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Production cycle. The structure of the production cycle of the enterprise

Production cycle. The structure of the production cycle of the enterprise

11.10.2019

The production cycle is a complete sequence of production operations, as a result of which the transformation of raw materials into finished products occurs.
The production cycle takes place in space and time, so it can be characterized by two parameters: the length of the production cycle and the duration of the production cycle.
The length of the production cycle is the distance of movement of the product from the very first to the last workplace. It can be measured in meters, but it is more logical to measure the length of the production cycle in square meters, since the production cycle is not a line, but an area where jobs and equipment are located.
The duration of the production cycle is the time interval between the first and last production operations performed on one product. It is measured in days, hours, minutes, seconds.
The duration of the production cycle includes three stages: the time of technological processing of the product (working period); time of technological maintenance of production; break time at work.
The total duration of the production cycle Tc can be determined as follows:
(35)
where Tr is the time of technological processing of the product, h; To - the time of technological maintenance of production, h; Tp is the time of breaks in work, h.
The time of technological processing of a product (working period) is a period of time during which a direct impact on the object of labor is made by the worker himself or by machines under his control, as well as the time of natural (flowing without the participation of a person or technology) technological processes.
The time of technological maintenance of production includes quality control of the product, adjustment and repair of equipment, cleaning of the workplace, transportation of workpieces and products.
The time of breaks in work is the time during which no impact is made on the object of labor and there are no changes in its qualitative characteristics, but the product is not yet finished and the production process has not yet been completed. This time includes scheduled and non-scheduled breaks. In turn, regulated breaks are divided into inter-operational (intra-shift) and inter-shift.
Interoperative breaks include:

partion breaks that occur when parts are processed in batches, when the part lies during the processing time of other parts of this batch;
wait breaks due to out-of-sync sequential operations;
picking breaks that occur as a result of products lying due to the unavailability of other parts included in the kit (assembly, mechanism, machine).

Inter-shift breaks occur due to downtime between shifts, as well as on weekends and holidays.
Unscheduled breaks are due to downtime, unforeseen modes of operation (lack of raw materials, equipment breakdowns, accidents, absenteeism, etc.).
The length of the production cycle essentially depends on the nature of the movement of objects of labor in the production process. There are the following types of movement of objects of labor:

the sequential movement of workpieces assumes that when they are manufactured in batches, the subsequent technological operation begins only after the completion of the previous technological operation on all parts of the batch. The total duration of the production cycle with the specified type of movement is maximum due to the significant amount of breaks in batching. This type of movement is typical for single and small-scale production;
parallel-sequential movement of objects of labor suggests that the execution of subsequent operations begins before the processing of the entire batch of products at the previous operation. With parallel-sequential movement, a reduction in the duration of the production cycle is provided in comparison with sequential movement;
parallel-straight-through movement of objects of labor occurs when the product, regardless of the readiness of the batch, is immediately transferred to the next technological operation. This type of movement provides the shortest duration of the production cycle, however, it can be implemented in conditions of mass or large-scale production.

Explanation of the essence of the production cycle indicator

The period of the production cycle (English equivalent - Production cycle) - the period during which production stocks are converted into finished products. To calculate the indicator, it is necessary to find the ratio of the product of the number of days in a year and the average annual amount of stocks to the cost of production. Also, this indicator can be calculated as the ratio of 360 days to inventory turnover. This ratio indicates the efficiency of the production process.

Normative value of the production cycle:

It is desirable to reduce the indicator. This dynamic will mean that the company is spending less and less time turning inventory into finished goods. A low operating cycle makes it possible to reduce the share of fixed costs in each ruble of goods produced and services provided. The value will differ for different industries and business segments. For example, the production cycle in a window manufacturing plant will be significantly lower than in a car manufacturing plant. In order to accurately determine the position of the company - it is desirable to compare it with competitors.

Directions for solving the problem of finding an indicator outside the normative limits

If the value of the indicator is too high, for example, in comparison with competitors, then it is necessary to look for possible reserves to reduce it. To do this, you can monitor the production process with the fixation of all losses of time. Working with weak links will increase the indicator.

The formula for calculating the production cycle:

Lead Time = (360 * Annual Average Inventory) / Cost (1)

Do not forget that often the amount of stocks in the company fluctuates and it is at the end of the year that the value of the indicator may decrease or increase above normal. Therefore, if you have access to such information, you must use more accurate values at the end of each business day or at the end of the month.

Average annual inventory (best practice) = Sum of inventory at the end of each business day / Number of business days (2)

Average annual inventory (when only monthly data is available) = Sum of inventory at the end of each month / 12 (3)

Average annual inventory (when only annual data is available) = (Inventory at the beginning of the year + inventory at the end of the year) / 2 (4)

Example of calculation of the production cycle:

JSC "Web-Innovation-plus"

Unit of measurement: thousand rubles

Production cycle period (2016) = (360*(87/2+89/2))/ 975 = 32.49 days

Production cycle period (2015) = (360*(89/2+94/2))/ 984 = 33.48 days

Reducing the period of conversion of raw materials into finished products indicates an increase in the efficiency of the production process. In 2015, this process took 33.48 days, and in 2016 - 32.49 days. To further increase the indicator, you can optimize the volume and structure of reserves. This will free up additional funds.

The production cycle (PC) is the central value of a technical nature. On its basis, many values of the enterprise's activities are calculated. The value of the PC is needed to establish the timing of launching objects into production. The deadlines for the latter establish the necessary resources that the departments must have.

What is a production cycle

The production cycle is a period of full turnover of funds that are needed to service the work of the enterprise. The beginning of the cycle is the arrival of raw materials and materials, its completion is the shipment of products. That is, the PV is the length of time needed for the complete manufacture of the goods. The result of the production cycle is the receipt of the finished product. Determining the duration of the production cycle ensures the establishment of the time spent on the production of goods. It is measured in days, hours and minutes. The considered indicator is needed in the following cases:

Confirmation of the correctness of the definition of the program for the manufacture of goods.
Formation of a schedule for the movement of objects during production (logistics).
Establishing the scope of work in progress.
Determining the amount of working capital.

The production cycle is necessary for internal planning in the company. The main task of carrying out calculations is the limiting decrease in the duration of the PC. It is necessary to achieve the following goals:

Reducing the amount of working capital used.
Reducing the duration of the turnover of funds.
Reducing the area of warehouses where objects of work in progress, raw materials are stored.
Improving the quality of operation of basic funds.
Reducing the cost of goods.

Shortening the production cycle is necessary to save the company's resources. In the future, this will help increase profits: the cost of production decreases, and sales increase.

Structure of the production cycle

Consider the components of the production cycle:

Execution period (time spent only on the work itself). It is divided into basic operations and auxiliary. The first includes procurement and assembly operations, the second - transport and control.
The period allotted for natural processes. Involves periods of rest due to natural causes (for example, this is at night).
Breaks. These are interoperational periods, breaks between cycles. Breaks are also due to the seasonal nature of work.

The complex of actions is called the technological cycle. This cycle reflects the period during which the direct or indirect influence of employees on the object is performed.

Breaks are divided into two types:

Rest periods due to the mode of work in the company. These are weekends, holidays, lunch breaks.
Rest periods related to technical conditions. For example, it may be waiting for the release of the workplace, the assembly of the necessary parts. Also, downtime can be caused by the interdependence of unequal production operations, lack of electricity.

So, the production cycle is not only the actions associated with the production of goods, but also periods of planned and forced rest.

Formula for calculating the production cycle

The cycle value is set by this formula:

T p.c. = Ttech + Tper + Test.proc.

The formula uses these values:

Tp.c. - the timing of the PC.
Тtehn - terms of the technological stage.
Tper - breaks.
Test.percent - the timing of natural downtime.

When calculating the duration of the cycle, only those intervals that are not compensated by the period of technological actions should be taken into account. These include control measures, transportation of raw materials and products. Rest periods caused by organizational and technical problems (for example, a delay in the supply of raw materials, problems with discipline at the enterprise) are not taken into account when determining the planned duration of the production cycle.

When determining the value of the cycle, the nuances of the movement of the object of labor through production activities are taken into account. The movement is divided into the following forms:

Sequential. Work with a new batch of homogeneous objects of labor is initiated only after the previous batch has been processed.
Parallel. The direction of items to the operation is performed after the past operation has been processed. The considered form of movement causes a reduction in the cycle indicators.
Parallel-serial. The direction of objects to an operation is implemented during the execution of an adjacent operation. The considered order allows to exclude breaks.

The time period of the cycle depends on the type of movement of objects of labor.

What is the value of the production cycle

The compression of the production cycle is determined by these factors:

Technological processes. The equipment of the enterprise with technical tools affects the duration of processing and assembly.
Organizational. Assume actions to organize work processes. These processes affect the duration of auxiliary activities, breaks.
Economic. They affect the values of mechanization, technical excellence and timing of processes, the value of work in progress.

The cycle time is the result of a whole host of factors present in the enterprise. A change in one of the factors contributes to both shortening and multiplying the cycle. That is, the terms of the production cycle can be changed. For this, different methods are used.

What is the value of the production cycle

The production cycle is a constituent element of the movement of working capital. Its reduction causes an increase in the turnover rate. That is, a shortened cycle leads to an increase in the number of turnovers during the reporting year. The result of this is the accumulation of additional funds that can be used to modernize and expand production. In addition, the scale of work in progress is decreasing. This entails the accumulation of funds in material form. That is, material resources are released.

The duration of the cycle also determines. The latter refers to the maximum possible release of goods in the reporting period. How does this happen? The less time it takes to create one product, the more goods can be produced. Therefore, the power increases.

With the compression of the cycle, the quality of labor productivity also increases. There is an increase in the volume of output of goods, which entails an increase in power. This entails a decrease in the share of labor of employees. The cost price is reduced by reducing costs, taking into account the increase in power.

How to shorten the cycle

It is possible to compress the cycle in the following ways:

Purchase of more technically advanced equipment.
Implementation of continuous processes.
Increasing the depth of specialization.
Using the methods of scientific organization.
Application of robotics.
Improving labor discipline.
Reducing the number of breaks in legal ways (for example, several shifts per day).
Modernization of the entire production.
Improving the quality of management.
Implementation of new methods of organizing workflows.

IMPORTANT! Reducing the production cycle is one of the key tasks of the head of the enterprise. This allows you to immediately improve a number of basic indicators. Reducing the PC involves drawing up a detailed plan. It makes sense to work on those factors, the change of which involves the least cost. Before executing the plan, it is necessary to analyze all the factors affecting the production cycle.

The production cycle is one of the most important technical and economic indicators, which is the starting point for calculating many indicators of the production and economic activities of an enterprise. On its basis, for example, the terms for launching the product into production are set, taking into account the timing of its release, the capacities of production units are calculated, the volume of work in progress is determined, and other planning and production calculations are carried out.
The production cycle of manufacturing a product (batch) is a calendar period of its being in production from the launch of raw materials and semi-finished products to the main production until the finished product (batch) is received.
Loop structure
The structure of the production cycle includes the time for performing the main, auxiliary operations and breaks in the manufacture of products (Fig. 8.2).
The time for performing the main operations of processing products is the technological cycle and determines the time during which the direct or indirect impact of a person on the object of labor is carried out.
Breaks can be divided into two groups: 1) breaks associated with the work schedule established at the enterprise - non-working days and shifts, between shifts and lunch breaks, intra-shift regulated breaks for rest of workers, etc.; 2) breaks due to organizational and technical reasons - waiting for the vacancy of the workplace, waiting for the assembly of components and parts, inequality of production rhythms at adjacent ones, i.e. dependent on each other, jobs, lack of energy, materials or vehicles, etc.;
T - T 4 t *¦¦¦
1 pi * GSH * 1 1 PSr ’
When calculating the duration of the production cycle, only those time costs are taken into account that are not overlapped by the time of technological operations (for example, time spent on control, transportation of products). Breaks caused by organizational and technical problems (untimely provision of the workplace with materials, tools, violation of labor discipline, etc.) are not taken into account when calculating the planned duration of the production cycle.
When calculating the duration of the production cycle, it is necessary to take into account the peculiarities of the movement of the object of labor through the operations that exist in the enterprise. One of three types is commonly used; serial, parallel, parallel-serial.
With sequential movement, the processing of a batch of the same-name objects of labor at each subsequent operation begins only when the entire batch has been processed at the previous operation.
Suppose that it is required to process a batch consisting of three products (n = 3), while the number of processing operations (t = 4), the time norms for operations are, min: t = 10, t2 = 40, t = 20.14 = 10.
For this case, the duration of the cycle, min;
TC (last) \u003d 3 (10 + 40 + 20 + 10) \u003d 240.
Since a number of operations can be performed not at one, but at several workplaces, the duration of the production cycle with sequential movement in the general case has the form:
T c (last) \u003d n E / "s.
where Xi is the number of jobs.
With parallel movement, the transfer of objects of labor to the next operation is carried out individually or by a transport batch immediately after processing at the previous operation:
where p is the size of the transport party, pcs; lmax - the time of the longest operation, min; Stah - the number of jobs in the longest operation. For the above example; p=1.
= (10 ¦+¦ 40 + 20 -g -‘g (3 - 1) 4(| = 160 min With a parallel type of movement, the duration of the production cycle is significantly reduced.
With a parallel-sequential type of movement, objects of labor are transferred to the next operation as they are processed at the previous piece by piece or by a transport batch, while the time for performing adjacent operations is partially combined in such a way that a batch of products is processed at each operation without interruptions.
The duration of the production cycle can be defined as the difference between the duration of the cycle for a sequential type of movement and the total time savings compared to a sequential type of movement, due to the partial overlap of the execution time of each pair of adjacent operations:
t- 1
: - ? I walked I em'
I h 1
For our example: p = 1.
Tc (par-seq) = 240 = 160 min.
Cycle duration
The duration of the production cycle is influenced by many factors: technological, organizational and economic. Technological processes, their complexity and diversity, technical equipment predetermine the processing time of parts and the duration of assembly processes. Organizational factors of the movement of objects of labor in the process of processing are associated with the organization of jobs, the labor itself and its payment. Organizational conditions have an even greater influence on the duration of ancillary activities, service processes, and breaks.
Economic factors determine the level of mechanization and equipment of processes (and, consequently, their duration), the standards of work in progress.
The faster the production process is performed (the shorter the duration of the production cycle), which is one of the elements of the circulation of working capital, the greater will be the speed of their turnover, the greater the number of revolutions they make during the year.
As a result, there is a release of monetary resources that can be used to expand production at a given enterprise.
For the same reason, there is a reduction (absolute or relative) in the volume of work in progress. And this means the release of working capital in their material form, i.e. in the form of concrete material resources.
The production capacity of an enterprise or workshop directly depends on the duration of the production cycle. Under the production capacity is understood the maximum possible output in the planned period. And therefore it is clear that the less time is spent on the production of one product, the greater the number of them can be manufactured in the same period of time.
Labor productivity with a reduction in the duration of the production cycle increases as a result of an increase in output due to an increase in production capacity, which leads to a decrease in the share of labor of auxiliary workers in a unit of output, as well as the share of labor of specialists and employees.
The cost of production with a reduction in the production cycle decreases due to a decrease in the cost of a unit of production of the share of general factory and workshop costs with an increase in production capacity.
Thus, reducing the duration of the production cycle is one of the most important sources of intensification and increasing the efficiency of production at industrial enterprises.
The reserve for reducing the duration of the production cycle is the improvement of technology and technology, the use of continuous and combined technological processes, the deepening of specialization and cooperation, the introduction of methods of scientific organization of labor and maintenance of workplaces, the introduction of robotics.
conclusions

The production structure of the enterprise characterizes the division of labor between the divisions of the enterprise and their cooperation. The rational construction of the production process in space is a necessary condition for its effectiveness.

2- The main elements of the production structure of the enterprise are jobs, sites and workshops.

The production structure can be organized according to technological, subject or mixed type, with a full or incomplete cycle

production.

All workshops and facilities of an industrial enterprise can be divided into workshops of the main production, auxiliary workshops and service facilities.
The formation of the structure of an enterprise depends on external factors (industry, regional, general structural) and internal (the nature and volume of products, features and capabilities of the enterprise's fixed assets, the level of specialization, cooperation, etc.).
Depending on the range of products, production volumes, types of equipment, labor intensity of operations, the duration of the production cycle and other factors, single, serial and mass production are distinguished.
The production process is a set of labor processes aimed at the transformation of raw materials and materials into finished products,

The principles of rational organization of the production process are: specialization, parallelism and proportionality, direct flow and continuity, rhythm and technical equipment.

Production processes are divided into mechanical, physical, chemical, etc.; continuous "discrete; procurement, processing and finishing; manual and mechanized.

The main parameters of the production process are the pace and tact of the operation.

The production cycle is the period of time for the manufacture of a product or batch from the moment raw materials and materials are launched into the main production until the finished product is received.

The structure of the production cycle includes the execution time of the main, auxiliary operations and breaks in the manufacture of products.

The duration of the production cycle is influenced by technological, organizational, economic and other factors.

Terms and concepts
Production structure of the enterprise
Type of production
Manufacturing process
Production cycle
Questions for self-examination

What is the essence of the general and production structure of the enterprise?
What are the main elements of the production structure? What factors determine the production structure of an enterprise?
What are the basic principles of the organization of the production process?
What parameters characterize the production process?
What is included in the concept of "production cycle"?
What standards are used to organize the production cycle in time?

Production cycle - one of the most important technical and economic indicators, which is the starting point for calculating many indicators of the production and economic activities of the enterprise. On its basis, for example, the terms for launching the product into production are set, taking into account the timing of its release, the capacities of production units are calculated, the volume of work in progress is determined, and other planning and production calculations are carried out.

The production cycle of manufacturing a product (batch) is a calendar period of its being in production from the launch of raw materials and semi-finished products to the main production until the finished product (batch) is received.

Loop structure

The structure of the production cycle includes the time for performing the main, auxiliary operations and breaks in the manufacture of products (Fig. 8.2).

Rice. 8.2. Structure of the production cycle

The time for performing the main operations of processing products is the technological cycle and determines the time during which the direct or indirect impact of a person on the object of labor is carried out.

Breaks can be divided into two groups:

- breaks, associated with the operating mode established at the enterprise, - non-working days and shifts, inter-shift and lunch breaks, intra-shift regulated breaks for rest of workers, etc.;

breaks, due to organizational and technical reasons, - waiting for the vacancy of the workplace, waiting for the assembly of components and parts, inequality of production rhythms at adjacent, i.e. dependent on each other, jobs, lack of energy, materials or vehicles, etc.:

Derivative Cycle Duration Calculation

T p.c , T tech- respectively, the duration of the production and technological cycles;

T lane- duration of breaks;

T est.pr- time of natural processes.

When calculating the duration of the production cycle T p.c only those time costs that are not overlapped by the time of technological operations are taken into account (for example, the time spent on control, transportation of products). Breaks caused by organizational and technical problems (untimely provision of the workplace with materials, tools, violation of labor discipline, etc.) are not taken into account when calculating the planned duration of the production cycle.

When calculating the duration of the production cycle, it is necessary to take into account the peculiarities of the movement of the object of labor through the operations that exist in the enterprise. One of three types is usually used: serial, parallel, parallel-serial.

With sequential movement, the processing of a batch of the same-name objects of labor at each subsequent operation begins only when the entire batch has been processed at the previous operation.

Example 8.1.

Suppose you want to process a batch consisting of three items (n = 3); the number of processing operations (m = 4), the norms of time for operations are: = 10,= 40,= 20,= 10 min.

For this case, the cycle time

T c(last)= 3(10 + 40 + 20 + 10) = 240 min.

Since a number of operations can be performed not at one, but at several workplaces, the duration of the production cycle with sequential movement in the general case has the form

Where , - the number of jobs.

With parallel movement, the transfer of objects of labor to the next operation is carried out individually or by a transport batch immediately after processing at the previous operation:

Where R- the size of the transport party, pcs; t max- execution time of the longest operation, min ; WITH max- the number of jobs in the longest operation. For the example above: p = 1.

T c(steam)= (10 + 40 + 20 + 10) + (3 - 1)40 = 160 min.

At parallel the form of movement, the duration of the production cycle is significantly reduced.

At parallel-serial In the form of movement, objects of labor are transferred to the next operation according to the measure of their processing at the previous piece by piece or by a transport batch, while the time for performing adjacent operations is partially combined in such a way that a batch of products is processed at each operation without interruptions.

The duration of the production cycle can be defined as the difference between the duration of the cycle for a sequential type of movement and the total time savings compared to a sequential type of movement, due to the partial overlap of the execution time of each pair of adjacent operations:

For example 8.1: p = 1.

240 - (3 - 1)(10 + 20 + 10) = 160 min.

Cycle duration

The duration of the production cycle is influenced by many factors: technological, organizational and economic. Technological processes, their complexity and diversity, technical equipment predetermine the processing time of parts and the duration of assembly processes. Organizational factors of the movement of objects of labor in the process of processing are associated with the organization of jobs, labor itself and its payment. Organizational conditions have an even greater influence on the duration of ancillary activities, service processes, and breaks.

Economic factors determine the level of mechanization and equipment of processes (and, consequently, their duration), the standards of work in progress.

The faster the production process is performed (the shorter the duration of the production cycle), which is one of the elements of the circulation of working capital, the greater will be the speed of their turnover, the greater the number of revolutions they make during the year.

As a result, there is a release of monetary resources that can be used to expand production at a given enterprise.

For the same reason, there is a reduction (absolute or relative) in the volume of work in progress. And this means the release of working capital in their material form, i.e. in the form of concrete material resources.

The production capacity of an enterprise or workshop directly depends on the duration of the production cycle. Under the production capacity is understood the maximum possible output in the planned period. And therefore it is clear that the less time is spent on the production of one product, the greater the number of them can be manufactured in the same period of time.

Labor productivity with a reduction in the duration of the production cycle, it increases as a result of an increase in output due to an increase in production capacity, which leads to a decrease in the share of labor of auxiliary workers in a unit of output, as well as the share of labor of specialists and employees.

Production cost with a reduction in the production cycle, it decreases due to a decrease in the cost of a unit of production of the share of general factory and workshop costs with an increase in production capacity.

Thus, reducing the duration of the production cycle is one of the most important sources of intensification and increasing the efficiency of production at industrial enterprises.

The reserve for reducing the duration of the production cycle is the improvement of technology and technology, the use of continuous and combined technological processes, the deepening of specialization and cooperation, the introduction of methods of scientific organization of labor and maintenance of workplaces, robotics.

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