This article reflects measures to unite the efforts of disparate and independent functioning economic entities aimed at forming a single, holistic, production system in order to ensure rational maintenance of technical capacity. State of the art Agriculture determined food security country, providing the population with food and raw materials for the processing industry and largely depends on the degree of equipment of agriculture with means of production, their novelty, duration of use, and speed of renewal. Limited resources and an increase in the need for the final product produced in agriculture predetermine the processes of reproduction of technical potential in modern conditions. The article substantiates the need to use a set of technological, technical, financial and economic indicators that characterize the efficiency of the organization's production and economic activities. It is shown that statistical methods of multidimensional classification make it possible not only to minimize their number, but also to detect correlations for each indicator, which are the basis for improving the methodology for an integrated approach to assessing the performance of organizations.

material and technical base

machine and tractor park

fare

repair services

repair products

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On modern stage development of agriculture, the repair and maintenance base should be considered as a single complex, problem solver maintaining and restoring the performance and serviceability of machinery and equipment for agricultural production. Its development and improvement occurs continuously in accordance with the development of the material and technical base of agriculture and its most active part - the machine and tractor fleet.

Maintenance and repair of the machine and tractor fleet developed in farms and districts of the Chelyabinsk region along the path of concentration and specialization; repair enterprises and workshops were created to restore parts, components, assemblies, engines, and repair grain harvesters and other combines.

Repair enterprises, divisions and services of the agro-industrial complex developed along the path of separating repair enterprises into an industry specializing in the repair of agricultural machinery. This direction of development met the requirements scientific and technological progress in repair production.

The components of the repair and maintenance base are material and technical means for repair purposes, technology and organization of production in repair enterprises.

The repair and maintenance base of farms includes specialized repair shops and agro-industrial complex plants, central repair shops, points Maintenance, car garages, machine yards, oil warehouses, mobile equipment for maintenance and repair of farm machinery.

The need of commodity producers for technical maintenance services, in our opinion, should have increased, since the tractor fleet had aged significantly (almost 80% of tractors and other machines were operating beyond their depreciation period by this time).

Taking into account the fact that the annual costs of repairing tractors are a manageable element, we carried out special studies, the analysis of the results of which allowed us to identify the following factors-conditions as the main ones for the regions of the Chelyabinsk region: the degree of supply of tractor machine operators, the amount of arable land per tractor, production area workshops on farms per tractor - m2, production area of ​​a specialized repair and maintenance base of the agro-industrial complex per tractor - m2, production area of ​​technical service workshops (maintenance points) per 1 tractor - m2 and determine the degree of influence of each specified condition with their combined impact on the specific indicator of annual costs for machine repairs.

The relationship between the annual costs per ruble of book value for repairs and maintenance of machines and the above conditions is described by the following linear equation:

where x1 is the supply of machine operators, people/tractor; x2 - amount of arable land per tractor, ha; x3 - production area of ​​workshops on farms per tractor, m2; x4 - production area of ​​a specialized repair and maintenance base for one tractor, m2; x5 - production area of ​​workshops for maintenance points per tractor, m2.

In the above equation, the coefficients for the unknowns show how much the annual costs will increase (plus sign) and decrease (minus sign) per one ruble of the book value of the machines if the value of the variables increases by one accordingly (table).

Calculation of coefficients of influence of factors-conditions on the level of annual costs for tractor repairs in regions of the Chelyabinsk region

From the analysis of the resulting equation, it follows, first of all, that the factors under consideration have different effects on the annual unit costs of maintaining machines in working condition (see table).

The capacity of the specialized workshops of the agro-industrial complex of the region in the above equation has a 1.6 times more positive impact on reducing the costs of repair and maintenance of machines than the central repair shops, and the workshops of the industrial industrial complex, respectively, have a more than 4 times more positive impact than the central repair shops of farms.

The statistical reliability of these dependencies indicates the need to take them into account in the formation and development of the repair base of the central repair shop and service station of farms and a specialized service base, as special factors that significantly influence the cost of repair actions.

These theoretical conclusions are confirmed not only by the practice of work at various levels of repair workshops of farms and specialized repair enterprises of the agro-industrial complex, but also by foreign experience.

In the territory of the former Federal Republic of Germany there are 5,723 specialized enterprises for the maintenance and repair of agricultural machinery. At the same time, in groups of farms with a production volume of 0.25-0.50 million euros, maintenance and repairs account for 86.6%, in groups of farms with 2-5 million euros, respectively - only 43.2%. The last large farms rely on the services of their repair shops.

The technical service system in the Republic of Korea is represented by dealer repair enterprises and their own enterprises (farmers). The share of dealers in the repair of tractors is 66.3%, and on the farm - 33.7%, respectively, for grain harvesters - 65.9 and 34.1%. In this case, the consumer is supplied with spare parts by dealerships.

An analysis of the work of technical workshops at various levels for servicing the machine and tractor fleet showed that they are an effective form of agricultural technical service and significantly reduce the costs of maintaining machines in working condition.

Method of determination economic efficiency performing maintenance and repair work on our own or in specialized enterprises, the agro-industrial complex was applied taking into account new principles of management in market conditions.

The main elements of novelty, along with the old ones, are: new criterion economic efficiency - increase in profit (reduction in production costs); determination of general (absolute) and comparative economic efficiency (new technologies with high efficiency compared to basic ones, for example, for repairs, do not receive approval if their use does not increase profits); The methods for calculating the costs of repairs and maintenance have been clarified (they include interest on loans, taxes, and insurance).

Previously, before determining the economic efficiency of repair and maintenance, a forecast calculation of the needs and demand of agricultural producers for various types of technical services was carried out, while it was stipulated that the volumes of individual complex work will be carried out by existing agro-industrial complex repair enterprises.

Economic justification A rational repair network involves establishing such sizes of repair plants and specialized workshops and their location in the region that should meet the demands of commodity producers at the lowest cost per unit of repair.

During the study, three options for a network of repair enterprises were calculated.

The first option is provided that the entire established volume of repairs of tractors and combines of commodity producers is carried out in the central workshops of former state farms.

The second option is that the established volume of current repairs is carried out in the workshops of former state farms, and capital repairs are carried out in currently existing factories with a capacity of 2 to 6 thousand conditional repairs.

The third option - the established volume of current repairs is carried out in the workshops of former state farms, and capital repairs are carried out at repair factories and workshops general purpose and workshops of service stations for energy-saturated tractors and workshops of car service stations located in agricultural areas of the region.

The calculations show that expanding the network of existing repair shops in the regions of the Chelyabinsk region, bringing technical services closer to the requirements of agricultural producers, specializing regional repair shops with repair plants will not only significantly reduce the cost of maintaining machines on farms, but will also make it possible to better use the production capacities of repair enterprises and central repair shops of former state farms.

When restoring scientifically based production volumes of agricultural products and with an appropriate machine and tractor fleet, taking into account the 3-fold increase in the number of commodity producers, it will be necessary to increase the capacity of workshops by 1.2-1.5 times through the construction of new ones and the reconstruction of old ones in newly organized farms (without farms) if repair specialization is not introduced.

Calculations show that with the current organization of machine repair only in farm workshops, the production capacity of 40.1 thousand conditional repairs will be required, and with the designed specialization - only 17.7 thousand conditional repairs. Consequently, when organizing a specialized network of repair enterprises (when converting a conventional repair unit into the production area it occupies, m2), less space will be required by 30 thousand m, or 21%, and capital investments - by 174,373 million rubles, or 82% less compared to the first option.

To comprehensively substantiate the economic efficiency of a specialized network of agro-industrial complex repair enterprises in comparison with farm workshops, it should be noted that in the conditions of the region, the removal of products from 1 m2 of area on average in service repair shops and in agro-industrial complex factories is 685 rubles, while in state farms - 261 rubles, productivity at repair enterprises of 1 worker is 33.6, and in repair shops - 11.7 thousand rubles, or less than 2.9 times, and capital productivity is correspondingly 2.6 times higher.

A specific reserve for reducing repair costs is reducing the cost of repair products. Calculations show that in the 3rd zone, which includes 6 districts of the Chelyabinsk region, occupying an area of ​​1848 thousand hectares, machine repairs account for only 14% of the total volume, the specific total costs of repairs are significantly higher than the average for the Chelyabinsk region.

As many years of experience and calculations show, specializing the repair of complex facilities at the district and zonal levels significantly reduces costs.

In general, in all zones of the region, as the analysis shows, with appropriate specialization repair work annual costs are reduced from 116,418 thousand rubles. up to 93966 thousand rubles, or by 19%.

To use existing production capacity Regional workshops of the agro-industrial complex require certain capital investments for the purchase of machines and equipment, of which fifty percent are completely worn out and require replacement.

Complex repairs of all equipment could be carried out at the seven existing repair plants in the Chelyabinsk region. The analysis shows that with an increase in the capacity of the enterprise to a certain size, the cost of a conventional unit of repair is reduced, but with an increase in capacity above these limits, transportation costs for the delivery of repair objects to the plant increase at a significant rate, which limits the growth of production of this enterprise.

Market business conditions require the creation competitive environment manufacturers of repair services, which significantly reduces selling prices and improves the quality of repair of machines, their components and assemblies. In modern conditions, the increase in existing agricultural industrial enterprises brings them closer to agricultural producers, allowing the latter to choose those that satisfy their needs and needs for technical services.

Of primary importance when choosing the most profitable and economical areas of specialization and concentration of repairs is reducing the cost of production, increasing the efficiency of capital investments, ensuring the greatest increase in the volume of repair products for each ruble of capital investments spent, and reducing their payback period.

Excessively large repair enterprises have a number of significant disadvantages compared to medium and small ones. These include: transportation over relatively long distances of repair facilities, spare parts, materials, causing an increase in transport costs; limited possibilities for uniform distribution of these enterprises throughout the agricultural areas of the region and a large distance between agricultural producers and service providers.

Reconstruction of regional agro-industrial complex workshops with their simpler equipment and organization, short terms re-equipment with a separate small number modern equipment and small existing fixed assets is completely economically justified and expedient.

The proposed specialization of the repair network, which includes specialized workshops, will free factories, as well as workshops of former farms, from the unusual functions of repairing many machines, components and assemblies, or restoring parts in small batches and will contribute to the specialization of large and small production.

It is shown that the specialization of repairs, the use of the existing extensive network of repair enterprises of the agro-industrial complex with the corresponding re-equipment of their equipment make it possible to bring the scope of technical services closer to the consumer, to most fully and efficiently satisfy in market conditions the diverse demand of commodity producers for technical services and ensure that they receive an economic effect.

In conclusion, it should be noted that the trend of expanding the production capacity of repair plants in the region, which has existed for many years, has a negative experience and does not contribute to increasing economic efficiency.

Reviewers:

Koledin S.V., Doctor of Economics, Professor, Head of the Department of Economics of Agro-Industrial Complex of the Chelyabinsk Branch of the National Educational Institution of Higher Professional Education "Chelyabinsk Institute of Economics and Law named after. M.V. Ladoshina", Chelyabinsk;

Pryakhin G.B., Doctor of Economics, Professor of the Department of Economics and Management of the Federal State Budgetary Educational Institution of Higher Professional Education "Ural State University physical culture", Chelyabinsk.

The work was received by the editor on January 14, 2013.

Bibliographic link

UDC 658.58

METHODOLOGY FOR ASSESSING THE QUALITY OF THE PROCESS OF MAINTENANCE AND REPAIR OF METAL-CUTTING MACHINES

A.V. Fedorov

A methodology for assessing the quality of the process of maintenance and repair of metal-cutting machines has been developed and a practical example of its use in the production conditions of an industrial enterprise is given.

Keywords: quality, service, process, machines, repair.

Modern concept Total Quality Management (TQM) and international standards ISO 9000:2000 focuses on process approach, according to which manufacturing process on industrial enterprises is proposed to be considered as a network of interconnected and interacting processes, the management of which should be carried out according to the Deming-Shewhart cycle PDCA (Plan-Do-Check-Act) (Fig. 1), which includes the functions of planning, execution, quality control and regulation for each process .

Managing an organization as a network of processes necessitates quality control of each component process. According to , process quality control means taking measurements of monitored process parameters and comparing them with established requirements in order to determine compliance or non-conformity. Based on this definition, we can conclude that to implement the process quality control function in PDCA cycle it is necessary to have measurable process parameters (its characteristics that are subject to measurement and control).

process indicators;

process product indicators;

indicators of customer satisfaction with the process.

Each of the listed groups of indicators can be expressed in cost, technical and time terms. Cost, time and technical indicators, in turn, can also be distributed among the levels of employee, site, workshop, subprocess, and function.

For the main business processes of an enterprise, the direct result of which is the release of products, carrying out activities to identify the characteristics of the processes that are subject to measurement and control in the PDCA cycle is usually not difficult. But when identifying measured parameters for auxiliary processes,

related to maintenance and repair of metal-cutting machines, providing basic production with equipment, fixtures, cutting and measuring tools, i.e. promoting the normal flow of the enterprise's main business processes, certain difficulties arise.

For example, in Fig. Figure 2 shows a matrix that takes into account the relationship between the measured parameters of one of the most important auxiliary processes in industrial enterprises - the process of maintenance and repair of metal-cutting machines and the requirements for its quality control.

As can be seen from Fig. 2, the quality of the maintenance and repair process cannot be comprehensively assessed by all elements of the matrix, since they are absolute indicators of the process and its product (functional equipment) and are expressed in quantitative form. Therefore, indicators for assessing process quality cannot be taken from operational data. They should be defined as relative values, i.e. as ratios. In this case, the conditions contained in the root columns of the matrix must be taken into account.

Based on the above, as measured parameters for comprehensive assessment quality of the maintenance and repair process were selected:

efficiency and effectiveness indicators (PER) of the repair service;

material damage to the main production from equipment downtime and unscheduled repairs.

Registration of values ​​of measured parameters with a certain pe-

frequency should be carried out in monitoring cards for the process of maintenance and repair of metal-cutting machines.

Measured parameters of the maintenance and repair process

ISO 9000 Cost indicators Time indicators Technical indicators

Process indicators Total cost of inventories, cost of subcontracts, labor costs for RS personnel Total time spent on repair work Level of RS technical equipment, advanced equipment fleet

Process product indicators Cost of repair work for a specific piece of equipment Time for subsequent operation of the equipment Technological accuracy

Indicators of consumer satisfaction with the process Total cost of repair work, share of repair costs in the cost of production Time to troubleshoot and troubleshoot Number of complaints, equipment failures

Maintenance and repair process monitoring map

STP for the maintenance and repair process

Requirements for the process owner to analyze deviations from the normal course of the process and document these deviations

Requirements for analyzing the effectiveness of corrective actions

Requirements for generating process reporting for a senior manager

Requirements for determining the planned values ​​of process indicators for the next period

Rice. 2. Quality parameters of the maintenance and repair process

Obviously, the most important parameter qualities for the maintenance and repair process are PER, as they reflect the degree to which the actual results of the process correspond to the planned ones, as well as the relationship between the achieved result and the resources used. The advantage of PEDs is also that they can be used as a tool for continuous process monitoring.

A number of technical and economic performance indicators of the repair service were selected as the PER, which fully satisfy the conditions of the matrix (Fig. 2).

To obtain a visual representation of the level of quality of the maintenance and repair process, in monitoring maps it is advisable to use pie charts constructed according to the relative technical and economic indicators of the quality of the maintenance and repair process, and their weight coefficients (Fig. 3).

Each indicator is depicted on the diagram as a circular sector, the radius of which, μ, is equal to the value of the indicator relative to the selected analogue, and the central angle is the weight coefficient, expressed in a conventional value in degrees or radians. Basic values ​​for all indicators are depicted by a circle with a radius equal to one. The central angle for the I-th indicator with the weight coefficient aI is defined as f = 2sh, rad, or f;- = 360°sh, deg.

The level of quality of the maintenance and repair process is determined on the basis of a complex average weighted indicator Uk, referred to here as the average weighted circular indicator. It is equal to the radius of a circle whose area is equal to the sum of the areas of the sectors of the diagram. It can be calculated using the formula

Rice. 3. Procedure for constructing a pie chart

where n is the number of relative indicators of the quality of the maintenance and repair process; w - weight coefficient; q is the value of the i-th indicator.

Experience shows that Uk is close to the weighted arithmetic average: deviations of Uk from this indicator in a wide range of changes in relative indicators and weighting coefficients do not exceed 10%.

The value of the average weighted circular indicator is graphically displayed by a circle in the form of a dotted line (Fig. 3). Uk< 1 означает, что уровень качества процесса ниже условного относительного аналога. Предлагаемый здесь средний взвешенный круговой показатель для широкого диапазона изменений относительных показателей и коэффициентов весомости имеет значения, близкие к значениям среднего взвешенного арифметического показателя. Более того, он обладает важным преимуществом по сравнению с арифметическим показателем. Оно заключается в том, что круговой показатель имеет геометрический смысл: он равен радиусу круга, площадь которого равна сумме площадей секторов диаграммы.

Weight factors for all indicators at each enterprise should be assigned using expert assessment methods and adjusted when compared with past results. The PERs themselves are also selected by a specially created expert group, depending on the characteristics of the maintenance and repair process and the current balanced scorecard (BSC) at each enterprise, and after a certain period of recording the indicators, the manager of the maintenance and repair process should determine standard and target values ​​for each of them .

When determining material damage to main production processes from unscheduled repairs and equipment downtime, utilization indicators should be taken into account in the maintenance and repair process monitoring map work force and equipment. Then the amount of actual damage (My) can be determined with a sufficient degree of reliability by the amount of material losses due to downtime of equipment (Mo) and workers (Mr).

Mu = I Mr + £ Mo, (2)

where n is the number of workers taken into account; m is the amount of equipment taken into account.

To make claims for each specific case of violation of production conditions, a special act on economic claims is drawn up. If the costs of claims are recognized by the guilty service,

ba, then the claim signed by the parties is transferred by the interested party to the economic planning service of the enterprise. Next, the correctness of the calculations made is checked, and the amount of expenses is reflected in the reports of the relevant departments.

To automate the task of managing the process of maintenance and repair of metal-cutting machines according to the RBSL cycle, a computerized system for its dispatch and control was developed, which includes a process quality monitoring module. In Fig. Figure 4 shows a pie chart constructed by this automated system and characterizing the quality of the maintenance and repair process of metal-cutting machines at the Rudakovsky Mechanical Plant Branch of Tulatochmash OJSC.

No. Indicator Value

01.2013 02.2013 03.2013 04.2013

1. Failure rate 0.744 0.756 0.810 0.797

2. Share of repairmen’s salaries in maintenance and repair costs 0.925 0.894 0.914 0.873

3. Time lost due to breakdowns 0.870 0.886 0.895 0.871

4. Degree of development of subcontracts 0.801 0.843 0.900 0.850

5. Operational readiness coefficient 0.635 0.667 0.685 0.661

6. Available level of spare parts 0.691 0.689 0.751 0.720

7. Equipment utilization rate 0.740 0.762 0.792 0.753

UK 0.778 0.790 0.825 0.793

Rice. 4. Pie chart level of quality of the maintenance and repair process in March 2013 at the Rudakovsky Mechanical Plant Branch

OJSC "Tulatochmash"

The diagram shows those PER that most fully take into account the connection between equipment operation and the amount of labor and spare parts at the enterprise. Monitoring cards compiled by an automated system for dispatching and monitoring the process of maintenance and repair of metal-cutting machines allow the manager to monitor the quality of this process, i.e. receive a signal when various inconsistencies occur during maintenance, conduct systematic comparisons with past results and find out trends in changes in parameters, judge the results of the work of various departments of the repair service.

The application of the proposed methodology for assessing the quality of the maintenance and repair process of metal-cutting machines is successfully used at the Rudakovsky Mechanical Plant Branch of Tulatochmash OJSC and can contribute to the real implementation of the principles of the process approach and TQM at

other domestic industrial enterprises.

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Fedorov Alexey Valentinovich, Ph.D. tech. Sciences, Associate Professor, Russia, Tula, Tula State University

METHOD OF EVALUATION OF QUALITY OF SERVICE AND REPAIR MACHINE TOOL

Developed a method of assessing the quality of the process of maintenance and repair of machine tools and a practical example of its use in the production of an industrial enterprise.

Key words: quality, service, process, machine, repair.

Fedorov Alexey Valentinovich, candidate of technical science, docent, Russia, Tula, Tula State University