d u s t r i a l and industrial c o m b i n e s , but a l s o for other e n t e r p r i s e s attached to such a maintenance unit, the leading maintenance and m e c h a n i c a l units must be furnished with the r e q u i r e d equipment, i n s t r u m e n t a t i o n , and d e v i c e s . The equipment obtained by a combine must be sent f i r s t of all to such units. The supply of the leading maintenance and m e c h a n i c a l units with the r e q u i r e d equipment can be effected a l s o by the r e d i s t r i b u t i o n or r e m o v a l of slightly loaded and unused machines f r o m other maintenance and m e c h a n i c a l units. The leading maintenance and m e c h a n i c a l units must dispose of all the m e a n s r e q u i r e d for the highquality and productive p e r f o r m a n c e of maintenance work. As a r u l e , they must include t h e r m a l sections with furnaces for gas cementation, units for heating with h i g h - f r e q u e n c y c u r r e n t s , shops for the r e g e n e r a t i o n and strengthening of p a r t s by various methods, well equipped with w a r e h o u s e s supplied with the n e c e s s a r y m e a n s for control and m e a s u r e m e n t . Control of the quality of maintenance w o r k should be done by the plant s e c t i o n for technical control. It must be noted that the leading maintenance and mechanical unit of a s c i e n t i f i c - i n d u s t r i a l or industrial combine s h ~ l d not n e c e s s a r i l y be located in the t e r r i t o r y of a leading e n t e r p r i s e . Such a solution must be adopted on the b a s i s of a m a n y - s i d e d a n a l y s i s of the technical and economic indices. In c h e m i c a l and p e t r o l e u m machine-building plants other m e a s u r e s a r e a l s o t a k e n a i m e d at i n c r e a s ing the efficiency of the maintenance and s e r v i c e industry: in a n u m b e r of plants, s y s t e m s have b e e n [nt r o d u e e d for the i n t e r m a i n t e n a n c e s e r v i c i n g of equipment, using g r a p h s of the e x a m i n a t i o r ~ of the m e t a l w o r k e r s on duty, and c e n t r a l i z e d l u b r i c a t i o n of the equipment; typical technologicaI p r o c e s s e s for m o d e r ate and capital maintenance of lathes, boring, milling, and grinding machines have b e e n developed and put t o use with application to actual industrial conditions; the n o m e n c l a t u r e of s p a r e p a r t s has bee u d e t e r mined a c c o r d i n g to types of equipment, and t h e i r m i n i m a l n u m b e r has b e e n d e t e r m i n e d , which must be constantly kept in s t o r a g e ; account is t a k e n of f a s t - w e a r i n g p a r t s , and a s y s t e m a t i c a n a l y s i s has been m a d e of the r e a s o n s for t h e i r getting out of o r d e r ; b r i g a d e s of m e t a l and m a i n t e n a n c e w o r k e r s , and m e t a l w o r k e r s - e l e c t r i c i a n s have been f o r m e d for the maintenance of hoisting and t r a n s p o r t equipment; specialized brig~ades have b e e n f o r m e d f o r the c e n t r a l i z e d capital m a i n t e n a n c e of equipment. With the a i m of organizing a p r a c t i c a l i n t e r m a i n t e n a n c e s e r v i c i n g of equipment, and to i n c r e a s e the p e r s o n a l r e s p o n s i b i l i t y of f o r e m e n , b r i g a d e s , and w o r k e r s f o r the c o r r e c t and c a r e f u l operation of the equipment, in s o m e plants of the b r a n c h it has b e e n divided into sections, to which b r i g a d e s of m e t a l and maintenance w o r k e r s and m e t a l w o r k e r s - e l e c t r i c i a n s a r e p e r m a n e n t l y attached. T h e r e has b e e n a b r o a d e r u s e of m e a n s of m e c h a n i z a t i o n and equipment, in the maintenance industry and of maintenance work. F o r e x a m p l e , such m e a n s a r e p o r t a b l e , r a c k - t y p e , and washing baths for the s t o r a g e and ~n~shing of dismantled s u b a s s e m b l i e s of m a c h i n e s , s p e c i a l b r i d g e s and c o u n t e r b r i d g e s for the control and v e r i f i c a t i o n of the guiding s u p p o r t s of v a r i o u s m a c h i n e s . In addition, the working places of the maintenance w o r k e r s a r e equipped with s t a n d a r d i z e d w o r k b e n c h e s , equipment, and devices~ The m a s t e r y of r e l a t e d t r a d e s has b e e n organized and the qualifications of the maintenance w o r k e r s has b e e n systematically- r a i s e d .

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More and m o r e attention in the e n t e r p r i s e s of the branch, in the maintenance s e r v i c e s , is being paid to questions connected with the introduction of economic calculation and economic stimulation. The i n t r o duction of an economic calculation in maintenance s e r v i c e s broadens the f r a m e w o r k of their independence, makes possible a m o r e operationally sound r e a c t i o n to the component of the capacity a r r a n g e m e n t , and maneuvering the m a t e r i a l and labor r e s o u r c e s . A n e c e s s a r y condition for the introduction of an economic calculation into the maintenance s e r v i c e s of plants is, as a rule, a c o r r e c t statement of the accountingtaking account of the production expenditures in a c c o r d a n c e with a s y s t e m of ordinances, whose nomenclature e m b r a c e s all kinds of work and s e r v i c e s p e r f o r m e d by the maintenance s e r v i c e . Under these c i r c u m s t a n c e s , intraplant units, taking account of expenditures for maintenance work and s e r v i c e s , a r e at the s a m e time the b a s i s for calculations between units. At the p r e s e n t t i m e , in the e n t e r p r i s e s of the branch, the basis of the economic relationships b e tween the production units and the maintenance s e r v i c e a r e c u r v e s of the planned p r e d e t e r m i n e d maintenance and the intermaintanance s e r v i c i n g of the equipment. At the s a m e time, not all e n t e r p r i s e s of the branch, in a selection of the economic indices, determining the economic interrelationships between the maintenance s e r v i c e s and the other units of the e n t e r p r i s e , take account of the fact that the m a i n t e n a n c e w o r k is financed f r o m different s o u r c e s . Specifically, about 40% of the y e a r l y volume of maintenance work is made up of capital and moderate maintenance of equipment, which is effected due to a m o r t i z a t i o n deductions, and which, in a c c o r d a n c e with the existing methodology of planning, is included in the volume of c o m m e r c i a l production. With r e s p e c t to this maintenance, t h e r e a r e no mutual calculations between the units. Approximately 60% of the volume of the maintenance s e r v i c e s in a plant consists of work connected with s m a l l maintenance jobs, inspections, and intermaintenance servicing. These a r e effected due to a unit cost estimate of expenditures for the equipment. T h e s e expenditures in the f o r m of applied calculations a r e included in the cost of the product put out. In view of this, a n e c e s s a r y condition for the i n t r o duction of an economic calculation is the p r e s e n c e of a cost estimate of the expenditures for c a r r y i n g out the planned maintenance operations and the intermaintenance s e r v i c i n g for each production unit, cons t r u c t e d on the basis of calculated interplant costs for maintenance work. These cost estimates a r e convincing documentation of a connection between the maintenance and mechanical unit, which plays the role of p r o d u c e r , and the production units, which play the role of p u r c h a s e r s . Economic calculation and economic stimulation of the work of a maintenance e n t e r p r i s e a r e intimately connected with questions of the organization of maintenance s e r v i c e . At the present time, t h e r e a r i s e s the question of whether the duties of the chief mechanic include not only the planning of maintenance work, but also the d i r e c t implementation of the whole complex of maintenance s e r v i c e s . Under t h e s e c i r c u m s t a n c e s , all the maintenance personnel a r e on the staff of the maintenance and mechanical unit of the plant. The maintenance s e r v i c e s of e n t e r p r i s e s , called on to e n s u r e the appropriate technical state of the active part of the principal funds, a r e bound to adopt all m e a s u r e s aimed at increasing the technical, economic, and organizational level of the maintenance industry, and to actively promote an i n c r e a s e in the production of the national economy.

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