An approximate list of equipment for car service enterprises. An indicative list of equipment for car service enterprises Purpose of a car repair company
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2. Abbreviations
3. Design assignment
8. Determination of warehouse areas
12. Energy part
Conclusion
Bibliography
Introduction
The working properties of the car gradually wear out during its operation. As a result of this, failures and malfunctions appear in the car, which are eliminated during repair and technological maintenance (MOT).
A car is considered serviceable if it meets all the requirements of regulatory and technological documentation (NTD). A working car can be faulty: have a deteriorated appearance, low pressure in the engine lubrication system, increased fuel consumption, etc.
Damage refers to the transition of a car to a faulty but operable state. The transition of a car to an inoperative state is called a failure.
Car repair is a complex of operations to restore the malfunction or performance of parts and restore the resources of products and their components.
During operation, cars undergo periodic maintenance at motor transport enterprises (ATP) and, if necessary, current repair (TR), which is carried out by replacing individual parts and assemblies. This allows the vehicles to be kept in good technical condition.
With long-term operation, cars reach such a state when their repair under the conditions of ATP becomes technically impossible or economically unprofitable. In this case, they are sent to a centralized maintenance or overhaul (CR) at a car repair company (ARP).
Routine repairs must ensure the guaranteed performance of the car on the run until the next scheduled repair.
GOST R 1.5 - 2002 GSS. Standards. General requirements for construction, presentation, design and designation.
GOST 2.301 - 68 ESKD. Drawing formats.
GOST 2.302 - 68 ESKD. The scale.
GOST 2.303 - 68 ESKD. Lines.
GOST 2.304 - 81 ESKD. Drawing fonts.
GOST 2.316 - 68 ESKD. Rules for drawing inscriptions, technical requirements and tables on drawings.
GOST 2.105 - 96 ESKD. Text documents.
GOST 2.104 - 95 ESKD. Main inscription.
GOST 7.1 - 84 SIBID. Bibliographic description of the document. General requirements and rules for drawing up.
GOST 7.12 - 93 SIBID. Bibliographic record. Abbreviations of words in Russian. General requirements and rules.
GOST 21.101 - 97 SPDS. Basic requirements for design and working documentation.
GOST 21.501 - 93 SPDS. Rules for the implementation of architectural and construction working drawings.
GOST 21.508 - 98 SPDS. Rules for the implementation of working documentation for general plans of enterprises, structures and housing and civil objects.
2. Abbreviations
In the text of the course work, the following abbreviations are used:
ATP - motor transport company;
TO - maintenance;
TR - current repair;
KR - major overhaul;
MC - mechanical workshop;
TsVID - workshop for restoration and manufacture of parts;
Tr is the complexity of the repair;
Фд - actual annual fund of equipment operation;
Fdr is the actual annual work fund of the worker;
F is the area of the main or auxiliary section;
Cn - the accepted number of machines;
fspecific area of one machine or stand;
Fuels and lubricants - fuels and lubricants;
Spare parts and accessories - spare parts, tools, devices;
RMC - mechanical repair shop.
3. Design assignment
The options for the assignments are shown in Table 1. The number of the option is selected according to the last digit of the student's record book code. In order to obtain comprehensive end results, all practical work is carried out for a given enterprise. Table 2 shows the approximate distribution of labor intensity by workshops as a percentage of the total labor intensity of major repairs.
Methodical instructions
When performing the first lesson, it is necessary to justify the organizational form of the repair of the given products and the structure of the production enterprise, based on the assignment for the corresponding option, to determine the main and auxiliary departments and their principal location. Give a layout diagram (no dimensions yet).
In subsequent lessons, calculations of the amount of main and auxiliary equipment are made according to the formulas and dependencies obtained in the lectures when studying theoretical material. Then, the composition and number of employees, the required areas for the mechanical, assembly and disassembly and other foreseen workshops and sections are determined. Energy calculations are made, auxiliary departments and services are designed according to the assignment and the main building of the auto repair enterprise is assembled with drawing a drawing at a given scale. All calculations and decisions made must be substantiated in detail. The layout drawing must contain all the necessary dimensions (length, width, height of the building, grid of columns, driveways and walkways; direction of freight flows, transport, designation of all rooms). An explication is drawn up indicating the areas and categories of fire hazard of the premises.
Table 1-Job options
4. Justification of the structure of the repair enterprise
Initial data:
Option 10
It is necessary to design an ARP for the repair of passenger cars of the same brand. The annual program of 6000 repairs, the labor intensity of one repair is 120 hours.
Repairs can be organized by aggregate (impersonal) and individual (non-impersonal) methods. When performing practical work, we substantiate the organizational forms of the car repair enterprise and the structure of the production and technical base of the enterprise and provide a diagram of the production process. When justifying the decisions made, it is necessary to make references to regulatory documents or to the current norms of operating enterprises. When repairing by the aggregate (impersonal) method, the cycle of work is shortened. When repairing by an individual (non-personalized) method, all faulty units are dismantled, disassembled, repaired and re-installed on the same products. At the same time, the repair cycle is lengthened, since individual units require a lot of time to recover. For a given option of work, we accept the organization of repairs by the aggregate method.
With such an organization of repairs, the production process diagram can be adopted as follows:
The diagram shows the stages: acceptance for repair and control of the car; removal of spare parts; general washing and cleaning; preliminary fault detection; disassembly into components and assemblies; disassembly into parts and boil-off; sorting of parts (unusable parts go to the scrap warehouse; parts that require restoration go to the mechanical shop through the warehouse of semi-finished products; good parts go to the assembly of units); mechanical shop work; assembly of units and products; refueling of fuels and lubricants; stationary and running tests; elimination of defects; completing with spare parts; delivery of the car to the quality control department and the customer.
Next, we substantiate the structure of the enterprise (with a full production cycle, a specialized enterprise, a mobile workshop, etc.). For a given project, we accept an ARP with a full production cycle of the following structure:
Disassembly shop with sections for external washing, disassembly of machines and assemblies, boiling and washing of parts, control and sorting of parts.
An assembly shop with departments for assembling and fitting parts, sorting units, assemblies and machines, a testing station, a section for assembling electrical equipment and fuel equipment, a section for copper and tin works.
Separate production shops: mechanical, frame-boiler, blacksmith, thermal, welding, galvanic, wallpaper, painting.
Auxiliary shops: RMTs of the chief mechanic and power engineer, instrumental.
Warehouses: parts awaiting repair; spare and repaired parts; metals; junk; fuels and oils; the woods; oxygen and acetylene cylinders; main warehouse for materials and spare parts.
Figure 1 shows one of the options for the layout of a given ATM. In the future, the layout can be clarified by design and design solutions.
Figure 1- Preliminary version of the ARP case layout
The following departments are numbered:
external washing and oil drain;
scrap warehouse;
disassembly of machines into units and assemblies;
evaporation and cleaning of parts;
troubleshooting of parts;
frame boiler room;
painting;
elimination of defects;
sharpening;
instrumental distribution pantry;
base mechanics and power engineering;
copper radiator;
tin;
galvanic;
wood finishing and wallpaper;
laboratory;
thermal;
welding;
parts warehouse;
completing;
spare parts warehouse;
repair of fuel equipment;
engine assembly workshop;
test station;
mechanical workshop;
Assembly shop.
5. Designing a machine shop
Technological design provides for the implementation of the following main sections: development of technological processes or justification of the technology of work; selection and calculation of the required amount of main technological and auxiliary equipment; calculation of the number of all workers (main and auxiliary) and other categories of workers (engineering and technical personnel, SKP, MOP); determination of the required areas.
At the preliminary design stage, technological processes may be absent and design is carried out according to standards or according to enlarged meters. The number of main equipment is calculated according to the appropriate formulas, and the number of auxiliary equipment is taken as a percentage of the number of main equipment. The number of workers in the main production is calculated by the number of technological equipment, the number of auxiliary workers is determined as a percentage of the number of main workers, and the number of all other categories of workers is determined as a percentage of the sum of the main and auxiliary workers. The required areas are calculated according to the specific norms and the amount of equipment accepted.
Due to the lack of technological processes, the design is carried out using enlarged meters.
The number of machines of the main production is determined by the formula
whereСп - the accepted number of machines, pcs;
T is the complexity of the repair for one car, h;
N is the annual number of repairs, pcs;
K - coefficient taking into account the labor intensity of the machine shop;
Фд is the actual annual fund of machine operation time, h;
hср - the average load factor of machines in time.
When working in two shifts, Fd = 4030 h, hav = 0.8-0.9. We accept hcr = 0.85.
The rest of the data is accepted according to the variant of the task.
We accept Cn = 43 machines.
We distribute the accepted number of machines into groups as a percentage of the total amount of equipment for a given type of production according to statistical data:
turning 20%: - we accept 9 machines;
milling 14%; - we accept 6 machines;
planing and grooving 8%; - we accept 4 machines;
grinding 18%; - we accept 8 machines;
drilling 7%; - we accept 3 machines;
gear-working 12%; - we accept 6 machines;
lingering 1%; - we accept 1 machine;
boring 10%; - we accept 5 machines;
others (CNC machines, modular, etc.) 10%; - we accept 5 machines.
The total amount of machines turned out to be 47, which is more than the estimated number. It is necessary either to justify this number 47, or to reduce it in some groups of machines. We will reduce one machine each from drilling, gear-working, boring and others, and we will use the accepted number of machines in our calculations 43.
The number of machines in auxiliary areas is determined as a percentage of the number of machines in the main production. The following percentages are recommended:
grinding section 3-4%;
repair of equipment 3-4%;
equipment and electrical installations repair area 4-5%.
We accept reasonably relevant figures and calculate the number of machines in the sharpening area.
We accept Szat = 3, since with a small amount it is recommended to take at least three; the number of machines at repair sites is also taken at 3.
The area of the mechanical department is determined according to the specific norms and the number of machines:
where Fпр - production area, m2;
Cп - accepted number of machines, pcs;
fspecific area per machine, m2.
Specific areas for:
small machines f beats = 8-12 m2;
medium machines fud = 18-25 m2;
large machines fud = 30-60 m2.
When repairing cars, we use medium-sized machines and take a specific area per machine of 20 m2.
for the mechanical department, the production area will be equal to
for grinding area m2;
for the tooling repair area m2;
for equipment repair m2;
for electrical repairersm2.
The number of machine operators of the main production is determined by the number of accepted machines:
where Fdr is the actual annual fund of the worker's time, h ..
We take FDR = 1820 hours.
We accept 81 machine operators.
The number of auxiliary workers is determined as a percentage of the number of machine operators.
We accept a coefficient of 0.3, and then a person.
From this number, we single out the number of sharpeners, repairmen, crane operators, quality control department inspectors, storekeepers, etc.
The total number of workers in the machine shop:
From this number, the number of engineering and technical workers, accounting and junior service personnel is calculated as a percentage.
K1 = (0.10-0.12); K2 = (0.05-0.06); K3 = (0.02-0.03).
We accept K1 = 0.10; K2 = 0.05; K3 = 0.02.
Then the number of employees will be:
We accept 11 people.
We accept 6 people.
We accept 3 people.
6. Design of the assembly shop
When performing assembly work, the following types of assembly are distinguished: subassembly, general assembly, intermediate assembly. According to the assembly methods, the following are distinguished: assembly by the method of complete interchangeability, assembly by the method of incomplete or partial interchangeability, selective assembly, assembly using movable and fixed expansion joints, assembly with fitting parts. Organizational forms of assembly distinguish between in-line and non-flow builds. In-line assembly can be carried out on continuously moving, stationary and pulsating conveyors. First, it is necessary to justify the types, methods and organizational forms of repairs by the number of repairs performed and labor intensity, and then to carry out the technological design of assembly areas.
The complexity of assembly work on the assignment is determined by:
where K is a coefficient that takes into account the labor intensity of assembly work.
Substituting the values into the formula, we will have:
The number of assembly stands is determined according to a given labor input using the formula
whereP is the work density coefficient, i.e. the number of workers working at one stand.
Having substantiated that the shop carries out nodal assembly by the method of complete interchangeability for a given repair program in a non-flow form on universal stands, and the number of nodal stands is equal to half of the total number of stands, if two assemblers (P = 2) can work at each stand, we will have the number of nodal stands assemblies
We accept 21 assembly stands.
Similarly, having substantiated the section of the general assembly at a work density of P = 3, we will have the number of stands of the general assembly
We accept 14 stands of general assembly.
The total number of assembly fitters is determined by the labor intensity and the actual annual fund of the worker:
We accept 186 people.
The number of auxiliary workers is taken as a percentage of the number of basic workers. We accept 20%.
We accept = 37 people.
The total number of workers in the assembly shop:
Rob = 186 + 37 = 223 people.
We accept 223 people.
Similar to the machine shop:
We accept 23 people.
We accept 12 people.
We accept 5 people.
The production area of the assembly department is determined by the number of stands or by the number of workers in the largest shift. The number of stands was determined earlier. We substantiate the specific area norms for each stand by the dimensions of the assemblies and products to be assembled. Substituting the values, we will have the production area of the assembly.
Auxiliary area for aggregated calculations can be determined as a percentage of the production area. The standards are 25-30%. We accept a coefficient of 0.3. Then the auxiliary area of the assembly department will be determined:
We accept 181 m2.
The total area of the assembly department will be
Fsb.ob = 602 + 181 = 783.
We accept Fsb.ob = 780 m2.
7. Determination of the number of workers and areas of production sites
The total number of workers in production areas is determined by dividing the annual volume of work in a given area by the actual annual time of the worker.
where Ti is the amount of work on the i-th section, h;
Fd.r. - the actual annual fund of the worker's time, h.
The annual volume of work performed by a specific production site is determined by:
whereKi is the share of the i-th type of work in the total labor intensity of the repair,%;
T is the complexity of repairing one machine, h;
N is the number of cars being repaired per year.
The numbers are taken from the assignment (see tables).
External washing and acceptance area:
Dismantling area:
Digestion area:
number of workers We accept 2 people.
Defect area:
Body section:
number of workers We accept 24 people.
Assembly area:
number of workers We accept 178 people.
Tin department:
number of workers We accept 16 people.
Painting area:
number of workers We accept 6 people.
Woodworking site:
number of workers We accept 2 people.
Wallpaper area:
number of workers We accept 3 people.
Picking area:
number of workers We accept 5 people.
Mechanical section:
number of workers We accept 68 people.
Thermal section:
Kuznetsk site:
number of workers We accept 4 people.
Welding area:
number of workers We accept 14 people.
Metallization area:
number of workers We accept 2 people.
Electroplating section:
number of workers We accept 4 people.
Radiator section:
number of workers We accept 8 people.
Fuel equipment section:
number of workers We accept 16 people
Test section:
number of workers We accept 4 people.
Power equipment repair area:
number of workers We accept 8 people.
Electrical equipment repair area:
number of workers We accept 8 people.
The data is entered into the summary table 3.
Repair sites work in two shifts. We distribute the number of workers by shifts.
In aggregate calculations, the area of production sites is determined by specific rates per worker in the largest shift.
where fi is the specific area per worker, m2.
The data is reflected in the final table 3.
The number of workers and the required areas of the mechanical and assembly shops, determined earlier, must also be entered in the table.
Table No. 3 - The results of calculating the number of workers and areas
|
Site name |
Annual volume of work of TGj, people hour. |
workers, people |
Specific area per worker, fPj, m2 / person |
Land area |
||||
|
In the 1st shift, rj |
||||||||
|
Disassembly |
||||||||
|
Troubleshooting |
||||||||
|
Bodies, frames |
||||||||
|
Zhestyanitsky |
||||||||
|
Painting |
||||||||
|
Woodworking |
||||||||
|
Collecting |
||||||||
|
Mechanical |
||||||||
|
Thermal |
||||||||
|
Metallization |
||||||||
|
Galvanich. |
||||||||
|
Radiator |
||||||||
|
Fuel equipment |
||||||||
|
Trial |
||||||||
|
Repair of power supplies |
||||||||
|
Repair of electrical equipment |
||||||||
8. Determination of warehouse areas
The area of any foreseen warehouse can be determined using the proposed formula:
where G is the annual mass of goods passing through the warehouse, t;
t - stock of products stored in the warehouse, days;
N is the number of working days in a year;
g - permissible floor load density, t / m2;
h is the utilization factor of the warehouse area. Usually 0.3-0.5.
We calculate the areas of the foreseen warehouses one by one, justifying the input values.
We provide the following warehouses:
scrap warehouse;
warehouse for blanks and semi-finished products;
warehouse of finished parts;
warehouse of purchased spare parts;
fuel warehouse.
For calculations, we accept 257 working days a year; permissible load density 2.5 t / m2; the number of days of stock in the warehouse 10 (for serial production); we take the mass of stored goods equal to 10% of the mass of finished products (for each warehouse).
Then the area of the warehouse for blanks and semi-finished products will be
We accept Pzag = 80 m2.
The area of the parts warehouse will be the same.
We accept Pdet = 80 m2.
Warehouse area for spare parts and purchased
We accept Ppok = 80 m2.
The area of the scrap warehouse is taken as Put = 10 m2.
The area of the fuel and lubricants warehouse is 40 m2.
The areas of all other sections are determined by the number of production workers in the largest shift and specific rates.
Adding all the production and auxiliary areas calculated earlier, we get the total area of the building:
Freq = Fmech + Fsb + Fuch + Fcl = 860 + 783 + 4462 + 290 = 6395m2
We accept Fob = 6500m2, which allows us to take the overall dimensions of it 90X72. But it is necessary to use standardized sizes and unified sections of industrial plants. The main sections are 72X72 m or 72X144 m in size. Additional sections are 72X24 m. The grid of columns can be 24X12 or 18X12 m. All sections must be arranged in the order of the production process.
Focusing on the accepted version of the layout of the main building of the ARP, made in work No. 1, we place all workshops and sections in the selected spans, maintaining the order of the production process, ensuring the minimum distances of the transport routes of freight flows. We locate hot shops in a group in one of the aisles, preferably at the outer wall. The test station is located near the assembly shop and next to the engine repair shop. We locate warehouses in several places of the building according to their functional purpose. We envisage auxiliary areas next to the production sites that they serve. The areas of all other premises, not previously determined, are calculated in proportion to the labor intensity or the number of workers working in these areas. After the calculations, a summary table is drawn up.
Household premises are located in a special multi-storey annex to the building. Their areas are determined according to specific rates per worker and the number of workers in the largest shift.
On the layout drawing, it is necessary to number all production and auxiliary areas and draw up an explication indicating the room number, its name, area in square meters and the fire hazard coefficient, show the positions of the columns and indicate their numbering, show the directions of cargo flows, the width of the aisles and aisles, give the length dimensions and the width of the building, as well as the grid of columns.
10. Design of welding and surfacing area
The welding and surfacing section is used to perform welding and surfacing operations when restoring parts.
The parts to be welded and deposited are delivered to the sections from the warehouse of parts awaiting repair or from the mechanical workshop. Welding and surfacing works are performed at specialized (by the type of welding and surfacing) workplaces. At the welding and surfacing section, most parts are restored, including cylinder blocks and heads, crankshafts, camshafts, etc.
According to 4 (p. 480), the approximate distribution of the volume of welding and surfacing works is as follows:
Preparatory work - 10%
Gas welding and cutting - 15%
Manual electric arc welding and surfacing - 20%
Automatic surfacing under a layer of flux - 35%
The number of pieces of equipment is calculated using the formula:
where T is the labor intensity of the 1st overhaul;
N - annual program;
K - coefficient taking into account the labor intensity of the welding and surfacing section according to (4, p. 444, tab. 34.4), K = 0.032
Ф0 - annual fund of working time of the equipment of the welding and surfacing section.
We accept
Distribution of equipment by type of work performed:
Preparatory work - 1 unit.
Gas welding and cutting - 2 units.
Manual electric arc welding and surfacing - 3 units.
Automatic surfacing under a layer of flux - 4 units.
The number of workers on the site with a two-shift operating mode is equal to:
Where Fore = 1860 is the actual annual fund of working time, hours.
We assume that 50% work on the first shift, i.e. 8 people
The area of the site is determined by the formula:
where is the specific average area of one production worker for a given site (1, p. 44). We accept 18m2.
8 people - the number of workers per shift.
One of the features of the arrangement of the equipment of the welding and surfacing section is the rules of technical safety, in accordance with which devices are required to protect workers on the site from the harmful effects arising from welding and surfacing. The distance from the welding table to the wall should be at least 0.8 m, and the distance from the welding transformer to the wall should be 0.2 m. We accept the dimensions of the welding booths 3x3 m. The height of the booth walls must be at least 2 m. In addition, the site provides for general exchange flow-exhaust and local ventilation with suction.
11. Design of the transport system
The efficiency of the enterprise depends on the type of transport system and its quantitative composition. We accept the mode of transport:
By type of storage - rack;
By the type of storage and height - low height;
By the nature of the interaction - dead-end;
By type of mechanization - mechanized.
The vehicles are electric cars, forklifts.
Number of transport units:
Where N is the annual number of transported products;
I - the average number of transport operations (We accept 20);
T - Average duration of one transport operation
(We accept 20 min.);
4030 h - time fund;
N = 2 - the number of simultaneous transport operations.
We accept Стр = 5 pcs.
By the mass of transported products - heavy;
By loading method - without containers;
Transported parts - all types;
Transport systems - discontinuous;
By the type of movement - floor and suspended;
Carts are also provided in the workshops.
12. Energy part
With a large-scale design, the annual consumption of power electricity is calculated by the formula:
Where Nav is the average installed power per machine, kW;
Сn is the number of standard machines;
Фд = 4030 - time fund;
Average load factor over time;
Power demand factor.
Annual consumption:
Where is the cost of one kWh of electricity
f is the specific rate of electricity consumption, W / m2 F is the illuminated area, m2 F is the annual number of devices operation for the middle band of the duration of the devices operation, h is the utilization factor of lighting devices (= 0.75)
Annual electricity cost for lighting:
The annual consumption of compressed air for the pneumatic drive is determined:
Where SC is the number of pneumatic drives, 30% of machine tools; Фд = 4030 - time fund; - load factor; q - specific rate of compressed air for 1 pneumatic drive (1-1.5 m2 / h).
The compressed air supply system is adopted centralized with a common compressor room under the machine shop,
Pressurized water is used for the preparation of emulsions, car wash:
Where q is the specific water consumption l / h; Сn - the number of machines working with cooling.
Taking into account outside consumers, add another 10%.
We get 135m2
Annual steam consumption for heating:
Where qt is the specific heat consumption of 1 cubic meter. building; V - Building volume by external dimensions, m3; Ф - duration of the heating season, h I - heat transfer, kC / kg.
Steam losses during transportation, steam demand by other consumers are compensated by 15% addition:
Wpair shbsch = 28066 + 4210 = 32276m3
Conclusion
As a result of the calculation on the assignment for course design, the following results were obtained:
1. The annual scope of work of ARP Tg = 720,000 hours.
2. The number of production and auxiliary workers 400 people.
3. The total area of production and auxiliary sites 4462 m2
4. The total area of storage facilities Fsc = 290m2
5. Estimated area of the production building ARP m2
In addition, the transport system and the energy part of the ARP have been calculated.
The experience gained in the design of the ARP will be used in the future in the diploma design.
List of used literature
1. Napolsky G.M. “Technological design of motor transport enterprises and service stations”. Textbook for universities. - 2nd ed., Rev. and add. - M .: Transport, 1993. - 271p.
2. Strugalin V.M. “Technological operation of cars”. Study guide for special students. 01.24 - Krasnodar: KutSTU, 1998. - 108p.
3. “Position and maintenance and technical requirements of the rolling stock of road transport”. Part 1 and 2 - M .: Transport, 1998. - 78s.
4. “Technical operation of cars”. Textbook for universities, ed. E.S. Kuznetsova M .: Transport, 1991. - 413p.
5. Melekhin L.F. "Methodological instruction for the implementation of the course project." Study guide for special students. 15.02.00. - Krasnodar, KubGTU, 2003. - 20s.
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Introduction
An auto repair enterprise is a system of industrial buildings and structures, technological equipment and tooling, performers and technical documentation, capable of overhauling cars of one or several brands and (or) their units.
The system of all production facilities of a car repair enterprise constitutes its structure, including workshops, sections and services, as well as connections between them that arise during the operation of the enterprise. The structure of a car repair enterprise determines its throughput, convenience for the client, and, consequently, profitability. This indicates the need for competent design of the structure of the enterprise, taking into account such factors as the number of employees, throughput, types of technological equipment used and services provided.
Currently, there is strong competition in the market for the provision of auto repair services against the background of growing demand, which indicates the need to increase the competitiveness of such enterprises. One of the tools to increase it is the organization of the most optimal and consumer-friendly infrastructure, which would increase the quality and speed of work performed, which is a determining factor when a consumer chooses a supplier of auto repair services.
The production structure of a car repair enterprise is the composition of its productions, workshops, sections and services, indicating the links between them. The purpose, structure, functions and production capacity of a car repair enterprise are determined by the types, content and volume of work performed.
An auto repair enterprise performs many functions related to car repair (diagnostics, repair, washing, adjustment, etc.), as well as a number of auxiliary functions that ensure the operation of the main production. service production, as well as the management department.
1.1
Primary production
The main production is a set of production workshops (sections) with provided with documentation performers and means of technological equipment, which directly affect the repaired products. The main production is also engaged in the release of products for sale or exchange.
)The shop structure is used in large enterprises with more than 500 employees. In this case, the enterprise, depending on its specialization and cooperation with other factories, consists of 3-5 independent workshops with 125-300 people working in each workshop. The shop management structure includes a shop manager, shift supervisors, senior foremen, foremen and foremen. )Workshops consist of sections. Factories employing less than 500 people have only sections headed by senior foremen. )The combined structure is used in enterprises employing at least 500 people, where the operations performed by the shops can be divided into more specific operations that require additional complex special work. A production site is a structural unit of an enterprise or a workshop (depending on the type of enterprise structure, the number of services provided to it and the number of workers) and consists of many jobs. Production sites are designed to perform a separate technological process or a set of work on the repair of individual units. In the first case, the production site is organized according to the technological basis, in the second - according to the subject. The technological specialization of the sites is more progressive than the subject specialization, because The nomenclature of technological processes, the use of which is possible for the repair or diagnostics of units and equipment units, is much larger than the nomenclature of the units themselves. 1.2
Auxiliary production
In the auxiliary production, the means of repair are made, which are necessary in the main production, the acquisition of which is impossible or impractical. This production contains buildings and structures, technological equipment, power systems and engineering networks in good condition. It provides the main production with resources (heat, cold, water, compressed air, clean air, gases, electricity, etc.). His services are the instrumental section, the departments of the chief mechanic and the power engineer, the repair and construction section. 3Service production
Service production provides materials, semi-finished products and services to the main and auxiliary production, controls the execution of orders. The service production includes: )A transport department, the main functions of which are the transportation of necessary goods and equipment within the enterprise, workshops or production sites, as well as monitoring the technical condition of the rolling stock. In its structure, the transport department may have sections (for example, dispatch, vehicle repair, operational, etc.). 2)Supply and sales services, performing operations to provide the necessary materials and equipment for the main and auxiliary production, as well as operations for the disposal of equipment and materials that are unusable or the sale of materials not in demand by production. The main task of the service production is to prevent the interruption of the optimal functioning of the main and auxiliary production due to various reasons: lack of materials and equipment, equipment failure, lack of electricity, water, heat or gas supply, excess production waste or unclaimed materials, interruptions in the receipt of orders, etc. .NS. 1.4Management department
The management of the enterprise consists of the administration, departments and laboratories. The composition and functions of the management department depend on the capacity and specialization of the car repair company. In enterprises with a total number of workers over 500, the following administrative structure takes place: Administration; maintenance service; production departments for various purposes; accounting; canteen; paramedic health center. The production departments are the departments of the chief technologist (OGT) and the chief designer (OGK) (maybe a combined one of them - the technical department), technical control (OTK), material and technical supply (OMTS), economic planning (PEO), financial and sales (FSO), production dispatch (PDO), labor and wages (OTiZ), personnel (OK). The main functions of the factory laboratories: chemical and metallographic analysis of materials, repair and verification of measuring instruments, collection of data on the reliability of the equipment sold, etc. Enterprises with a total number of workers less than 500 people have a smaller number of elements in their administrative structure (there may be no canteen, health center, the number of departments and sections is reduced). The car repair company has a hierarchical structure with functional management, where each functional block is divided into production areas, closely related to each other (often combined), where special work is performed, characteristic of a given functional block (workshop). Each site is characterized by the presence of special equipment that requires competent control by a specialist, due to a specific production task. .1 Main production areas
The main production is closely related to the direct solution of the production problem, repair and production of technological equipment. The activities of the main production are focused on making a profit and achieving the goals of an auto repair company. The main production sites include: )Dismantling and cleaning area: diagnostics of units, external cleaning of vehicles, disassembling them into units, disassembly, cleaning of subassembled units, disassembly of units into assembly units, cleaning of assembly units, disassembly of assembly units, cleaning of parts. The equipment of this section is classified depending on the type of work performed: diagnostic, washing equipment, fixtures and tools for disassembly. Car diagnostics provides for the determination of the main technical indicators of the car using special equipment (Fig. 2.1.): Central diagnostic module Battery tester Installation for checking and cleaning injection nozzles Air conditioning service unit with leak tester Exhaust gas extraction device Electrician Tool Set Stroboscope Fuel pressure tester Compressor and pneumatic vacuum gauge Figure 2.1 Vehicle diagnostics area Washing operations are carried out with the help of special washing equipment: washing platforms (for external car washing), washing installations, blocks and machines for washing small parts and car assemblies. 2)Parts flaw detection area: determination of technical condition and sorting of parts. Fault detection of parts implies instrumental and multi-stage control. In the process of detecting parts, the following control methods are used: · organoleptic examination (external condition of the part, presence of deformations, cracks, scoring, chips, etc.); · instrumental inspection using devices and devices (revealing hidden defects of parts using non-destructive testing tools); · scaleless measures (calibers and levels); · micrometric instruments (rulers, rod-instruments, micrometers, etc.) to assess the size, shape and location of the surfaces of parts. 3)Parts recovery area: welding, surfacing, electrochemical coating, rubber and plastics processing, mechanical, locksmith, forging, thermal, press, restoration of individual parts (housing, shafts, etc.) or their groups. 4)Mednitsky section: repair of water and oil radiators, fuel tanks, oil filters, pipelines, thrust washers, bushings, etc. This section mainly uses welding and surfacing operations. 5) Thermal section: thermal and chemical-thermal processing of workpieces. In the thermal section, metallic or non-metallic materials are heated and held at high temperatures in chemically active media (solid, liquid, gaseous). Chemical-thermal treatment is carried out in order to enrich the surface layers of products with certain elements. They are called saturating elements or saturation components. As a result of this treatment, a diffusion layer is formed.<#"justify">6)Woodworking department: production of wooden blanks, repair of wooden bodies of trucks, packaging containers, repair of backs and seats. On this site, all work related to the processing of wooden parts of the car is carried out. Depending on the capacity of the enterprise, the tire repair section can consist of 3 departments: Washing and drying of wheels; dismantling / mounting of tires; vulcanization department; department of repair and painting of disks. 8)Electrical equipment repair area: checking and repairing electric motors, starters, generators and relays-regulators, repairing headlights, electrical wiring, devices (including electronic), current repair and charging batteries. The operations of this section provide for preliminary thorough diagnostics of electrical equipment with special devices. 9)Fuel equipment repair area: repair of fuel booster pumps, carburetors, injectors, high pressure fuel pumps and injectors. Repair of fuel equipment, as well as repair of electrical equipment, is impossible without diagnostics with special equipment, which determines the continuity of these processes. 10)Locksmith-mechanical department: selection of parts and adjustment of mating surfaces, work on metal-cutting equipment, manufacturing of parts. The locksmith-mechanical department can be equipped with machines and equipment for various purposes, which allows the production of metal products and metal structures. On the site can be placed presses for punching and stamping metal parts, crank shears that allow cutting metal sheets up to 4 mm thick, with a cutting machine, drilling machines of various modifications, turret lathes, sharpening machines. Manufacturing of metal products of increased complexity depends on the qualifications of workers. 11)Unit repair area: performance of work on the repair of individual units. At this site, repairs are being made to units and assemblies that are not related to the scope of activities of the remaining sites. 12)Painting area: surface preparation, application and drying of paint and varnish coatings. )Assembly and assembly area: accumulation of parts, formation and storage of assembly kits of parts, assembly and general assembly of units and vehicles. At this site, final work is underway on the assembly of all repaired units and assemblies and preparation for running tests. )Run-in and test section: refueling with fuel and oil, running-in, testing, post-repair diagnostics, troubleshooting, conservation and delivery of units and vehicles. At this site, final work is being carried out related to checking the quality of all previous work, eliminating all remaining shortcomings and releasing the car into operational mode. .2 Ancillary production sites
The main purpose of auxiliary production is to maintain the uninterrupted functioning of the main production, providing it with the necessary materials and resources. 1)Department of the chief mechanic: scheduled preventive maintenance of technological and handling equipment. This implies the repair and prevention of malfunctions of all technological, as well as lifting and transport equipment, as well as diagnostic and repair tools. This stage of production is necessary to prevent production downtime due to the impossibility of carrying out work due to malfunctioning technological equipment. 2)Tool section: manufacture of equipment, devices and tools, repair of devices, maintenance and sharpening of tools. The instrumental section performs the same functions as the department of the chief mechanic, but for a different group of technological means: tools and fixtures. On this site, it is possible to manufacture the necessary elements of equipment, as well as independent devices. )Department of the Chief Power Engineer: repair and maintenance of power, lighting, heat engineering and ventilation equipment, maintenance of engineering networks, operation of a compressor and boiler room. In this section, the prevention and repair of equipment supporting the operability of power systems, heating and ventilation is carried out, which indicates the inadmissibility of failures in the operation of this section, because this can lead to work stoppages in all other areas of production. 2.3 Service production
) Warehouse of the repair fund: acceptance and storage of the repair fund. The warehouse contains equipment for repair work, spare parts for replacing defective parts and assemblies, and also provides temporary storage of dismantling units during the processes of diagnostics and repair of vehicle assemblies and assemblies. 2) Logistics warehouse: re-entry and incoming inspection of parts, accounting and storage of spare parts, materials, metal, chemicals, cylinders with compressed and liquefied gas, calcium carbide, etc., delivery to the workshop. This warehouse is associated with the direct supply of new consumables, parts and equipment for production. Here, strict accounting and control of materials purchased by production is carried out, as well as accounting for the release of these materials into production. ) Transport area: operation of interdepartmental transport. The activity of the site involves the use of internal production vehicles: carts, lifts, forklifts, etc. Conclusion
Repair is a complex of organizational, technical and technological measures that ensure the reliable operation of vehicles and all rolling stock. For this purpose, specialized repair enterprises are intended for the repair of complete vehicles and units, as well as repair shops of motor transport organizations. A car repair company has a complex interconnected structure. At the same time, each technological section of the enterprise, performing its highly specialized function, maintains the operability of the entire enterprise as a whole, preserving and maintaining its productivity, and, consequently, profitability. This necessitates constant control over the performance of all operations in production, each of which directly or indirectly affects the performance of other operations. Currently, there is an intensive development of auto repair production, which leads to a change in the functions of auto repair enterprises, which become enterprises for the repair of individual vehicle units. This contributes to the development and improvement of special equipment, deepening the special knowledge of specialists of auto repair enterprises, which together has a positive effect on the growth of the quality of work performed at these enterprises. Application
Fig. 1. Scheme of the master plan of a car repair enterprise: 1- administrative building; 2- production building; 3-water tank; 4-10- platforms and warehouses for fuel and lubricants, building materials, scrap, repair fund, timber, metal, finished products; 11- site for acceptance and delivery of cars; 12- car parking Rice. 3.4. Layout of the dismantling and washing area of the enterprise for the repair of power units: 1- overhead conveyor for the delivery of the repair fund; 2- tool cabinet; 3- suspended crane beam; 4- overpass for power units disassembly; 5- overhead conveyor with suspensions for disassembly of units and storage of parts; 6- workbench; 7- roller conveyor; 8- monorail; 9- electric hoist; 10- support for the block of cylinders; 11- washing plant with vibrating platform; 12- installation for cleaning parts in molten salts; 13- installation for flushing channels in cylinder blocks; 14- lifting table; 15- parts washer; 16- parts storage; 17- stand for disassembling cylinder blocks; 18- installation for removing scale from cylinder heads; 19- installation for cleaning parts with stone chips; 20- stand for unscrewing plugs from the crankshaft; 21- overhead conveyor; 22- installation for external washing and steaming of units; 23- installation for washing normals; 24- installation for washing bearings; 25- stand for disassembling gearbox assemblies; 26- stand for disassembling oil pumps; 27- stand for compressor disassembly; 28- stand for disassembling the gearbox cover; 29- stand for disassembling engine components; 30- clutch disassembly stand; 31- installation for washing oil filters; 32 - drying chamber; 33- washing machine for sub-disassembled units; 34- submersible washing machine. Rice. 3 .5. Layout of the power unit assembly area: 1- cylinder block storage (elevator type); 2- conveyor for assembling engines; 3- electric hoist; 4- stand for unscrewing (wrapping) the nuts of the bearing caps; 5- stand for pressing out (pressing) covers; 6- jib crane; 7- hydraulic unit; 8- tilter; 9- press for inserting sleeves; 10- stand for tightening cylinder head nuts; 11- overhead pushing conveyor; 12- overhead conveyor; 13- assembly table; 14 - elevator type storage; 15- rack; 16- stands for repair and testing of lubrication devices; 17- drive; 18- stand for assembling units; 19-stand for assembly and testing of liquid pumps; 20 - stands for the assembly of the connecting rod-piston group; 21- stand for repair and assembly of cylinder heads; 22- roller conveyor; 23- washing machine; 24- chamber for heating cylinder heads; 25- stand for hydraulic testing of cylinder heads; 26- stand for assembling gearbox assemblies; 27- overhead conveyor for assembly of gearboxes; 28- stand for testing gearboxes; 29- monorail.
8 General provisions design of auto repair enterprises
8.1. The current state and the technical and economic significance of the development of auto repair production
The main task facing the automotive and auto refinish industries, is to improve reliability rolling stock of automobile transport.
It prepares customer of the project with direct participation design organization.
The design assignment specifies:
♦ name of the enterprise and type of construction (new or reconstruction);
♦ range of products in physical and value terms;
♦ a system for receiving repair stock and sending finished products;
♦ receipt of spare parts and components by cooperation;
♦ site for the construction of the enterprise;
♦ requirements for waste water discharge, conditions for their treatment and measures for environmental protection;
9) calculation of the areas of production, warehouse and administrative premises;
10) determination of the needs of production shops and sites for energy resources;
11) general layout of the enterprise and a schematic diagram of the organization of production;
12) development of the scheme of the general plan of the ARP;
13) an aggregated calculation of the value of the enterprise;
14) determination of technical and economic indicators of a car repair enterprise.
Basic initial data for the technological calculation, the annual program in the nomenclature and quantitative terms of the repaired objects, the operating mode of the enterprise and the calculation standards are used.
11.2. The structure of the enterprise and methods of organizing the technological process
Primary production includes workshops and sections directly related to the implementation of the technological process of repairing products.
Auxiliary production ensures the normal technical functioning of the main shops and areas of the main production.
Organizationally, the main production of a car repair enterprise can have a workshop or a workshopless structure of construction. With the shop structure all areas of the main production are combined into independent administrative units, formed according to the technological or subject principle, and are headed by the heads of the shops. With a workshopless structure areas of the main production are headed by foremen and are directly subordinate to the management of the enterprise.
Organizationally, the technological process can be carried out or dead end, or in-line method. More progressive is the flow method, which ensures high labor productivity, the quality of repair work, and a decrease in the cost of production.
1. Primary production:
1) dismantling shop, which includes sections: external washing, dismantling of cars and units, washing, control and sorting;
2) an assembly shop with sections: repair of frames, assembly, repair of electrical equipment, tire fitting, general assembly of cars, adjustment and elimination of defects;
3) assembly and assembly shop with sections: repair of main parts and assembly of engines, testing of engines, assembly and testing of units, repair and assembly of power and lubrication system units, painting of the engine and units;
4) body shop with sections: tin-reinforcement, repair of cabins and plumage, woodworking, wallpaper, painting;
5) a workshop for the restoration and manufacture of parts with sections: metalwork and mechanical, forging, welding and metallization, thermal, galvanic, restoration of parts with polymer materials, copper and radiator.
2. Auxiliary production:
1) a tool shop with mechanical fittings and sharpening sections and a tool-distributing storeroom (IRK);
2) the department of the chief mechanic (OGM) with sections: repair and mechanical, electrical, repair and construction;
3) central compressor station.
3. Warehouses with warehouses: cars and units awaiting repair (repair warehouse); finished products; picking; parts awaiting repair (DOR); spare parts and materials; metals; fuels and lubricants; flammable gas and oxygen cylinders; timber; central instrumental (CIS); junk.
11.3. Mode of operation and calculation of annual funds of time for workers, equipment and work posts
Based on the accepted operating mode of the enterprise, the funds of the time of workers, equipment and work posts are determined. Distinguish between nominal Fnr and real Fd p funds of workers' time.
Nominal annual fund takes into account the full calendar working time and is determined by the formula
Valid fund of time takes into account the time actually worked by the worker in hours during the year, taking into account the vacation and losses for valid reasons and is determined by the formula
Nominal annual fund of equipment operation time Phno call the time in hours during which it can work at a given mode:
(11.3)
Actual annual fund of equipment operation time
Fdo takes into account equipment downtime in preventive maintenance and repair and is determined by the formula
(11.4)
Production workers, in turn, are subdivided into workers in main production and workers in auxiliary production.
The number of production workers employed in the main production is calculated for each section, depending on the labor intensity of the work performed on it and the annual funds of time.
Distinguish list PC and safehouse Rya compositions of workers.
For sections, the annual volume of work of which is estimated by the labor intensity, number of production workers(except for machine operators) is determined by the following formulas:
(11.17)
(11.18)
where Ггр is the annual volume of the corresponding type of repair work, man-hours;
Fd r (Fn r) - real (nominal) annual fund of working time, h.
Number of workers in auxiliary production calculated on the basis of the labor intensity of these works and the annual funds of time.
The number of workers in auxiliary production is determined according to the norms.
Number of auxiliary workers when calculating according to aggregated indicators, they are determined as a percentage of the total number of production workers (including workers in auxiliary production): at enterprises for the repair of complete vehicles - 25 ... 35%; at enterprises for the repair of power and other units - 35 ... 40%.
Number of engineers and technicians (Engineers), accounting staff (UPC), junior service personnel (MOP), fire brigade (PSO) determined by the staffing table depending on the category of the enterprise or as a percentage of the number of production and auxiliary workers.
Methodology calculation technological equipment
12.1. Classification of technological equipment ARP
Depending on the destination ARP technological equipment is subdivided into equipment of the main production, designed to perform various operations related to the restoration of repaired products, and auxiliary production equipment, which is designed to perform a variety of work related to the preparation of production.
By place and serial production ARP technological equipment is divided into typical, stipulated by state standards, produced and supplied by the engineering industry in relatively large or small series according to specifications, and non-standardized, which, by virtue of its purpose, differs from standard designs, manufactured individually according to orders or in small batches.
Depending on the range the technological operations performed and the productivity of the ARP equipment is subdivided into:
universal, designed for a variety of work (universal metal-cutting machines, painting booths, welding and surfacing equipment, etc.);
specialized, designed to perform certain 11 operations, for which universal equipment is equipped with special devices;
special, designed to perform a specific techno-iogical operation (machines for grinding crankshaft necks-IOB, regrinding camshaft cams, boring
and honing of cylinder liners, stands for engine testing, balancing of crankshafts and propeller shafts, etc.).
The nature of the work performed, the equipment of the main and auxiliary production is divided into the following groups: dismantling and assembly, metal cutting, forging and pressing, welding and surfacing, thermal, galvanic, equipment for metal spraying, painting, washing and cleaning, control and testing, woodworking, equipment for locksmith, wallpaper and tin works, energy and sanitary engineering.
12.2. Calculation of the number of equipment and work stations of production areas of the main production
12.2.1. Methods calculation quantity equipment
Depending on the method of calculating the annual program and the technical characteristics of the equipment in terms of performance number of equipment calculated by:
♦ annual volume of work, expressed in man-h or machine-h;
♦ physical parameters of the objects of repair (mass and surface area of the restored parts);
♦ duration of technological operations.
12.2.2. Calculation quantity equipment for labor intensity (machine-tool capacity) objects renovation
When using equipment associated with a manual or machine-manual method of work, mainly in disassembly and assembly, bodywork, tin, copper and other areas, the amount of equipment is calculated according to labor intensity work performed according to the formula
(12.1)
where Tgr - the annual volume of a certain type of repair work, man-h;
Fd is the actual annual fund of equipment time, h.
In this case, the time the equipment is busy is equal to the time spent by the worker to perform the technological operation.
At auto repair enterprises with a small-scale type of production, disassembly and assembly, bodywork, copper and other repair work is carried out at posts equipped in accordance with the nature of the technological operations performed with various stands, work benches, tables, etc. number of work posts, not equipped with mechanized equipment, on the site for the implementation of the annual volume of the corresponding repair work is determined by the formula
(12.4)
where RP- the number of workers simultaneously working at one post, people.
12.2.3. Calculation quantity equipment for physical parameters objects renovation
The need for technological equipment, the passport performance of which is determined by the mass of the processed parts (for thermal and heating furnaces, certain types of washing machines, etc.) or the surface area of the coating (for galvanic baths, painting chambers, installations for restoring parts by surfacing and spraying), find by the physical parameters of the objects to be repaired.
The required number of pieces of equipment, calculated from masses repair objects for each type of work are determined by the formula
(12.5)
where Grp is the annual program for this type of processing of parts on the appropriate equipment, kg;
qo - passport capacity of the equipment, kg / h;
Kv - coefficient taking into account the time for loading and unloading products (Kzl =1,03-1,1).
Annual program a certain type of work, expressed by the mass of the processed parts, is determined by the formula
(12.6)
where G, is the mass of the repaired product, kg;
TO - the ratio of the mass of parts subject to a certain type of processing to the mass of the repaired product,%.
12.2.4. Definition quantity technological equipment on duration technological operations
In production areas, the technological operations of which are characterized by the process time (baths for washing and cleaning parts, drying chambers, test benches), the required number of units corresponding equipment is determined by the formula
where fTO is the duration of the technological operation, h;
t3 B- time for loading and unloading products, h;
N- number of items for the annual program, pcs;
NS - the number of products simultaneously placed on one installation;
Kn- coefficient of unevenness, taking into account the irregularity of production (AGN = 1.1 - 1.2).
12.3. Calculation of production lines
The initial value for calculating production lines is rhythm of productionR- the time interval between the release of two products disassembled or assembled on the production line:
(12.18)
where Fdl is the actual annual fund of time of the production line, h;
Nn- annual program for the repair of products (disassembled or assembled on the production line), pcs.
In accordance with the number and complexity of technological operations, as well as taking into account the scope of work, the number of posts on the production line is assigned, the average number of performers at one working post and is calculated production line beat tl, i.e. the time of the product's stay at one post.
For batch line
(12.19)
for continuous conveyor lines
(12.20)
where GL is the annual volume of work performed on the production line, man-h; L: p - the average number of workers at one post of the production line; Z is the number of posts of the production line; tn- time of movement of the repaired product from one post to another, min;
(12.21)
where L- length of the repaired product, m;
but - distance between production line posts, m (a = 1,0...2,5);
VK - conveyor speed, m / min.
If tl> R, then the required number of production lines is calculated:
(12.23)
When designing one line number of postsZ is calculated based on the conditions of equality of the production rhythm and the production line stroke according to the expressions:
for batch line
for line with continuous flow
(12.25)
12.4. Calculation of production areas
The areas of premises of production sites are calculated depending on the stage of design work in two ways: by aggregated indicators (at the stage of feasibility study of the project) and by physical parameters (total area) of equipment (at the stage of development of a technical project).
Production areas by aggregated indicators calculated by one of the following formulas:
where f - specific areas per worker in the most numerous shift, per unit of equipment, per work post, per one major overhaul, respectively;
Ря, х0, хрп, N- the number of workers in the most numerous shift, the number of pieces of equipment, the number of work stations, the number of major repairs, respectively.
The most universal and accessible for the aggregated calculation is the first method, i.e. calculation by specific area per worker.
With a detailed development of a workshop or production site, its area is determined by the floor area occupied by the equipment and the coefficient taking into account the density of the arrangement of the equipment:
(12.32)
where is the total floor area occupied by the equipment, m2;
Ko6 - the coefficient of density of arrangement of equipment.
To determine the value, a list of site equipment is drawn up.
The main production includes workshops, departments and sections directly related to the implementation of the technological process and the release of finished products. The structure of the main production of auto repair production is as follows:
disassembly shop with areas for external washing, disassembly of vehicles and units, cleaning and washing of parts, control and sorting;
assembly shop with sections: picking, electrical repair, battery, tire repair, tire fitting, car assembly, adjustment and elimination of defects;
modular assembly with areas for repair of main parts and assembly of engines, testing station, assembly and testing of units, repair and assembly of units;
workshop for restoration and manufacture of parts with locksmith-mechanical, forging-spring, copper-radiator, thermal, welding, galvanic sections;
body shop with cabins and plumage repair, wallpaper, painting.
Auxiliary and service production is designed to meet the needs of the main production. Structural components of auxiliary and service production:
tool economy;
repair facilities;
transport facilities;
storage facilities;
material and technical support;
energy economy.
Production processes of a car repair enterprise
The production process of repair is the whole set of actions carried out from the moment the objects of repair arrive at the enterprise until the receipt of fully repaired products.
According to their purpose and role in production, the processes are divided into main, auxiliary and service ones.
The main production processes are called, during which there is a direct change in the forms, sizes, properties, internal structure of objects of labor and their transformation into finished products.
Ancillary processes include processes that ensure the uninterrupted flow of the main processes. The auxiliary processes are the processes for the repair of equipment, the manufacture of technological equipment (tools, devices for performing repair work), the generation of steam and compressed air, the production of heat and electricity.
Service processes are labor processes for the provision of services necessary for the implementation of the main and auxiliary production processes. These include the processes of material and technical support of the enterprise, warehouse operations of all types, transportation processes. In order for the capacity of the workshops and sections of the enterprise to be used to the fullest, the production processes must be properly organized in space and time. The organization of the production process in space is expressed in the construction of the production structure of the enterprise and in its planning. The organization of the production process in time involves the establishment of the duration of production, technological, operating cycles.
The complex of the main, auxiliary and service processes, organized in a certain way in time, necessary for the manufacture of a certain type of product, is called the production cycle.
The duration of the production cycle (TC.p) of car repair is the period of time from starting the car for repair to its exit from repair and can be presented in the form:
Shopping mall n = Tts. t nper
where Kper is a coefficient that takes into account the time of breaks Tts. t is the duration of the technological cycle; K lane - coefficient taking into account the break time (0.96);
The technological cycle of a truck repair includes the following set of works:
disassembly of units, assemblies into parts, washing and sorting;
repair of parts;
assembly of units;
testing and adjustment of units;
general vehicle assembly, testing, adjustment and elimination of defects.
The mechanization of technological processes of maintenance and repair of automobiles affects the efficiency of the activities of auto repair enterprises, since the introduction of automation means allows: to reduce the labor intensity and cost of maintenance and repair of automobiles; improve the quality of work performed; reduce the number of maintenance workers; reduce vehicle downtime in the queue for maintenance and repair; increase the operating time of cars; to improve the efficiency of the motor transport enterprise (ATP).
As the results of the analysis of the activities of ATP with different levels of mechanization of maintenance and repair of rolling stock show, the level of provision of these enterprises with technological equipment significantly affects the results of their activities. With the increase in the equipment of car repair enterprises with technological equipment, the required number of repair workers significantly decreases, the coefficient of technical utilization of the car fleet increases sharply (due to the reduction of downtime for repairs and waiting for repairs), which ultimately leads to a decrease in the size of the wage fund and an increase in income enterprises.
Currently, the task of comprehensive mechanization of auto repair production is becoming especially important in connection with the significant growth of the fleet of automotive vehicles. In this regard, it is necessary to determine the most effective directions of mechanization, identify posts and sections of the ATP with the greatest use of manual labor (including heavy and unskilled labor), develop a set of measures to increase the level of mechanization, and choose the best option for technological equipment.
Based on the results of the analysis of the existing ATPs, it is necessary to develop plans for increasing the levels of their mechanization, which will allow to achieve greater efficiency of maintenance and repair of vehicles, reduce the number of repair workers, and increase the useful life of vehicles.
The quality of technological equipment to a large extent affects the level of mechanization of maintenance and repair, labor productivity of repair workers, material and labor costs. Low productivity of equipment leads to an increase in the number of pieces of equipment used, the number of workers; insufficient reliability - frequent downtime of equipment, an increase in labor and material costs for the repair and restoration of equipment. A large material and metal consumption contributes to an increase in the cost of equipment, a low degree of mechanization - to an increase in the share of manual labor. The larger the area occupied by the equipment, the greater the depreciation deductions. Large energy consumption - additional cash costs.
Of great importance for increasing the level of mechanization of maintenance and repair processes is the production capacity (in terms of the number of serviced and repaired vehicles) ATP. The smaller the ATP, the less opportunities for increasing the level of mechanization of maintenance and repair processes, which is due to the lack of funds for comprehensive mechanization, the economic inexpediency of equipping a car repair enterprise with high-performance equipment due to the impossibility of ensuring its full load, limited opportunities for updating technological equipment, lack of prerequisites for creating specialized posts of maintenance and repair, lack of space for the installation of equipment, limited energy resources.
An analysis of the actual availability of mechanization means at car repair enterprises of various capacities shows that the technically possible level of automation of technological processes of maintenance and repair at ATP serving 200,300 and 450 trucks is 28, 33 and 38%, respectively.
One of the measures to increase the level of mechanization of maintenance and repair at auto repair enterprises is the introduction of production lines with mechanization of maintenance, specialized posts with comprehensive mechanization of maintenance and repair, a centralized production control system, mechanized lubrication and refueling stations, etc.
The implementation of comprehensive mechanization of technical maintenance and repair processes at auto repair enterprises is impossible without the introduction of small mechanization means and, first of all, a mechanized tool, the use of which can significantly (from 30 to 60%) reduce the labor intensity of dismantling and assembly works. For example. The use of an automatic line for washing cars reduces the complexity of these works by 7.5 times, the use of an electromechanical lift - 2 times, an electric nutrunner for wheel nuts - 1.5 times, a tire changer for truck wheels - 2 times.
Only by equipping auto repair enterprises with technological equipment can the level of mechanization of maintenance and repairs be increased in comparison with the actual 1.6 ... 1.8 times (for the enterprise as a whole), and for zones TO-1, TO-2, and 1.8 ... 1.9 times, for aggregate, tire fitting and other sections - 1.5 ... 1.6 times, reduce the labor intensity of maintenance and repair of cars by 40 ... 60%, depending on their type, increase the coefficient of technical utilization by 5 ... 7%, free up a large number of production workers.
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