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Organization of production - Kurochkin A.S.

6.4. Organization of technical control in the enterprise

Technical control of product quality

One of the main elements of the system of rhythmic and defect-free operation of production is the control of product quality. This is the most important component of technical control at the enterprise.

Technical control - a component of any production process, carried out at all its stages - from the receipt of raw materials, fuel, semi-finished products, components to the release of finished products.

All materials, raw materials, semi-finished products, components received by the company from outside, details at all stages of processing, assemblies and products at various stages of assembly, all means of labor, including equipment, tools, devices, technological processes and their modes, are subject to technical control, and Also the state of the culture of production, temperature, humidity in the shops, and so on.

Technical control means checking compliance with the requirements for the quality of the product at all stages of its production, and all production conditions and factors that ensure the required quality.

Technical control is designed to ensure the production of products that meet the requirements of design and technological documentation, to facilitate the production of products with the least expenditure of time and money, to provide raw data and materials that can be used to develop measures to improve product quality and reduce costs.

Technical control is a complex of interrelated and conducted in accordance with the established procedure of control operations. The vast majority of control operations are an integral and indispensable part of the production process and therefore are assigned to the workers performing the corresponding production operation.

At the same time, in order to ensure the production of proper quality and to prevent losses in production, individual control operations are performed by commissioners, foremen, masters and special personnel - workers of the factory department of technical control (OTK).

The department of technical control is an independent structural subdivision of the enterprise. Its main functions include:

• control of incoming to the enterprise from suppliers of labor - raw materials, materials, semi-finished products, components;

• control over the state of means of labor - equipment, tools, tools;

• control over the implementation of the technological process at all stages of product manufacturing;

• control over the quality of products;

• Prevention, identification and recording of marriage;

• determining the causes of marriage;

• monitoring the implementation of measures to eliminate marriage, complaints and improve product quality.

The products manufactured by the enterprise are supplied to the consumer only after it is accepted by the OCT and formalized by a special document confirming the conformity of the product with normative documents: State Standards (DSTU), TU, etc.

The head of the OTK is directly subordinate to the general director (director) of the enterprise. OTK employees are subordinate only to its chief.

Depending on the size of the enterprise, the OTK device consists of the following bureaus, groups or individual performers:

• control of incoming materials, semi-finished products, components, tools;

• technical control in production units;

• control of the instruments of production;

• testing and delivery of finished products;

• on accounting and analysis of marriage and claims;

• inspectors and others.

The technical control shop is headed by the chief or senior control master. The Bureau consists of replaceable control masters and their subordinate controllers.

It is very difficult to determine the number of controllers, since it is difficult to determine the complexity of control works because of their wide variety and many factors that influence the norms.

Widely used in domestic enterprises, the system of defect-free manufacturing of products and delivery from the first presentation significantly changes the functions of controllers and reduces them to final control and acceptance of products, stamping the products, determining the causes and sizes of the marriage, processing documentation for the acceptance and accounting of good and defective products.

The standards of service for controllers in various production conditions are varied and are determined, as a rule, by experience in each enterprise.

Types and objects of technical control

Depending on the tasks facing the TCI, a type of technical control is determined

Control, which primarily differs by objects of control:

• the objects of labor - raw materials, materials, semi-finished products, etc .;

• means of production - equipment and technical equipment;

• technological production processes;

• working conditions.

Technical control is also different for the purpose:

• input - checking the compliance of incoming raw materials, materials, semi-finished products and components to the requirements specified in the purchase orders;

• preliminary - checking the quality of raw materials, materials, semi-finished products and components before starting their start-up in the production process, i.e. before starting their processing or arriving at the assembly;

• intermediate - is carried out in the process of manufacturing a part, a unit for individual operations. This type of control can be operational, when the verification is performed after each operation, and group, if the check is performed after a group of (several) operations;

• final - is carried out at acceptance of finished products and is accompanied by special tests.

Control varies in coverage:

• continuous, when all objects of control of one name are checked without exception;

• selective, when only part of a batch of homogeneous articles is inspected. Statistical methods of control are used.

There is a different control and, if possible, further use of the object:

• destructive, when after an inspection test the object breaks down;

• non-destructive, carried out with the help of magnetic, acoustic, optical and other methods.

In the place where control operations are performed, this control varies:

• stationary - is carried out on a specially equipped permanent workplace of the controller, where the objects of control are supplied; As a rule, it is used when checking a large number of homogeneous objects of control;

• mobile - is carried out at the workplace where control operations are performed; It is used to check bulky, heavy and non-transportable objects of control.

A special place in the system of technical control is self-monitoring, carried out directly by the executor. For the first time self-control was carried out Lviv SBT. After that, entire brigades and sections began to pass to self-control. And at the Lviv Telegraphic Equipment Plant in 1977, a whole shop worked on self-control. The right to work on self-control of the plant's OTK is given when the worker permanently surrenders the products for the longest time from the first presentation. In this case, the worker receives a personal brand, which marks the personal products produced.

Means of technical control

Depending on the characteristics of the monitored parameters, the following controls are different:

• geometric shapes and sizes;

• physical-mechanical, chemical and other properties of materials and semi-finished products;

• Internal product marriages (shells, cracks, etc.);

• technological properties of materials, etc.

Depending on the monitored parameters, various instrumentation instruments (KPI), instruments and apparatus are used, which are combined into one concept - control means. The latter, in turn, are divided into two large groups:

• determining absolute values ​​of controlled values ​​- calipers, manometers, scales, etc .;

• defining only the limits of controlled quantities, which allows you to sort objects by quality groups - control and sorting devices with two limiting values ​​of the measured quantities (largest and smallest, calibers, plugs, etc.).

According to the principle of operation, the means of control are subdivided into mechanical, electrical, chemical, optical, etc.

By the nature of the impact on the course of the technological process, the following control means are distinguished:

• passive - are used to assess the quality of products after performing the appropriate technological operation;

• active - control the necessary parameters during the process. Upon reaching the specified critical parameters of the monitored object, the equipment automatically stops. These tools include indicators, automatic sub-assistants, and others.

Metrological assurance of product quality

Metrological quality assurance is aimed at the timely implementation in full of measures to achieve unity and the required accuracy of measurements of the parameters of products, materials and raw materials, modes of technological processes, characteristics of equipment and tools.

Metrology is the scientific basis of measuring technology, the science of measurements. It is engaged in the creation and improvement of the theoretical foundations of measurement technology and, first of all, the general theory of measurements, the system of units of measurement, standards from model measuring instruments; The development of scientific bases for the unity of measures and measurements in the country; Creation of standard and reference data and standard samples.

Metrological support is carried out in accordance with the requirements of regulatory documents, State standards (State system for ensuring the uniformity of measurements (ICG)) and the company's standards for metrological support of business units and services under the guidance and with direct participation in the metrological service of the enterprise.

Metrological support is provided by the metrological service of the enterprise - the department of the chief metrologist.

The main tasks of the enterprise on metrological support are the following:

• analysis of the state of measurements at the enterprise, development on its basis of measures to improve metrological support;

• Establishment of rational nomenclature of measured parameters and optimal standards of measurement accuracy at the enterprise;

• Creation and implementation of modern methods for performing measurements and measuring instruments, establishing a rational nomenclature of the instruments used and verification equipment;

• Implementation of state standards, development and implementation of enterprise standards, regulations for accuracy, measurement, measurement techniques and other provisions for metrological support for design, production, testing and consumption (operation) of products in the enterprise;

• metrological examination of projects and current design, technological and other normative and technical documentation;

• verification and metrological certification of measuring instruments used in the enterprise; Attestation of measurement techniques;

• control over the manufacture, condition, use and repair of measuring instruments and the observance of metrological rules, requirements and norms.

The State Committee for Standardization, Metrology and Certification (State Committee for Standardization of Ukraine) is responsible for state supervision of the state and use of measuring instruments, observance of metrological rules, and the work of metrological services. It is entrusted with ensuring the unity and reliability of measurements in the country, strengthening and developing state metrology and reference base, creating new and improving existing methods and measuring instruments of high accuracy.

The structure of the State Standard of Ukraine includes the republican center of metrological service, which develops scientific and methodological, technical and economic, organizational and legal bases for metrological support of the national economy of the country; Regional (interregional) laboratories of state supervision of standards and measuring equipment.

Accounting and analysis of marriage

Products manufactured with deviations from standards and specifications are considered defective or defective. If the defect is correctable and it is technically possible and economically feasible, the marriage is considered to be recoverable. If the correction is inappropriate, then the marriage is final, subject to disposal as waste products.

Depending on the place of detection, the marriage is different:

• internal, when it is detected inside the enterprise;

• external, when it is detected by the consumer and the enterprise has received a complaint about poor-quality products.

In identifying the causes and perpetrators of marriage, the creation of classifiers at the enterprise (Table 31) is of great help, where the most common causes of marriage and possible culprits are indicated.

Table 31

EXAMPLE OF CLASSIFIER OF REASONS OF MARRIAGE

For every case of marriage, an act is signed by the controller, the workshop master and the control master. The presence of defective parts is noted in the work order and the shift report, and the loss from marriage is attributed to the culprit.

An unrecoverable marriage must necessarily enter a marriage isolator. The department of technical control together with the shop control services keeps records of the marriage, analyzes its causes and develops measures to improve the quality of products, improve the technology of its production, and so on.

The work of the divisions and the enterprise for quality improvement is assessed according to the following indicators:

• availability of complaints;

• the percentage of products surrendered from the first presentation;

• Specific weight of losses from marriage in the actual cost of sold products.

For a more in-depth analysis of the causes of marriage, its cost and other purposes, 31 are supplemented with quantitative indicators of defects, their specific gravity, etc. Then, using the methods of economic statistics, the resulting aggregate is examined by the grouping method. With the help of this method, the structure of the aggregate is defined, the actions of some factors on others, and so on.

After ranking the factors of marriage (causes), graphical diagrams are constructed, which in a convenient and visual form allow us to estimate the loss from marriage, depending on the reasons for its appearance.