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Modern capabilities of 3D technologies make it possible to present the process of operation of many logistics functions of an enterprise. However, the choice of technology is not always obvious. This article provides a description and analysis of various technological solutions for presenting graphic information. Graphic libraries OpenGL, Direct 3D, JAVA3D and JavaOpenGL are considered. Web technologies for creating three-dimensional scenes are presented, such as Alternativa 3D, Unity 3D, WebGL, VRML. A comparative analysis of the considered technologies has been performed. When comparing technologies, the choice was made in favor of JavaOpenGL as a more flexible and cross-platform visualization solution within the framework of the developed system. The necessary results of interaction of the developed 3D service with the existing system are presented. The choice of visualization tool was made taking into account the criteria of the developed tracking, control, analysis and optimization system for the full production cycle of metallurgical products.

logistics processes

graphic information

visualization

3D technology

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Introduction

At the Department of Information Technologies of the Federal State Autonomous Educational Institution of Higher Professional Education "Ural Federal University named after the first President of Russia B.N. Yeltsin" work is underway on the project: "Development of an automated system for tracking, control, modeling, analysis and optimization of the full cycle of production of metallurgical products (AS VMP) based on the creation and integration mathematical models of technological, logistics and business processes of an enterprise.” Project initiator: I-Teco CJSC (Moscow).

The automated system being developed should include the following functions:

• collection and storage of technological information and quality indicators in relation to the unit of production, time and place of processing;
• visualization of data for a wide range of specialists and managers;
• automatic detection of deviations of parameters from pre-selected criteria;
• statistical tool for analyzing deviations and developing corrective actions to eliminate the causes of deviations;
• analysis of end-to-end technology and development of relationships between technological parameters and product quality parameters in order to adjust the existing technology.

The list of these functions can be implemented using different software, but it is obvious that the process visualization module must be integrated with the data warehouse.

Computer visualization of an enterprise's production processes becomes relevant when production occupies large areas or is geographically divided. In the case of metallurgical production, we have a plant whose production area is more than 10 thousand square meters. m. Obviously, even monitoring the movement of products can cause a problem.

Formulation of the problem

Due to the intensive development of computer graphics, the use of three-dimensional models to solve various scientific and industrial problems has recently become widespread. This list also includes the management of logistics processes. Logistics functions such as warehousing, supply management, inventory and purchasing, transportation management, and optimization of vehicle routes are usually controlled by some kind of modeling system. Graphic display of warehouses, production facilities, and products using 3D visualization will undoubtedly allow you to better navigate in space. The user of the system will have the opportunity to observe the movement of production objects in the same way as in real space, and make management decisions thanks to auxiliary visual tools (Fig. 1).

Rice. 1. 3D visualization of the workshop

To create a 3D graphic service, it is necessary to consider possible tools and technologies that allow you to visualize objects in three-dimensional space. The technology was selected based on the following criteria:

1. Possibility of integrating the visualization module with an existing system.
2. Cross-platform support.
3. Browser support.
4. Visualization performance taking into account the variety of graphic elements used.

In its simplest form, the structure of the system can be represented in the form of a diagram (Fig. 2). VMP AS simulation modeling software places the model design result in a data warehouse (DW) selected by the customer. The data storage can be either a file resource or a relational database. The data warehouse receives information on the execution of enterprise processes. To visualize the model, a three-tier architecture is used on the WEB platform, which allows you to flexibly change and update the model display tools, the simulation data access protocol and the operating algorithm without changing the requirements for client devices.

Rice. 2. Place of the 3D model in the system structure

First, let's look at existing graphics libraries that work with 3D graphics at a low level of abstraction.

Graphics libraries

Open Graphics Library is a graphics standard that supports a low-level programming model and provides extensive capabilities in 3D graphics modeling. It is one of the most popular graphics standards around the world. Programs written using OpenGL can be transferred to almost any platform, while obtaining the same result, be it a graphics station or a supercomputer. OpenGL frees the programmer from writing programs for specific hardware. If the device supports a certain function, then this function is performed in hardware; if not, then the library performs it in software.

The Direct3D graphics library is part of the DirectX API and is a programming interface for 3D graphics output. Direct X is a set of interfaces designed to solve problems associated with programming under the Microsoft Windows operating system. Almost all parts of the DirectX API are collections of COM-compatible objects. One of the most important features of Direct3D is its transparent access to graphics accelerators. If the hardware platform does not support a feature, Direct3D implements its equivalent in software. In addition, Direct3D enables fast software rendering using a complete 3D graphics rendering pipeline.

JavaSoft has implemented 3D capabilities in Java (Java 3D), creating its own library and linking it to standard OpenGL and DirectX tools. But the programming interface for 3D applications in Java is significantly different from OpenGL, approaching that of the high-level OpenInventor library. The library is conventionally divided into a basic part (javax.media.j3d, javax.vecmath) and an auxiliary part (com.sun.j3d.audioengines, com.sun.j3d.loaders, com.sun.j3d.utils). The first serves as the foundation of the Java 3D API, determines its technical capabilities and sets the mechanism for interaction of objects. The second is an add-on implemented using base classes, facilitating the use of the most frequently used operations and expanding the developer's capabilities.

The JavaOpenGL Library (JOGL) is a direct binding of OpenGL functionality to the Java programming language. It is a reference implementation of the JSR-231 specification (JavaBindingstoOpenGL). JOGL gives the programmer access to all the capabilities of the OpenGL API and to two major OpenGL extensions. JOGL differs from other OpenGL shells in that it provides the programmer with the ability to work with the OpenGL API by accessing OpenGL commands through calls to the corresponding methods with the types of arguments familiar to the Java developer. The low level of abstraction of JOGL makes it possible to build programs that are quite efficient in terms of execution speed, but complicates the programming process compared to shells for OpenGL for Java (for example, such as Java3D).

Web technologies for creating three-dimensional scenes

In accordance with the technical requirements and within the framework of the problem being solved, to ensure cross-platform conditions, it is more expedient to consider existing Web technologies for three-dimensional modeling.

VRML (VirtualRealityModellingLanguage) is an open standard developed by ISO (International Organization for Standardization). The first three-dimensional modeling language developed for the Web, it can be classified as a scripting language. The language is designed to describe three-dimensional objects and design 3D worlds. The VRML language allows you to create complex 3D scenes using text commands. These commands describe polygonal objects and special effects to simulate lighting, environments, and to add realism to an image.

Alternativa3D technology is designed to display three-dimensional graphics in the Flash Player environment. The Alternativa3D 8 graphics engine was developed by Alternativa Platform for use in its own projects. The capabilities of Alternativa3D are multifaceted and varied, and applications range from creating fully three-dimensional websites on the Internet to developing multiplayer browser games and projects for social networks in 3D. Visualization occurs through the Direct3D and OpenGL libraries, or the SwiftShader software emulator, which means it can work on all popular operating systems and devices, including PCs, laptops, netbooks and mobile platforms, including Android. Alternativa3D's special binary format reduces the amount of data required to transfer over the network, which speeds up loading the scene into the engine. Models are exported to this format from the 3DSMax package using the appropriate plugin.

WebGL (Web-basedGraphicsLibrary) is a software library for the JavaScript programming language that allows you to create interactive 3D graphics in JavaScript that operate in a wide range of compatible web browsers. By using low-level support for the OpenGL library, some WebGL code can be executed directly on video cards. WebGL is based on the OpenGL API, and with some degree of convention we can say that WebGL is a “binding” of OpenGL for JavaScript. WebGL focuses on the set of capabilities provided by OpenGL ES 2.0, which allows it to be used on a wide range of equipment: both on desktops and on mobile platforms. Like OpenGL, WebGL is a low-level API, and in order to create projects using it directly, you need to have a fairly good understanding of many of the more advanced aspects of 3D graphics. Currently, WebGL is already supported by the Google Chrome, Mozilla Firefox and Opera browsers for Windows, Linux and MacOS, and the Firefox for Android browser. Safari builds for MacOS have the option to enable WebGL support.

Unity 3D is a multi-platform tool for developing 2D and 3D applications running on Windows and OSX operating systems. Applications created with Unity run on Windows, OSX, Android, AppleiOS, Linux operating systems, as well as on Wii, PlayStation 3 and Xbox 360 game consoles.

The Unity game engine is adapted to the development environment, which allows you to render the scene directly in the editor. Import from a large number of formats is supported. Network support is built-in.

Technology Analysis

As a result of the analysis of the technologies considered, a comparative table was compiled (Table 1). The table shows that only Web technologies and the JOGL library satisfy all the criteria.

Table 1. Comparison of technologies

Development Tool	Work under Windows OS	Work under Linux OS	Web support	Integrated Development Environment	Mobile platform support
				All programming languages
				Editor Unity3D, C#, JavaScript, Boo
				VRML editor

In development tools such as OpenGL ES (OpenGL for Embedded Systems) and Direct3D, there is support for Mobile platforms, but they are not taken into account in the table, since they are subsets and varieties of OpenGL and Direct 3D.

Research work on 3D modeling technologies was carried out with the goal of finding the most suitable tool for three-dimensional visualization of production and logistics processes of a metallurgical enterprise.

As a result, graphics libraries OpenGL and Direct 3D, JAVA 3D and Java OpenGL were considered. When comparing these libraries, the choice was made in favor of Java OpenGL as a more flexible and cross-platform visualization solution within the framework of the developed system.

The use of the high-level language JAVA for developing a simulation modeling tool and the availability of high-quality implementation of three-dimensional visualization tools in JAVA give reasons for choosing this language as the main tool for developing a visualization module for the Linux OS.

In accordance with the technical requirements and within the framework of the problem being solved, to ensure cross-platform conditions, it was concluded that it is advisable to consider Web technologies for three-dimensional modeling. Analysis of Web technologies for creating three-dimensional scenes Alternativa3D, Unity 3D, WebGL and VRML showed that the use of ready-made engines (for example, Unity 3D) also has prospects for integration with the developed AS VMP modules. Particularly noteworthy is the WebGL visualization technology, which is supported by most modern browsers: GoogleChrome, Opera, Mozilla.

The work was performed under contract No. 02.G25.31.0055 (project 2012-218-03-167).

Reviewers:

Shabunin S.N., Doctor of Technical Sciences, Professor, Department of High-Frequency Radio Communications and Television, Federal State Autonomous Educational Institution of Higher Professional Education "Ural Federal University named after. the first President of Russia B.N. Yeltsin", Yekaterinburg.

Dorosinsky L.G., Doctor of Technical Sciences, Professor, Head of the Department of Information Technologies, Ural Federal University. the first President of Russia B.N. Yeltsin", Yekaterinburg.

Bibliographic link

Dmitriev I.L., Papulovskaya N.V., Aksenov K.A., Kamelsky V.D. 3D VISUALIZATION OF PRODUCTION AND LOGISTICS PROCESSES: CHOICE OF DEVELOPMENT TOOL // Modern problems of science and education. – 2014. – No. 2.;
URL: http://science-education.ru/ru/article/view?id=12657 (access date: 02/03/2020). We bring to your attention magazines published by the publishing house "Academy of Natural Sciences"

We thank the editors of the newspaper "Tutaevsky Motor Builder" for providing this material.

What is special about SFM?

Visualization of management processes through a system of information centers is a distinctive feature of SFM, or Shopfloor Management, which translated means “management from the place of value creation.” Shopfloor is a “gemba”, a workshop or simply the place where value is created in an enterprise. Management means management system.

Each organization chooses the most suitable management system and adapts it to its specifics and its own leadership style: project management, process approach, management by objectives, and so on. Each management system sets priorities differently, organizes planning, focuses on different aspects of the enterprise’s activities, forms different groups of indicators and, in general, achieves results in different ways. What is special about SFM?

This is not a set of tools, not a set of recommendations, this is a new philosophy of enterprise management. The goal of SFM can be formulated as constantly ensuring the efficiency of processes by identifying and eliminating losses, achieving the proper state of the enterprise according to standardized indicators (safety, quality, process flow, costs, corporate culture, personnel involvement, and so on).

Difference from traditional control systems

The main difference between SFM and traditional control systems is that O Each manager spends most of his time where value is created - in core production. This allows you to quickly make informed and effective decisions. Having up-to-date information about the progress of the main process, you can easily predict the development of events, prevent problems and prevent their occurrence, and eliminate the causes of possible failures in advance. In addition, this style of work makes it easier to control the execution of orders: the result is clearly visible and does not require additional reporting.

The SFM system assumes complete standardization of the roles and responsibilities of each participant in the process, rhythmic measurements of process parameters: production volume, product quality, staff training status and others, constant comparison of work results with the goals of the enterprise and prompt corrective actions. The more accurately roles and responsibilities are standardized, the better each employee knows what, when, how and in what situation he must perform. Moreover, responsibility is transferred from the bottom up, and one of the main roles of a manager is to help subordinates solve problems, that is, the closer an employee is to the place where value is created, the more valuable his time becomes and the simpler his responsibility should be.

To maintain standard roles and responsibilities, the enterprise uses a single work routine, which includes all the repeated actions of managers at all levels of management during the week: meetings, rounds, reports, work in specialized groups, project activities, monitoring the execution of orders, and so on. The advantage of organizing work according to a single routine within the framework of SFM is that each manager always receives the most up-to-date information, and each employee during the shift learns about the decisions made by the manager and begins to implement them.

Visualization of the management process

An integral part of SFM is the visualization of the management process through a system of information centers located directly in production. Sometimes more time is spent on making and formalizing decisions than on their implementation: it is necessary not only to clearly present the information, but also to agree on it with all interested parties - this always takes time. In SFM, visualization capabilities are used as widely as possible: information is presented in the form of graphs and diagrams, the set of information is carefully standardized, and the volume is limited to what is necessary. This makes it possible to quickly understand and assess the state of processes, identify problems and eliminate the causes of their occurrence. The performance indicators of the department become transparent, the content of meetings is standardized: searching for deviations and solving problems, implementing the “Come and See” principle in process management - meeting participants discuss reliable information in real time.

The availability of up-to-date information brings the team together, the manager has the opportunity to assign duties, powers and responsibilities to performers. To speed up decision-making, the goals of the enterprise are expressed through key process performance indicators - KPIs, by visualizing which, at any time you can assess how close the enterprise has come to the set goal.

Potential for improvement

By making performance indicators transparent, SFM gives the manager the opportunity to quickly respond to problems that arise (we must not forget that problems are a colossal potential for improvement, and the sooner we see them, the sooner we realize this potential), establish ongoing feedback with employees, without distortions promptly transmit and receive up-to-date information. Openness of management in itself already makes the enterprise personnel involved in decision-making, motivates them and involves them in work to improve processes. SFM, by focusing personnel's attention on the place and process of value creation, relieves both managers and employees from unnecessary and ineffective actions.

At our enterprise we are just beginning to master this management system. The main challenge is to apply SFM tools and techniques to each production site.

Lean manufacturing

The concept of Lean Manufacturing is based on the Toyota production system, known by the abbreviation TPS (Toyota Production System). After the Second World War, Toyota used the principle of “flow production” proposed by Henry Ford and supplemented it with many ideas, tools and methods from the field of quality and logistics , production planning, motivation and leadership. As a result, despite the shortage of labor and financial resources, Toyota was able to offer higher quality products at a lower cost than its competitors.1. Muda losses. To increase the value added during the production process, the following types of losses are distinguished. Muda - "waste" - everything that wastes resources, but does not add value. Lean manufacturing identifies seven types of muda:

• · Overproduction (producing items that no one wants; producing more of a product earlier or faster than what is needed in the next step in the process).
• · Inventories (any excess supply of products into the production process, be it raw materials, semi-finished products or finished products)
• · Overprocessing (effort that does not add value to the product/service from the consumer's point of view)
• Waste movement (any movement of people, tools or equipment that does not add value to the final product or service)
• · Defects and rejects (products requiring inspection, sorting, disposal, downgrading, replacement or repair).
• · Waiting (interruptions in work associated with waiting for people, materials, equipment or information)
• · Transportation (transportation of parts or materials within the enterprise)
• 2. Pull-line production. Pull production is a production organization scheme in which production volumes at each production stage are determined solely by the needs of subsequent stages (ultimately by the needs of the customer). The ideal is a “single piece flow,” i.e., the upstream supplier (or internal supplier) produces nothing until the downstream consumer (or internal customer) will not inform him about this. Thus, each subsequent operation “pulls” products from the previous one. This way of organizing work is also closely related to line balancing and flow synchronization.3. KANBAN is a Japanese word meaning "signal" or "card". This system is based on the Just-in-Time system - delivery of the required products in the required quantity at the required time - serves for operational production management. The essence of the system is that all production areas of the enterprise, including final assembly lines, are supplied strictly on schedule with exactly the amount of raw materials that is really necessary for the rhythmic production of a precisely defined volume of products. The means for transmitting an order for the delivery of a certain number of specific products is a signal label in the form of a special card in a plastic envelope. In this case, selection cards and a production order card are used.
• 4. The 5C system is a technology for creating an effective workplace. Under this designation the system of establishing order, cleanliness and strengthening discipline is known. The 5C system includes five interrelated principles for organizing the workplace. The Japanese name for each of these principles begins with the letter "S". Translated into Russian - sorting, rational arrangement, cleaning, standardization, improvement. Principles:
• 1. SORTING: separate necessary items - tools, parts, materials, documents - from unnecessary ones in order to remove the latter.
• 2. RATIONAL ARRANGEMENT: rationally arrange what is left, place each item in its place.
• 3. CLEANING: Maintain cleanliness and order.
• 4. STANDARDIZATION: Maintain accuracy by regularly performing the first three S's.
• 5. IMPROVEMENT: making established procedures a habit and improving them. (to table of contents)
• 5. Quick changeover (SMED -- Single Minute Exchange of Die) SMED literally translates as “Die change in 1 minute.” The concept was developed by Japanese author Shigeo Shingo and revolutionized changeover and retooling approaches. As a result of the implementation of the SMED system, changing any tool and readjusting can be done in just a few minutes or even seconds, “with one touch” (“OTED” concept - “One Touch Exchange of Dies”). As a result of numerous statistical studies, it was found that the time for carrying out various operations during the changeover process is distributed as follows: preparation of materials, dies, fixtures, etc. - 30% securing and removing dies and tools - 5% centering and placement of tools -- 15% trial processing and adjustment -- 50%. As a result, the following principles were formulated to reduce changeover time by tens and even hundreds of times: separation of internal and external adjustment operations, transformation of internal actions into external ones, use of functional clamps or complete elimination fasteners, use of additional devices..
• 6. TPM (Total Productive Maintenance) system - Total maintenance of equipment, mainly serves to improve the quality of equipment, focused on maximum efficient use thanks to a comprehensive preventive maintenance system. The emphasis of this system is on prevention and early detection of equipment defects that can lead to more serious problems. TRM involves operators and repairmen, who together ensure increased equipment reliability. The basis of TPM is the establishment of a schedule for preventive maintenance, lubrication, cleaning and general inspection. This ensures an increase in such an indicator as Overall Equipment Effectiveness (OEE).
• 7. JIT system (Just-In-Time - exactly on time). It is a materials management system in manufacturing in which components from a previous operation (or from an external supplier) are delivered exactly when they are needed, but not before. This system leads to a sharp reduction in the volume of work in progress, materials and finished products in warehouses. A just-in-time system involves a specific approach to selecting and evaluating suppliers, based on working with a narrow range of suppliers selected for their ability to guarantee just-in-time delivery of high-quality components. At the same time, the number of suppliers is reduced by two or more times, and long-term economic relations are established with the remaining suppliers.8. Visualization is any means of communicating how work should be done. This is such an arrangement of tools, parts, containers and other indicators of the state of production, in which everyone at first glance can understand the state of the system - the norm or deviation. The most commonly used imaging methods are:
  • Contouring
  • · Color coding
  • Road sign method
  • · Paint marking
  • “it was - it became”
  • · Graphic work instructions

Outlining is a good way to show where tools and assembly fixtures should be stored. To delineate means to outline the assembly fixtures and tools where they are to be permanently stored. When you want to return the tool to its place, the outline will show you where to store this tool.

Color coding indicates what specific parts, tools, fixtures and molds are used for. For example, if some parts are needed in the production of a particular product, they can be painted the same color and be stored in a storage area painted the same color.

The road sign method uses the principle of indicating objects in front of you (WHAT, WHERE and in what QUANTITY). There are three main types of such signs: pointers on objects, indicating where objects should be; signs in places indicating exactly what items should be there; quantity indicators that tell you how many items should be in a location.

Paint marking is a technique used to highlight the location of something on the floor or in aisles. .Paint markings are used to mark dividing lines between work areas or transport passages.

“It was” - “It became.” The image of the workplace/area/shop “before” and “after” the changes clearly demonstrates the changes that have occurred, increases the motivation of workers and supports the new standard. Graphic work instructions describe work operations and quality requirements at each workplace in as simple and visual a form as possible. Graphic work instructions are located directly at the workplace and standardize the optimal way to perform work, ensuring universalization of workers and compliance with standards. 9. U-shaped cells. The arrangement of the equipment is in the shape of the Latin letter “U”. In a U-shaped cell, the machines are arranged in a horseshoe shape according to the sequence of operations. With this equipment arrangement, the final processing stage occurs in close proximity to the initial stage, so the operator does not have to walk far to begin the next production cycle.

Table. 3 The general model of a production system built on Lean principles is shown in the figure

§ High quality. § Low costs. § Minimum order fulfillment time. Delivery guarantee. § High morale and safety levels due to reduced production flow by eliminating waste.
equipment management Autonomous service	Thread management Alignment Pull Fast changeover	People and teamwork Selection and general goals Staff involvement and delegation of authority Related professions Problem solving is ongoing. committed "Why" - root causes	Quality control Built-in quality in the workplace Automatic stop Release man from machine Warning errors (“Bye-eke”)	Service management Flexible work teams Process Improvement Self-organization Office productivity management

VISUALIZATION - arrangement of all tools, parts, production steps and information about the performance of the production system in such a way that they are easily visible and so that anyone involved in the production process can assess the status of the system at a glance.

TRM - (total equipment care) A set of methods aimed at ensuring that each machine involved in the production process is constantly ready to perform the necessary operations.
PULL PRODUCTION - A method of production management in which subsequent operations signal their needs to previous operations. Pull manufacturing aims to prevent overproduction and serves as one of the three most important components of a just-in-time production system.
KAIZEN - Continuous improvement of the entire value stream as a whole or a separate process in order to increase value and reduce waste.
KANBAN - a means of information with the help of which permission or instructions are given for the production or withdrawal (transfer) of products in the pull system. Translated from Japanese it means “tag” or “badge”.

Some areas suffer from excess moisture, others from lack. Areas located along the Northern and Southern tropics, where temperatures are high and the need for precipitation is especially great, receive especially little precipitation. Vast areas of the globe, which have a large amount of heat, are not used in agriculture due to lack of moisture. How can we explain the uneven distribution of precipitation? The main reason is the placement of low and high pressure belts. Distribution of atmospheric pressure belts on Earth. On the Earth's surface there are three belts with a predominance of low pressure and four belts with a predominance of high pressure (see Fig. 16). Atmospheric pressure belts are formed as a result of the uneven distribution of solar heat on the earth's surface, as well as the influence of the deflecting force of the Earth's rotation around its axis. Air moves not only horizontally, but also vertically. Strongly heated air near the equator expands, becomes lighter and therefore rises, i.e., upward movement of air occurs. In this regard, low pressure forms at the Earth's surface near the equator. At the poles, due to low temperatures, the air cools, becomes heavier and sinks, i.e., downward air movement occurs (see Fig. 17). In this regard, the pressure at the Earth's surface near the poles is high. Rice. 17. Pattern of air movement In the upper atmosphere, on the contrary, above the equatorial region, where upward air movement predominates, the pressure is high (although it is lower than at the Earth’s surface), and above the poles it is low. Air constantly moves from areas of high pressure to areas of low pressure. Therefore, the air rising above the equator spreads towards the poles. But due to the rotation of the Earth around its axis, the moving air gradually deviates to the east and does not reach the poles. As it cools, it becomes heavier and sinks to about 30°. At the same time, it forms areas of high pressure in both hemispheres. Over the thirtieth latitude, as well as over the poles, downward air currents predominate. Now let’s look at the relationship between pressure belts and precipitation. Thus, near the equator, in a low-pressure zone, constantly heated air contains a lot of moisture. As it rises, it cools and becomes saturated. Therefore, many clouds form in the equator region and heavy precipitation occurs (see Fig. 17). A lot of precipitation also falls in other areas of the earth's surface where pressure is low. In high-pressure belts, downward air currents predominate. Cold air, as it descends, contains little moisture. When lowered, it contracts and heats up, due to which it moves away from the state of saturation and becomes drier. Therefore, in areas of high pressure over the tropics and near the poles, little precipitation falls (see Fig. 17).

Albert Sadykov - on the effectiveness of simple decisions in business

Many of the problems faced by small business entrepreneurs are similar. And often someone else’s useful experience in solving certain problems can be applied in your company, even though you work in a different niche, with a different business model and for a different audience. We regularly publish opinion columns from practicing entrepreneurs who share their experience in solving specific problems. And our guest today is crisis manager from Perm Albert Sadykov.

Entrepreneur from Perm, crisis manager, managing partner of the professional expert community Experteam, project participant "Raking - practical tools for business survival". Education: Faculty of Physics, Perm State University. He organized his first business at the age of 15 (1992).

...Once I was invited to a construction company to create a new division - a workshop for the production of building metal structures. I brought the workshop to a fully operational state in six months, but the problems inherent in enterprises of this kind could not be completely eradicated - issues with product quality still arose periodically.

I decided to go the standard and repeatedly tested route.

I introduced a system of penalties - it helped, but not much.

I entered a product route map - all operations with a specific product were noted there, the time it took to complete the manufacturing stages, and the names of the workers involved. This led to a noticeable reduction in defects - about 30%, but also led to an increase in the number of papers... However, papers turned out to be important not only in matters of improving quality, but also in interaction with the client - the product quality certificate was tied to this route sheet, the production process became very “transparent”, and the customers really liked it. But the marriage rate still didn’t suit me.

I decided on a kind of experiment - I relieved the process engineer of his duties for one week, and made him a quality control inspector - I decided to see the performance of such a unit in action, especially since the engineer had experience in such work. “At the exit” I received an even larger mountain of papers and an even lower percentage of defects.

But this was not enough for me, although in many other companies they definitely stopped at this stage, and the detected defect was redone right on the construction site, because it was there that the defect was most often discovered - and daylight lighting is better than the workshop one, and the products are joined “live.”

Oh, I'm tired of all this...

Then I decided to take a non-standard path for such productions. I assembled the workshop and explained the following:

if a defect is discovered, the customer “doesn’t care” who exactly caused the defect – the defective product still remains defective;

if a defect is discovered, the customer does not pay money to the entire company, and not just to the one who caused the defect;

I can hire a staff of inspectors, but only by reducing the wage fund of shop workers.

Therefore, I said, in three days the following rules will come into force:

if a defect is discovered before the product leaves the workshop, all workers who were involved in this product are punished - the cost of the “redistribution” is deducted from their salary;

if a defect is discovered at a construction site, the damage is compensated by all employees of the department, including engineers (3 people per 50 workers) in double amount, since this negatively affects the company’s reputation;

I will not hire additional controllers, and I will return the process engineer to his duties.

He issued a simple recommendation: before accepting a product for work from previous contractors, the next contractor must check it for quality and compliance with the drawings. If the defect is detected on time, no sanctions will be applied, but the information should be recorded for statistics.

There was no limit to the indignation, but where to go - everyone went to work.

Three days later, the issue with the marriage was completely resolved - the workers turned out to be excellent controllers when they realized that “everyone is in the same boat”, and that for the “jamb” of one person, everyone else would suffer financially.

Eventually:

It was: the percentage of defects in terms of products was about 10%.

Now: defect rate – 0%.

“The moral of this story is this”: do not complicate the system, but simplify it, use common sense and the hidden capabilities of the team. The simpler the system, the more reliable it is.