Introduction
2.3 Selection and adjustment of labor intensity standards technological service and overhaul for 1000 km of run
3. Organizational section
3.3 Technological map
4. Labor protection
Conclusion
Literature
Introduction
Increasing productivity, efficiency of using rolling stock road transport largely depends on the level of development and operating conditions of the production and technical base of the road transport enterprise, the main task of which is to ensure the required level of technical readiness of the rolling stock.
The development and improvement of the production and technical base of road transport enterprises must meet the modern requirements of scientific and technological progress. In solving the problems of studying production and technical bases, bringing it into line with the requirements of a dynamically developing road transport, an important place is occupied by the issues of improving the design of an enterprise.
Road transport is quite convenient compared to other modes of transport. It has great maneuverability, good maneuverability and adaptability to various conditions. The production service plays a significant role in the implementation of many complex tasks. The automotive industry is systematically working to improve production technologies and improve the design of rolling stock.
Considering that the growth of labor productivity depends on the level of mechanization and automation of production processes, therefore, one of the main tasks is to equip each workplace, post with a set of technological equipment, tools and devices as much as possible.
Of great importance for increasing labor productivity during maintenance and repair and ensuring their quality is the widespread introduction of the scientific organization of labor (NOT) in production. The latter includes a large range of measures, including improving the organization and maintenance of workplaces, improving the techniques, methods and regulation of labor, creating favorable sanitary, hygienic and aesthetic working conditions, etc.
The goal of my course project is to design a battery compartment.
The objectives of the project are to calculate the frequency of maintenance; determination: the number of services per year, the technical readiness coefficient, the daily program of cars; distribution of labor intensity for maintenance and repair of vehicles and self-service of the enterprise; distribution of work intensity; calculation of the number of workers; selection of technological equipment; department layout, etc.
1. Characteristics of the design object
The motor transport enterprise (ATP) is located in an area with a warm, humid climate and belongs to the third category of operation.
The list of vehicles is 400 KAMAZ 5415 vehicles, of which 60% have been overhauled and 320 KRAZ 256B1 vehicles, of which 80% have been overhauled.
Mode work of ATU five-day, the number of work shifts is 2, which provides an eight-hour working day. ATP specializes in the transportation of goods.
The design theme is the battery compartment. The accumulator department carries out repairs of accumulators according to the applications recorded in the control coupons, and according to the applications of all divisions of the auto service.
The battery compartment is equipped with equipment in accordance with the nature of the work performed on it. Specialization makes it possible to mechanize labor-intensive work as much as possible, reduce the need for equipment of the same type, improve working conditions, employ less skilled workers, and increase the quality and productivity of labor. We use the following equipment in the battery compartment: Waste bin, baths for parts washing and electrolyte preparation, racks, stands, rectifier, cabinets, etc.
2. Settlement and technological section
2.1 Selection and adjustment of maintenance intervals
The frequency of maintenance depends on the number of rolling stock, category of operating conditions and climatic conditions.
The frequency of TO - 1, L 1 km is determined by the formula:
L 1 = L K 1 K 3, (1)
where L is the standard maintenance frequency - 1, km, selected according to table 2.1 L KaMaz 5415 = 4000 (km); L KRAZ 256 B1 = 2500 (km).
K 1 - coefficient taking into account operating conditions, K 1 = 0.9, table 2.7 K 3 - coefficient taking into account natural and climatic conditions, K 3 = 1, table 2.9
L 1 Kamaz 5415 = 4000 0.9 1 = 3600 (km);
L 1 KRAZ 256B1 = 2500 0.9 1 = 2500 (km).
The frequency of TO - 2, L 2 km is determined by the formula:
L 2 = L K 1 K 3, (2)
where L is the standard maintenance frequency - 2, km, selected according to table 2.1 L (km); L Kamaz 5415 = 12000 (km);
KRAZ 256 B1 = 12000 (km).
L 2 Kamaz 5415 = 12000 0.9 1 = 10800 (km);
L 2 KRAZ 256B1 = 12000 0.9 1 = 10800 (km).
2.2 Selection and correction of mileage before overhaul
It is also necessary to adjust the frequency of the run before overhaul. The service life (mileage before overhaul) depends on K 1, modifications of the rolling stock - K 2 and K 3.
The frequency is calculated using the formula:
L KP = L K 1 K 2 K 3, (3)
where L is the standard frequency before overhaul, km, which is determined according to table 2.2 L KaMaz = 300000 (km); L KRAZ 256 B1 = 160,000 (km).
K 2 - correction factor taking into account the modification of the rolling stock, km, which is selected according to table 2.8
K 2 Kamaz 5415 = 0.95; K 2 KRAZ 256B1 = 0.85;
K 3 - coefficient of adjustment of standards depending on natural and climatic conditions, which is selected according to table 2.9
L KR Kamaz 5415 = 300000 0.9 0.95 1.0 = 256000 (km);
L KR KRAZ 256 B1 = 600000 0.9 0.85 1.0 = 122400 (km).
If cars are operated after overhaul, then the overhaul mileage, L, km, is reduced by 20%
L Kamaz 5415 = 0.8 256500 = 205200 (km);
L KRAZ 256 B1 = 0.8 122400 = 97920 (km).
If new and overhauled cars are operated in the car park, then it is necessary to calculate the separate mileage of cars L КР СР, km, according to the formula:
where A u is the percentage of cars that have not undergone major repairs A u KaMaz 5415 = 40%; And u KRAZ 256 B1 = 65%;
A - the percentage of cars that have undergone major overhaul A KaMaz 5415 = 60%; A KRAZ 256 B1 = 35%;
After repair, taking into account the coefficients, it is necessary to correct the multiplicity factor b 1; b 2; b 3 maintenance services and maintenance.
For TO - 1, the multiplicity factor b 1 is determined by the formula:
where L CC is the average daily mileage, km: L CC KaMaz 5415 = 160 km;
L CC KRAZ 256 B1 = 100 km;
For TO - 2, the multiplicity factor b 2 is determined by the formula:
For KR, the multiplicity factor b 3 is determined by the formula:
The corrected and initial data are summarized in table 1.
Table 1. Correction of vehicle mileage
| car | Mileage, km | ||||
| Correct taking into account the coefficients | Correct taking into account the multiplicity | to the calculation |
|||
| Average day. | |||||
| Average day. | |||||
2.3 Selection and adjustment of standards for the labor intensity of technological maintenance and overhaul per 1000 km of run
Correction of the labor intensity of maintenance is carried out depending on K 2 and the number of units of technologically compatible rolling stock (K 5) Labor intensity of daily maintenance, t EO, man hour. determined by the formula:
t EO = t K 2, (9)
where t is the standard labor intensity for daily maintenance, man-hours, we choose according to table 2.1 t KaMaz 5415 = 0.67 (man-hour),
t KRAZ 256 B1 = 0.45 (man hours)
t EO Kamaz 5415 = 0.67 1.10 = 0.73 (man-hours);
t EO KRAZ 256 B1 = 0.45 1.15 = 0.51 (man hours).
Labor intensity of TO - 1, t TO-1, person hour. determined by the formula:
t T O -1 = t K 2 K 5, (10)
where t is the standard labor intensity for maintenance - 1, is selected according to table 2.1, t Kamaz 5415 = 2.29 (man-hours), t KRAZ 256 B1 = 3.7 (man-hours)
t T O -1 Kamaz 5415 = 2.29 1.10 0.80 = 2.01 (man hours);
t T O -1 KRAZ 256 B1 = 3.7 1.15 0.80 = 3.4 (man hours).
Labor intensity of TO - 2, t TO-2, man hour. determined by the formula:
t Т O -2 = t K 2 K 3, (11)
where t is the standard labor intensity for maintenance - 2, is selected according to table 2.1, t Kamaz 5415 = 9.98 (man-hour), t KRAZ 256 B1 = 14.7 (man-hour)
t T O -2 Kamaz 5415 = 9.98 1.10 0.80 = 8.78 (man hours);
t T O -2 KrAZ-260V = 14.7 1.15 0.80 = 13.5 (man hours).
The complexity of current repairs per 1000 km of run depends on the type of cars, operating conditions, modification, natural conditions, vehicle mileage and the size of the vehicle, t TR, person hour. and determined by the formula:
t TP = t K 1 K 2 K 3 K 4 K 5, (12)
where t is the standard labor intensity for current repairs, we choose according to table 2.1, t Kamaz 5415 = 6.7 (man-hours), t KRAZ 256 B1 = 6.4 (man-hours)
К 1 - coefficient of standard correction depending on operating conditions, К 1 = 0.9
K 2 - the correction factor taking into account the modification of the rolling stock, km, which is selected according to table 2.8 K 2 KaMaz5415 = 0.95; K 2 KRAZ 256 B1 = 0.95
K 3 - coefficient of adjustment of standards depending on natural and climatic conditions, K 3 = 1.0
K 4 - the coefficient of correction of the norms of the specific labor intensity of the current repair (km) and the duration of the downtime of maintenance and current repair (K), depending on the mileage from the beginning of operation, K 4 KaMaz 5415 = 1.4; K 4 KRAZ 256 B1 = 1.4
К 5 - coefficient of adjustment of standards of maintenance and current repair, depending on the number of serviced and repaired vehicles at the ATP and the number of technologically compatible groups of rolling stock К 5 = 0.80.
t TR Kamaz 5415 = 6.7 0.9 1.10 1.0 1.4 0.80 = 7.42 (person hour);
t TR KRAZ 256 B1 = 6.4 0.9 1.15 1.0 1.4 0.80 = 7.41 (person hours).
2.4 Determination of the technical readiness of the park
The coefficient of technical readiness of the park, α Т, is calculated by the formula:
where D TO TR is the duration of the idle time of the rolling stock in maintenance and current repair, is determined according to table 4.5, D TO TR GAZ-53A = 0.5; D TO TR MAZ-53363 = 0.6; D TO TR MAZ-64226 = 0.8, D KR - the duration of the rolling stock downtime in overhaul, determined according to table 4.5, D KR KaMaz 5415 = 22; D KR KRAZ 256 B1 = 22
2.5 Determination of vehicle utilization rate and annual fleet mileage
Since the park is constantly being equipped with new technology, more productive equipment, the level of labor, the reliability of cars, etc. will increase. The utilization rate of the fleet, α u is determined by the formula:
where D RG is the number of working days, D RG = 257
D KG - the number of calendar days, D KG = 365
Knowing the utilization rate of the fleet, it is possible to calculate the annual mileage of the fleet, L PG, km, using the formula:
L PG = D RG α u L CC A u, (15)
L PG KaMAz5415 = 257 0.6 160 400 = 9868800 (km);
L PG KRAZ 256 B1 = 257 0.6 100 320 = 4934400 (km).
2.6 Determine the number of services per year
The number of overhauls, N, is determined by the formula:
The amount of daily maintenance, N, is determined by the formula:
The amount of TO - 2, N, is determined by the formula:
The amount of TO - 1, N, is determined by the formula:
2.7 Determination of the annual scope of maintenance and repair work
Annual volume of work on daily maintenance, T person hour. determined by the formula:
Т = t ЕО N, (20)
T Kamaz5415 = 0.73 61680 = 45026.4 (man-hour);
T KRAZ256B1 = 0.51 49344 = 25165.44 (person hour).
The annual scope of maintenance work - 1, T, man-hour, is determined by the formula:
T = t TO-1 N, (21)
T Kamaz5415 = 2.01 1728 = 3533.58 (man hours);
T KRAZ256B1 = 3.4 748 = 2543.2 (person hour).
The annual scope of maintenance work - 2, T, man-hour, is determined by the formula:
T = t TO-2 N, (22)
T Kamaz5415 = 8.78 864 = 7585.92 (person hour);
T KRAZ256B1 = 13.5 374 = 5049 (person hour).
The annual volume of work on current repair, T, man-hour, is determined by the formula:
T Kamaz5415 = (person hour);
T KRAZ256B1 = (person hour).
If the park is operated vehicles different types, then it is necessary to determine the total labor input for maintenance and overhaul. The total labor intensity of daily maintenance, Σ T EO, is determined by the formula:
Σ T EO = T Kamaz5415 + T KRAZ256B1, (24)
Σ T EO = 45026.4 + 25165.44 = 70191.84 (person hour)
The total labor intensity of TO - 1, Σ T TO - 1, is determined by the formula:
Σ T TO - 1 = T Kamaz5415 + T KRAZ256B1, (25)
Σ T TO - 1 = 3533.58 + 2543.2 = 6076.78 (person hour)
The total labor intensity of TO - 2, Σ T TO - 2, is determined by the formula:
Σ T TO - 2 = T Kamaz5415 + T KRAZ256B1, (26)
Σ T TO - 2 = 7585.92 + 5049 = 12634.92 (person hour)
The total labor intensity of the current repair, Σ Т ТР, is determined by the formula:
Σ T TR = T Kamaz5415 + T KRAZ256B1, (27)
Σ T TR = 73127.808 + 36563.904 = 109691.71 (person hour)
In addition to maintenance and current repairs, the vehicle fleet carries out self-service work of the enterprise, that is:
a) Maintenance and repair of machine tools, energy and power equipment;
b) Manufacturing, maintenance and repair of technological equipment;
c) Repair of buildings, structures, water pipes, sewerage systems, etc.
Therefore, it is necessary to enter the self-service work scope in the annual scope of work. The scope of work for self-service of the enterprise, T CAM, man hours, is determined by the formula:
where K CAM is the coefficient taking into account the amount of work on self-service of the enterprise in%. The coefficient depends on the number of cars at the ATP.
2.8 Calculation of the number of production workers
Productive workers include work areas and sections directly performing maintenance and repair work on rolling stock.
When calculating the number of workers, there is a distinction between the turnout (technically necessary) - Р Я and the staff (payroll) - Р Ш number of workers.
The number of technologically necessary workers corresponds to the number of jobs. In this case, a workplace is understood as a section of the area on which work is performed by one worker. One or several workers can work at a work station at the same time.
The number of technologically necessary workers is determined by the formula:
where T OTD is the annual volume of work of the department T OTD = 2786 man-hours.
Ф RM - the annual fund of time of the workplace
where H N is the duration of the worker's work during the week, H H = 40
D N - the number of working days per week, D N = 5
D K - number of calendar days, D K = 365
D B - the number of days off, D B = 103
Д П - number holidays, D P = 5
Determine the number of full-time workers using the formula:
where Ф ПР - the annual fund of time for regular workers is determined by the formula:
where Ф T is the annual fund of time of one worker
D O - the number of days of vacation of the worker
D U.P - the number of days of absence from work for a good reason
5 - the number of working days
2.9 Calculation of the number of posts for a branch
where T POST is the labor intensity of the post, T POST = 1229 man-hours.
P - number of posts
K N - reservation ratio, K N - 1.35
С - number of shifts, С - 1
D RG - the number of working days per year, D RG - 302
T CM - shift duration in hours, T CM - 8 hours
Р СР - the number of workers simultaneously working at the post, Р СР = 2
η P is the coefficient of using the working time of the post, η P - 0.98
3. Organizational section
3.1 Selection of technological equipment and tooling at the site
overhaul car battery
The technological equipment includes stationary, mobile and portable stands, machine tools, all kinds of devices and devices that occupy an independent area on the layout, necessary to perform work on TR.
Organizational equipment includes production equipment (workbenches, racks, cabinets, tables) that occupy an independent area on the layout. Technological equipment includes all kinds of tools, fixtures, devices necessary for performing work on TR, which do not occupy an independent area.
When choosing technological equipment, it is necessary to take into account that the number of many types of stands, installations and devices does not depend on the number of workers in the workshop, while workbenches, work tables are taken based on the number of workers.
The list of necessary technological equipment and accessories is given in the table.
Table 2 Technological equipment
| № | Name | Brand | Dimensions (edit) | ||
| 1-repair department | |||||
| 1 | Waste bin | 2 | 0.6x0.8 | 0,48 | |
| 2 | Parts rinsing bath | 2257 | 1 | 0.9x0.5 | 0,45 |
| 3 | Workbench | 1019 | 1 | 1.0x0.8 | 0,8 |
| 4 | Electrolyte drain bath | E - 204 | 1 | 0.58x0.21 | 1,22 |
| 5 | Rack | 2242 | 1 | 1.0x0.4 | 0,4 |
| 6 | Stand | 1 | 0.7x0.6 | 0,42 | |
| 7 | Rectifier | BCA-5A (BCA-111B) | 1 | 0.41x0.31 | 1,28 |
| 8 | Melting workbench | 1 | 1.0x0.8 | 0,8 | |
| 9 | Material cabinet | 551 | 1 | 0.5x0.6 | 0,30 |
| 2- charging compartment | |||||
| 1 | Shelving rack | E-409 OG | 4 | 1.10x1.10 | 1,21 |
| 3-pantry | |||||
| 1 | Rack for parts | 3 | 0.6 x0.5 | 0,30 | |
| 2 | Rack for bottles | 1 | 1.0x0.6 | 0,6 | |
| 3 | Battery rack | E-405A | 1 | 0.5x0.6 | 0,30 |
| 4-acid department | |||||
| 1 | Electrolyte bath | E-204 | 1 | 0.58x0.21 | 1,22 |
| 2 | Acid dispenser | P-206 | 1 | 0.4x0.4 | 0,16 |
| 3 | Electric distiller | 737MRTU / 2 | 1 | 0.5x0.5 | 0,25 |
| TOTAL: | 10,19 | ||||
3.2 Calculation production area
The area of the site is determined by the formula:
3.3 Technological map
The charging of the battery is checked by measuring the density of the electrolyte. By changing the initial density of the electrolyte poured into the battery (which must correspond to the data in Table 2.4), you can determine the degree of its discharge. A decrease in the density of the electrolyte, reduced to a temperature of +25 ° C, by 0.01 g / cm3 indicates that the battery is discharged by about 6%. that is, when the density drops by 0.04 g / cm3, the battery discharge is 25%, 0.08 g / cm3 - 50%, and when the density drops by 0.16 g / cm3, the battery is completely discharged. With a different decrease in the density of the electrolyte in individual batteries, the total discharge value of the storage battery can be roughly determined as the average discharge value of its batteries. The measurement of the density of the electrolyte in the batteries is carried out in the same manner as in the preparation of the electrolyte. For accuracy, check the electrolyte level before measuring the density of the electrolyte. After charging the storage battery or long-term operation of the engine, before measuring, it is necessary to hold it for about 30-40 minutes until gas evolution stops. After adding distilled water to the battery, the electrolyte density can be measured only after 10-15 minutes so that the water mixes with the electrolyte, and the electrolyte density becomes equal. A battery discharged in summer by more than 50% (with an average decrease in electrolyte density by 0.08 g / cm3), and in winter by more than 25% (with a decrease in electrolyte density by 0.04 g / cm3) should be removed from the car and charge. A storage battery put into storage should be recharged when discharged by 25-30%, which corresponds to a decrease in the density of electrolyte in batteries by 0.04-0.05 g / cm3.
4. Labor protection
Self-service repair and maintenance rechargeable batteries admitted are persons at least 18 years of age, having the appropriate qualifications, having received introductory briefing and initial briefing at the workplace, trained in safe working methods and having the appropriate certificate.
A battery operator who has not undergone a timely re-training on labor protection (at least once every 3 months) and an annual examination of knowledge on labor safety should not start work.
The battery operator is obliged to comply with the internal labor regulations established at the enterprise.
The duration of the battery operator's working time should not exceed 40 hours per week. The duration of daily work (shift) is determined by the internal labor regulations or the shift schedule approved by the administration in agreement with the trade union committee. The battery operator must know that hazardous and harmful production factors that can act on him in the process of performing work are:
electricity;
sulphuric acid;
caustic potassium;
lead and its compounds;
Sulfuric acid, if it gets on parts of the body, damages the skin, and dermatitis and burns are formed.
Potassium hydroxide works in a similar way to sulfuric acid.
Lead and its compounds lead to poisoning of the working organism, as well as to the disorder of the peripheral and central nervous systems, damage to the locomotor system, lead paralysis.
Hydrogen is released during battery charging, mixing with atmospheric oxygen to form an explosive oxyhydrogen gas.
It is forbidden to use tools, fixtures, equipment, handling of which the battery operator has not been trained and instructed.
The battery operator must work in special clothing and special shoes, and, if necessary, use other personal protective equipment.
In accordance with the Standard Industry Standards for the Issuance of Special Clothing, Special Shoes and Other Personal Protective Equipment, the battery operator is issued:
cotton suit with acid-proof impregnation;
rubber ankle boots;
rubber gloves;
rubber apron;
protective glasses.
The battery operator must follow the rules of personal hygiene:
before using the toilet, eating, smoking, you should wash your hands with soap and water;
do not store or consume in battery food and drinking water, in order to avoid the ingress of harmful substances from the air into them;
for drinking it is necessary to use water from specially designed devices (saturators, drinking tanks, fountains, etc.);
to protect the skin of the hands, apply specially designed protective ointments.
It is prohibited.
in the room for charging batteries, in order to avoid an explosion, light a fire, smoke, use electric heating devices (electric stoves with an open spiral, etc.) and allow sparking of electrical equipment;
allow unauthorized persons to enter the charging and acid rooms;
connect the battery terminals with a wire;
check the battery with a short circuit;
pour molten lead into wet molds and put wet pieces of lead in the molten mass;
pour water into acid, as this causes "boiling" and possible splashing out of the electrolyte from the vessel;
store in the repair and charging compartments battery vessels with sulfuric acid and alkali in an amount exceeding the daily requirement, as well as empty vessels, which should be stored in a separate room;
jointly store and charge acid and alkaline batteries in the same room;
take in battery food and store drinking water there in order to avoid the ingress of harmful substances from the air;
use glass promises for electrolyte preparation.
END OF WORK SAFETY REQUIREMENTS
At the end of the work, the battery operator must:
Turn off ventilation and electrical equipment.
Tidy up the workplace. Remove electrolyte, devices and tools in the place provided for them.
Used personal protective equipment (gloves, apron, ankle boots), rinse in water and put away in a designated place.
Take off personal protective equipment, special clothing and shoes and put them in their designated place. Timely hand over them and other personal protective equipment for dry cleaning (washing) and repair.
Wash your hands with soap and water and take a shower.
Conclusion
In this course project developed:
- organization of the battery section
- the method of organizing the production of the TOD complex and the site has been selected and justified;
- calculated the annual labor intensity of work in the Asia-Pacific region and the site;
- the equipment of the site is selected;
- the number of production works is calculated
- requirements for safety and fire safety were developed;
- a planning drawing of the accumulator section has been completed.
Literature
1. Regulations on the maintenance and repair of the rolling stock of road transport / Ministry of Transport and Communications of the Republic of Belarus - Minsk: Transtekhnika 1998 - 59s.
3. Design of motor transport enterprises and service stations. Educational / M.M. Bolbas, N.M. Kapustin and E.I. Petukhov, V.I. Pokhabov - Mn. Universitetskoe, 1997 - 24bc.
4. Maintenance and repair of cars. A guide to coursework and diploma design. M .: Transport, 1985 - 224s.
5. Maintenance and repair of cars. Graduation design manual / B.N. Sukhanov et al. - M .: Transport, 1991 - 159p.
8. Maintenance of cars. G.V. Kramarenko, I. V. Barashkov M .: Transport, 1982 - 368s.
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Introduction
1. General part
1.1 Purpose of the site
1.2 Technological process of the site
1.3 Work and rest hours of workers, funds of equipment operating time
1.4 Annual production program
1.5 Annual scope of work
1.6 Number of employees
1.7 Selection of equipment for the site
2. Technological part
2.1 Calculation of the area of the site
2.2 Calculation of electricity demand
2.3 Calculating the compressed air requirement
2.4 Calculation of water and steam demand
2.5 Battery cover remover
2.6 Calculating the number of battery groups to charge
2.7 Layout solution
3. Organizational and economic part
3.1 Calculation of capital costs
3.2 Calculation of economic efficiency
3.3 Technical and economic indicators of the project
4. Labor protection
4.1 Requirements of T.B. for ventilation, heating and lighting
4.2 Requirements of T.B. presented to the tool, equipment and fixtures
4.3 Safety precautions during assembly work
4.4 Personal protective equipment used on the site
Literature
Introduction
technological area repair battery
During the operation of the car, its reliability and other properties gradually decrease as a result of wear of parts, as well as corrosion and fatigue of the material from which they are made. Various malfunctions appear in the car, which are eliminated during maintenance and repair.
It is known that it is impossible to create a machine of equal strength, all parts of which would wear out evenly and would have the same service life. Consequently, repairing a car, even only by replacing some of its parts and assemblies that have a small resource, is always advisable and justified from an economic point of view. Therefore, in the process of operation, cars undergo periodic maintenance at motor transport enterprises (ATP) and, if necessary, routine repair (TR), which is carried out by replacing individual parts and assemblies that have failed. This allows the vehicles to be kept in good technical condition.
With long-term operation, cars reach the limit technical condition and they are sent for overhaul (CR) at the ARP. The task of overhaul is to restore the performance and resource lost by the car to a new level or close to it with optimal costs.
The CD of automobiles is of great economic and, therefore, national economic importance. The main source of the economic efficiency of the KR of cars is the use of the residual resource of their parts. About 70-75% of car parts that have passed the service life before the first overhaul have a residual life and can be reused, either without repair, or after minor repairs.
Thus, the main source of the economic efficiency of the KR of cars is the use of the residual resource of the parts of the second and third groups.
The KR of cars also allows maintaining a high level of the number of the country's car park.
1. a common part
1.1 Appointmentplot
The site is intended for recharging, charging and repairing batteries.
In the practice of repairing batteries, the following defects are encountered: a decrease in the tapered surface of the outlet in diameter due to wear when the terminal is tightened, melting or corrosion. Looseness of the terminal in the cover sleeve, breakage by the terminal or by the bridge and the block of electrodes, through annular and radial cracks of the covers around the terminals, deformation or breakdown of the thread at the filler neck of the cover or plug, violation of the fastening of handles (brackets) for transporting batteries, sulfation of electrodes (plates) , accelerated self-discharge, cracks in the mastic and its delamination, cracks in monoblocks, destruction of positive electrodes.
1.2 Technologicalprocessplot
Batteries are delivered to the battery repair section from the dismantling section.
Batteries received for repair are pre-washed with a hot 3-5% solution of soda ash, using a hair brush, after washing, rinsed with cold water and wiped with a rag.
Then, the batteries are visually inspected and the voltage values of each battery with and without load are checked.
Leaks and cracks in acid-resistant battery mastic,
Detected by electrolyte leakage, eliminated without disassembly. The slots are packaged (at an angle of 90-120 degrees) and filled with hot mastic. In case of electrolyte seepage around the pin, remove the mastic in this place with a heated chisel and solder the pin and lead sleeve connections in the lid. Cracks in the mastic on the lid are smoothed out with a heated metal plate.
Before disassembling the battery during repair, it is discharged with a current of 1 / 20-1 / 15 of the nominal capacity to a voltage of 1.5 V in each battery. After that, the electrolyte is poured into a ceramic bath or into a glass bottle and the battery is washed with distilled water.
Then the jumpers are removed by drilling them with a tubular cutter or a drill with a diameter of 18 mm , and the acid-resistant mastic is removed from the covers, for which the surface of the battery, filled with mastic, is heated in a special electric reflective oven; you can remove mastic with heated scrapers or electric heating paddles. The covers removed from the mastic are removed with a special remover. Individual plate blocks can be removed from the tank using hand grips or pliers.
A defective set of blocks can be removed from the tank without removing the jumpers-extractor or pliers using grips to hold the battery.
The disassembled battery is washed in wooden baths with water, dried, examined and the nature of the repair is determined.
Wooden charred separators are replaced, and mipor and miplastic separators, which do not have mechanical damage, are used again.
Plates with a damaged lattice, warped, with cracks and bulges on the surface of the active mass, sulfated, as well as the plates by the active mass dropped from the cells are separated from the baffle, melting their ears in the places of welding with the baffle. Warped plates are melted under a press between two wooden planks. Broken ears are welded on the plates. If one or more unusable plates are found in the block, they are replaced with serviceable, but used ones. To detect cracks in the walls of the tank, it is filled with water heated to 80-90 degrees celt and watched for seepage.
The tightness of the tank walls can also be checked by their electrical conductivity. To do this, a weak aqueous solution of sulfuric acid is poured into the tank and installed in a bath filled with the same solution. In the bath inside the tank, electrodes are placed, into which a current with a voltage of 127-220 V is supplied through the voltmeter. If the tightness of the outer walls is not broken, the voltmeter needle will remain at the zero division of the scale.
In the same way, the internal partitions are checked by immersing the electrodes in the adjacent compartments of the tank.
Tanks with mechanical damage (chips, cracks or breaks in the walls) are replaced or repaired depending on the material from which they are made. The assembled blocks (positive and negative plates with separators inserted between them) are checked with a voltmeter for a short circuit, then installed in the tank compartments. On each block, covers are placed, which are sealed with an asbestos or rubber cord, and the surface of the battery is poured with mastic. The assembled storage battery is filled with an electrolyte of the appropriate density, cooled to 25-30 degrees.
The electrolyte is prepared from chemical pure sulfuric acid and distilled water in an acid-resistant container. If the battery was assembled from new plates during the repair, then after filling the electrolyte before charging it is kept for 4-5 hours. The battery, assembled from old plates, is put on charge without exposure. The charge is carried out until the onset of intense gas evolution from the electrolyte (boiling) at a steady-state voltage on the pins of each can of 2.6-2.75V. And the unchanging density of the electrolyte, which should maintain their values for 2 hours. Changed at the end of the charge, the density of the electrolyte should be brought to the norm of 1.23 summer and 1.27 winter.
1 .3 Labor regime andtime fundsworkworkersequipment
The operating mode of the site is determined by the number of working days per week - 5, the number of working days per year - 252, the number of work shifts per day and the duration of the work shift - 8 hours based on the operating modes of the equipment and workers. There are two types of time funds: nominal and real.
The nominal annual fund of equipment operating time is the time in hours during which the equipment can operate at a given operating mode.
F but= D RNSt (1.3.1.),
where D p = 252 days - the number of working days in a year,
t = 8 hours - duration of the work shift
F but = 252 x 8 = 2016 hours.
The nominal annual fund of working hours cannot be fully used, because there are inevitable downtime of equipment for repairs and maintenance.
The actual (calculated) annual fund of equipment operation time F to is the time in hours during which the equipment can be fully loaded with production work
F before= F butNSNS (1.3.2.),
where P = 0.98 is the equipment utilization factor taking into account equipment downtime during repairs
F to = 2016 x 0.98 = 1776
The annual fund of the workplace Frm is the time in hours during which the workplace is used, the numerical value of the annual nominal fund of the time of the workplace is practically equal to the annual nominal fund of the working time of the equipment.
The nominal annual fund of working time of the worker F nr is equal to the product of the number of hours worked per shift by the number of working days in a year.
The actual (calculated) annual fund of the time of work of one worker Ф dr is determined by excluding from the nominal fund of time that falls on the next vacation, fulfillment of public duties, illness, etc.
|
ELEMENTS OF TIME |
unit of measurement |
Received data |
|
|
Calendar time |
|||
|
Weekends |
|||
|
Holidays |
|||
|
Nominal time |
|||
|
Planned absenteeism, total |
|||
|
Another vacation |
|||
|
Due to illness |
|||
|
For good reasons |
|||
|
Work time |
|||
|
Length of work shift |
|||
|
Annual nominal time fund |
|||
|
Annual valid time fund |
|||
|
Student leave |
1.4 Annual production program
The annual production program of the production site is determined by the size of the annual production program of the auto repair enterprise specified in the assignment for the diploma design and is:
FORD F-250 cars - 150 pieces.
IVECO 138E18 cars - 150 pieces.
The car repair company is designed to carry out major overhaul of trucks different models therefore, in order to simplify the calculations, its production program is reduced in terms of labor intensity to one model, taken as the basic model.
The given production program of the site is determined by the formula:
N pr = N + N1 K M (pcs)
where N = 150 pcs. - annual production program of major overhauls of FORD F-250 cars - 150 units, taken as the basic model;
N1 = 150 pcs. - annual production program of overhaul of IVECO 138E18 vehicles - 150 pcs.
K M = 1.75 - coefficient of reduction of labor intensity FORD car F-250 for the IVECO 138E18 car adopted as the base model;
then N pr = 150 + 150 1.75 = 412 (pieces)
1.5 Annual volume of work
The annual volume of work refers to the time that must be spent by production workers to complete the annual production program. The annual volume of work represents the annual labor intensity of the repair of certain products and is expressed in man-hours.
The labor intensity of a product is the time that needs to be spent by production workers directly on the production of a given product. Labor intensity is expressed in man-hours, which is understood as the standard time according to the current planning standards.
In the course of the diploma design, the enlarged norms of time are used, obtained on the basis of the analysis of existing projects for the reference conditions of the annual production program of the given overhauls of 200 pieces. With a production program that differs from the reference conditions, the normative labor intensity is adjusted according to the formula:
t = t n K 1 K 2 K 3 (man-hour)
where t n = 10.73 man hours is the standard labor intensity of the repair of units;
K 1 - the coefficient of correction of labor intensity, depending on the annual production program, is determined by the formula:
K 1 = KN 2 + [KN 1 - KN 2] / N 2 - N 1 x (N 2 -N PR)
with N 1 = 3000 KN 1 = 0.95 from the table
N 2 = 4000 KN 2 = 0.9 N PR = 3400
then K1 = 0.9 +
K2 is the coefficient of labor intensity correction, taking into account the multi-model nature of the repaired vehicle units (with carburetor and diesel engines). = 1.05 out.
K3 - coefficient of correction of labor intensity, taking into account the structure of the plant's production program (the ratio of overhauls of complete vehicles and complete sets of units, with a ratio of 1: 0) = 1.03
then t = 10.73 0.95 1.05 1.03 = 11.03 (man-hour)
The annual volume of work is determined by the formula:
T YEAR = t N PR (man-hour)
where t = 11.03 (man-hour) - labor intensity per unit of work per vehicle;
N PR = 412 - the annual reduced production program of overhaul of automobiles;
then T YEAR = 11.03 412 = 4544 (man-hour)
1.6 Number of employees
The composition of the employees is distinguished between the payroll and the safe.
Payroll - the full composition of employees who are listed according to the lists at the enterprise, including those who actually come to work and who are absent for a good reason (due to illness, on labor leave, on a business trip, etc.)
Explicit is the composition of workers who actually come to work.
The number of workers produced is determined by the formula:
T YV = T YEAR / F NR (people)
T SP = T YEAR / F DR (people)
where T YV is the actual number of production workers;
T SP - payroll number of production workers;
T YEAR = 4544 (man-hour) - annual labor intensity renovation works;
F NR = 2016 hour - the annual nominal fund for the working time of the worker;
Ф ДР = 1776 hours - the actual annual fund of the worker's work time;
then T YV = 4544/2016 = 2.25 (people)
T SP = 4544/1776 = 2.55 (people)
The calculation of the number of production workers is summarized in Table 2.
table 2
Production Workers Calculation Sheet
|
Name of works |
Labor intensity per unit, man-hour |
Annual number of overhauls |
Annual volume of work, man-hour |
Annual fund of time |
Number of employees |
|||||
|
estimated |
adopted |
|||||||||
|
F HP |
F DR |
T I'M IN |
T Joint venture |
T I'M IN |
T Joint venture |
|||||
|
Battery repair |
In addition to production workers, employed directly in operations for the release of the main products (overhaul of units), there are also auxiliary workers on the site who are engaged in servicing the main production. These include workers, toolmakers, handymen, etc.
The number of auxiliary workers is determined from the payroll of production workers according to the formulas:
T VSP = P1 T SP (people)
where P1 = 0.25? 0.35 - the percentage of auxiliary workers;
T VSP = 0.26 2.55 = 0.66
we accept T VSP = 0.66 people.
The payroll of production and auxiliary workers is distributed by profession and grade. The category of workers is assigned according to the tariff and qualification guide, depending on the nature and complexity of the work performed on the site.
We accept: production workers - 6th grade battery repair mechanic - 1 person;
5th category - 1 person;
total: 2 people
auxiliary workers - handyman 2 categories - 1 person;
transport worker of 3 categories - 1 person.
total: 2 people
The average discharge of the working area is determined by the formula:
where is M1? M6 is the number of workers of the corresponding category;
R1? R6 - categories of workers;
then R CP =
The data obtained on the payroll of production and auxiliary workers are summarized in Table 3.
Table 3
List of production and auxiliary workers
|
Worker profession |
Total |
Number of workers |
|||||||
|
by shifts |
by category |
||||||||
|
Production workers: |
|||||||||
|
repairman |
|||||||||
|
auxiliary workers: |
|||||||||
|
handyman |
|||||||||
|
transport worker |
|||||||||
The number of engineering and technical workers, office workers and junior maintenance personnel is determined as a percentage of the total number of production and auxiliary workers according to the formula:
where P i = 0.1 is the percentage of engineers and technicians;
then: M i = 0.13 (2 + 2) = 0.52
We accept three (1) masters.
The obtained data on the total composition of workers at the site are summarized in table. 4.
Table 4
The composition of the working section
|
Name of groups of workers |
Number of employees |
average category of workers |
justification of the calculation |
||
|
Total |
in the first longest shift |
||||
|
Auxiliary workers |
30% of the number of main workers |
||||
|
Total workers |
|||||
|
Engineering and technical workers and employees |
10% of all workers |
||||
|
Total employed |
1.7. Selection of equipment for the site
Table 5
|
equipment identification |
Brand, type |
Qty |
Set power |
Dimensions (edit) |
Footprint |
|
|
Waste bin |
||||||
|
Battery repair workbench |
||||||
|
Electrolyte drain bath |
||||||
|
Battery rack |
||||||
|
Sharpening machine |
||||||
|
Mobile washing tub |
||||||
|
Rack for battery charging |
||||||
|
Locksmith workbench with equipment for smelting lead and mastic |
||||||
|
Material cabinet |
||||||
|
Bench drilling machine |
||||||
|
Hydraulic press |
||||||
|
Chest for cleaning materials |
||||||
|
Electric distiller |
||||||
|
Rack for bottles |
||||||
|
Electrolyte preparation bath |
||||||
|
Total: |
14 ,7 |
1 8,52 |
2. Technological part
2.1 Calculation of the area of the site
The production area of the site is determined by a detailed method according to the floor area occupied by the equipment and inventory and the coefficient of transition from the area of equipment and inventory to the area of the site, taking into account the workplaces in front of the equipment and building elements, with subsequent refinement of the area after the planning solution of the site.
The production area of the site is determined by the formula:
F У = F O · К P [m 2]
where F O = 18.52 m 2 is the floor area occupied by equipment and inventory from tobl. 5
K P = 4.5 - the coefficient of transition from the area of the site for the repair of batteries.
Then F Y = 18.52 4.5 = 83.34 m 2
After completing the planning decision from the graphic part, the area of the site is specified in accordance with the KMK.
F У = b · t · n = 9 · 6 · 2 = 108 m 2
where b = 9m - span of the building;
t = 6m - column pitch;
n = 2m - number of columns.
We accept the area of the plot F U = 108m 2.
2.2 Electricity demand calculation
The annual consumption of power electricity demand is determined in an enlarged manner:
where = 14.7 kW is the installed power of the section pantographs from Table 5;
3950 hours - an annual effective fund of equipment operating time for two-shift work
0.75 - equipment load factor during the shift, taken from.
The annual electricity consumption for lighting is determined by the formula: [kW]
where R = 20W is the specific rate of electricity consumption per 1m 2 of floor area per one hour of operation;
2100 hours - lighting operation time during the year;
108m 2 - plot area;
The total energy consumption is:
2.3 Compressed air demand calculation
Compressed air is used to blow off parts when assembling mechanisms and assemblies, to power mechanical, pneumatic tools, pneumatic drives, fixtures and stands, as well as paint spray guns for applying paints and varnishes, installations for cleaning parts with crumbs, for mixing solutions.
The need for compressed air is determined on the basis of its consumption by individual consumers (air inlets) with continuous operation of their utilization factor in each change of the simultaneity factor and the annual actual fund of their operation.
The annual consumption of compressed air is determined as the sum of costs by different consumers according to the formula:
Qsqueeze = 1.5qx P x Kch x Codex Fdo ; (3.3.1)
where q = 5 / hour - specific consumption of compressed air by one consumer
1.5 is a coefficient that takes into account operational air losses in pipelines.
P - The number of single-shift consumers of compressed air.
Кч - coefficient of use of air inlets during the shift.
Kodn, - coefficient of simultaneous operation of air inlets.
Fdo = hourly real fund of time of operation of air inlets when changing work
Qsqueeze = 1.5 x 5 x 4 x 0.9 x 0.7 x 2000 = 37800
2.4 Calculation of water and steam demand
Water for production needs is consumed in baths and its need can be roughly taken according to the formula:
Qin =gNSnx Fdo ; (3.4.1)
Where q = 0.05 - specific water consumption per hour of operation of one bath
P = 1 - bath
Fdo = 1776 - the annual real fund of equipment operation time.
Qw = 0.05 x 1 x 1776 = 88.8 (3.4.2)
The required amount of steam for heating is determined based on the maximum hourly heat consumption Qm.h. according to the formula:
Qm.h. =Vn (qo + qb) NS (tv-tn) ; (3.4.3.)
where Vn = 648 is the volume of the heated room.
qo + qb - specific heat consumption for heating
qo = 0.45 kcal.h.
qb = 0.15 kcal.h.
tv = internal room temperature = + 18C
tn = minimum outside temperature = -10C
Assuming that the heat transfer is 1 kg. steam is 550 kcal. (2300J).
The duration of the heating period is 4320 hours.
Qincl. = 648 x (0.45 +0.15) x(+18 -10) = 311 0 m.h.
2.5 Battery cover remover
The covers from the battery monoblock are removed using a tool. When performing this operation, from the stripper bracket, they are installed on the side of the upper part of the monoblock so that the lower end of the grip is twisted into the filler hole of the battery cover. Then the grip is fixed in the working position. Smoothly pressing the lever, remove the monoblock cover. In this case, a force of more than 50 N should not be applied in order to avoid damage to the cover. If, for removal, a force of more than 50 N is required, then it is necessary to additionally warm up or clean the mastic.
2. 6 Calculation of numbersagroups of batteries installed on charge in parallel
Charge the 6ST75 battery from the unit, which has an output voltage of 70 V and a current of 8 A.
1. We count the number of batteries connected in series in one group, based on the voltage of 2.7 V per battery
2.K = U / (2.7 X n) = 70 / (2.7X6) = 4.32
where, U = voltage at the unit output, V: n = number of batteries in 6ST75 batteries.
Thus, include batteries in the group.
Since the charging current of 6ST75 batteries is 7.5A, one battery group can be connected to a unit that provides a current of 8 A.
2. 7 Breading solution
Equipment and inventory must be arranged in accordance with SNiP and technological process. Products requiring repair are delivered to the racks in a clean state after outdoor sink... When disassembling, parts that are not suitable for further assembly are rejected, and those that are fit without dismantling are assembled with the replacement of all rubber products. Locksmith workbenches are installed in such an arrangement near the main wall, where there is working artificial lighting, where workers spend most of their working time. The site has a washstand, a sand box and a fire shield. The floors are covered with concrete tiles.
The rational arrangement of the equipment allows to carry out the repair of hydraulic equipment with the least loss of time.
3. Orgeconomic-economic part
3 .1 Capital Cost Calculation
Capital expenditures on the site represent the money spent on the purchase, delivery, installation of new and dismantling of old equipment, for the construction of a part of the building for the site. Capital costs are accounted for in the fixed assets of the enterprise throughout the entire period of operation at their original cost.
Fixed assets participate in the production (overhaul of cars) in an unchanged form over a long period of time, gradually wear out and lose their value in parts, as physical wear and tear. The monetary value of depreciation is called depreciation and during the year the depreciation cost is included in the cost of the product.
Depreciation deductions (the transfer of depreciation in parts of the value of fixed assets to the product produced with their help) is carried out for the accumulation of funds in order to restore and reproduce fixed assets.
The amount of depreciation, expressed as a percentage of the original cost, is called the annual depreciation rate H a... The depreciation rate is set at the state level or can be adopted by a formula;
N a= 100: T sl ; [%] (4.1.1.),
where T sl is the service life of the equipment or building, according to technical specifications.
The annual rate of depreciation deductions, included in the prime cost of the rate of capital repairs, is determined by the formula:
A r = [Sum] (4.1.2.),
where PS is the initial cost of fixed assets.
Fixed assets are conditionally divided into two groups: passive fixed assets (buildings, structures) are not directly involved in the creation of products, but are necessary for its production, and active fixed assets are directly involved in the creation of products (overhaul)
Calculation of the cost of fixed assets and depreciation charges
Table 1
Calculation of the cost of the main equipment and depreciation deductions
|
equipment identification |
Brand or type |
Price is one equipment (thousand soums) |
Accruals |
First. price |
depreciation |
|||||
|
Price of all equipment |
Transport expenses 15% |
Installation 20% |
Amount (thousand soums) |
|||||||
|
Waste bin |
||||||||||
|
Acid-proof bath for rinsing parts |
||||||||||
|
Battery repair workbench |
||||||||||
|
Electrolyte drain bath |
||||||||||
|
Battery rack |
||||||||||
|
Sharpening machine |
||||||||||
|
Vertical drilling machine |
||||||||||
|
Mobile washing tub |
||||||||||
|
Stand for checking and discharging the battery |
||||||||||
Summary calculation of capital investments and depreciation charges for the site
Table 3
|
Name of capital investments |
Initial cost thousand soums |
Depreciation deductions |
||
|
Sum thousand soums |
||||
|
Building for a plot |
||||
|
Access roads and structures (30% of the building value) |
||||
|
Basic equipment |
15194,25 |
|||
|
Unaccounted for equipment (10% of the cost of new equipment) |
||||
|
Fixtures and expensive tools (1% of the cost of equipment) |
||||
|
Inventory (8% of the cost of equipment) |
||||
|
Site preparation (1% of the building value) |
||||
|
Other costs (1.5% of the building value) |
||||
3 .1.2 Calculation of payroll costs
The remuneration of workers for the repair of equipment is based on a tariff system, depending on the complexity of the work, working conditions and forms of payment. The site belongs to the production with harmful working conditions. The tariff system is based on hourly tariff rates and a six-digit tariff scale.
The main production workers are paid according to the piece-rate-bonus system for the actually completed volume of repair work at the hourly tariff rates of the piece-workers, depending on the working conditions, according to the formula:
3P T= C 1 TO TT yearR R ; [Sum] (4.1.2.1.),
where C 1 is the hourly tariff rate of the first category, taken according to table 4
Table 4
К т - tariff coefficient, showing how many times the tariff rate of the accepted category is higher than the first, is taken according to table 5.
Table 5
|
Tariff coefficient |
T year = 4544 man.h - the annual volume of repair work;
R p = 2 people - the number of repair workers of the accepted category.
Payment for the work of auxiliary workers is made according to the time-based system for the hours actually worked according to the hourly tariff rates of time workers, depending on the working conditions according to the formula:
3 P vp= C 1 TO TF drR vp ; [Sum](4.1.2.2),
where Ф dr = 1776 hours - the annual real fund of the working time of one worker,
R vsp = 1 person - the number of auxiliary workers of the accepted category
For all workers of the section, additional payments are made to wages: the bonus for the timely and high-quality performance of repair work is taken in the amount of:
Basic workers - 30%
Auxiliary workers - 20%
Engineering workers - 40% 51
Civil servants and MNP - 15%
Regional coefficient in the amount of 60% of the tariff, but not more than 15630 soums per month.
Basic salary is determined by the formula:
3 P main= 3 P T+ P + K R ; [sum](4.1.2.3.)
In addition to the basic wage, all employees of the enterprise receive additional wages for the period of work leave, illness, business trips, student leave, which is determined as a percentage of the basic wage according to the formula:
3 P add= P d3 P main; [sum](4.1.2.4.),
where P d is the percentage of additional wages, for design purposes it can be adopted:
Basic workers - 22%
Auxiliary workers - 15%
Engineers and technicians - 30%
Civil servants and MNP - 15%
The wage fund of the workers of the site is determined by the formula:
FZP = 3 P main+ 3 P add[sum](4.1.2.5)
The enterprise makes contributions from the wage fund of all employees to public social security funds in the amount of:
Social Insurance Fund - 31.6%
Pension fund - 0.5%
Employment Fund - 0.9%
TOTAL: - 33%
Contributions to public funds in the amount of 33% are included in the cost of repair work per hour. The calculation of the costs of wages of workers of the section of workers of the section will be presented in the form of tables.
Calculation of the payroll of repair workers
|
Profession |
discharge |
Qty |
Rate. bid |
Time fund |
salary according to the tariff |
Supplements |
Basic w / payment |
Additional salary |
Salary fund |
||
|
Prize |
TO R |
||||||||||
|
Main workers |
|||||||||||
|
Handymen |
Summary calculation of the payroll for the site
|
Number of |
Salary fund |
Contributions to public funds 33% |
||
|
Main production workers |
||||
|
Auxiliary workers |
||||
|
TOTAL workers: |
||||
|
Engineers and technicians |
||||
|
Employees |
||||
|
Junior attendants |
||||
|
TOTAL staff: |
||||
|
TOTAL working: |
3 .1.3 Calculation of material costs
Material costs on the site are made up of the cost of materials and spare parts required to carry out repair work.
The amount of material costs is determined based on the consumption rates for one major overhaul, the annual production program for major overhauls and the price per unit of material assets.
When calculating the total cost of material costs, transport and storage costs are taken into account in the amount of 15%.
Calculation of the cost of materials
3.1.4 Rcalculation of other shop expenses
Other shop floor expenses are expenses that are not involved in the production of products, but are necessary for its production. The amount of shop costs is determined by drawing up the corresponding estimate, consisting of two sections, each of which includes the costs of the corresponding group.
Group A includes the costs associated with the operation of equipment:
For power electricity:
WITH NS= WC NS; [sum](4.1.4.1.),
where W = 113,250 kWh - annual power consumption,
Ts e = 18.5 sum - the price of one kilowatt-hour,
then WITH NS= 113250 x 18.5 = 2095125 sum
For compressed air:
WITH squeeze= Q squeeze C squeeze ; [sum](4.1.4.2.),
where Q squeeze = 64997m 3 - annual consumption of compressed air,
Ts comp = 2.5 sum - one m 3 of compressed air.
then WITH squeeze= 64997 x 2.5 = 1624925 sum
On water for production purposes:
WITH tue = Q tueC tue; [sum](4.1.4.3)
where Q W = 8000 m 3 is the annual water consumption for production purposes,
Ts t = 276 soums - the price of one m 3 of technical water.
then WITH tue= 8000 x 276 = 2208000 sum
For domestic water:
WITH b = qD RR C b; [sum](4.1.4.4)
where q= 0.08 m 3 - specific consumption of drinking water per worker per shift,
D R= 225 days - the number of working days in a year,
R= 3 people - the number of workers at the site,
C b = 258 sum - the cost of one m 3 of drinking water,
then WITH b= 0.08 x 225 x 3 x 258 = 13932 sum
Total water consumption: 2208000 + 13932 = 2221932
Steam consumption for heating the premises of the site:
WITH NS = VF beforeq / I 1000 ; [sum](4.1.4.5)
where V= 648 m 3 - the volume of the building site,
F before= 4140 hours - heating operation time during the year,
q= 20 kcal / hour - specific steam consumption per 1m 3 of the building per hour of operation,
I= 540 kcal / h - heat transfer of one ton of steam,
C p = 15450 soums - the cost of one ton of steam
then WITH n = x 15450 = 1535112 sum
3-5% of its cost is accepted for current repair of equipment: 0.05 x 15194300 = 759713 sum
3-5% of the cost of basic materials is accepted for auxiliary materials: 0.05 x 4929360 = 246468 sum
For spare parts for repairing equipment, 5% of its cost is taken: 0.05 x 15194300 = 759713 sum
Group B includes general workshop expenses:
On the salaries of engineers, employees and MOPs from the table;
For the renovation of the building at the rate of 2% of its cost: 0.02 x 34020000 = 680400 sum
For labor protection, 5.5% of the wages fund of all workers is taken: 0.055 x 3820333 = 210118 sum
Safety measures are taken at the rate of 35,000 soums per worker (main and auxiliary) 35,000 x 3 = 105,000 soums
Other unaccounted for expenses are accepted 10% of the total shop expenses.
To determine the total amount of expenses, we draw up an estimate:
Shop cost estimate
|
Name of expense items |
||
|
salary of engineers, employees and MOP |
||
|
Compressed air costs |
||
|
Electricity costs |
||
|
Water costs |
||
|
Heating costs |
||
|
Equipment maintenance |
||
|
Supporting materials |
||
|
Building renovation |
||
|
Spare parts for equipment repair |
||
|
Occupational Safety and Health |
||
|
Safety engineering |
||
|
Other shop floor expenses |
||
Cost estimate and costing
The cost estimate for the maintenance of the site is the sum of all the costs of the repair work. Costing refers to the sum of all costs per unit of production.
Only part of the overhaul work is performed on the site, therefore, the standard hour of repair work is conventionally taken as a unit of production, and the costs for it are determined by the formula:
WITH LF= 3C / T year ; [sum](4.1.4.6)
where 3C is the sum of costs from the estimate,
T year = 3243 man.h - annual labor intensity of repair work.
Cost estimate for the maintenance of the site
The prime cost of a standard hour will be:
WITH LF= = 8461 sum
3 .2 Raceeven economic efficiency
The annual economic effect of the implementation is determined by the formula:
E = C 1 - (WITH 2 + E nTO); [ cmind](4.2.1)
where C 1 and C 2 - the cost of the planned and base years, sum.
E n = 0.15 - standard coefficient of comparative efficiency
K - capital investments, sum.
comparison table
|
Name of cost items |
|||
|
Production workers wages |
|||
|
Social security contributions |
|||
|
Cost of materials |
|||
|
Spare parts cost |
|||
|
Depreciation deductions |
|||
|
Other shop floor expenses |
|||
|
Total |
26901409 |
16140845,40 |
|
|
Non-production costs, 2% |
|||
|
Total |
27439437 |
16463662,31 |
E = 27439437 - (16463662.31 + 66063000NS 0,15) = 1066324,69 sum.
3 .3 Technical and economic indicators of the project
|
The name of indicators |
unit of measurement |
Project data |
|
|
Annual production program of refurbished overhauls |
|||
|
Annual volume of repair work |
|||
|
Number of employees, total |
|||
|
Including workers |
|||
|
Payroll, total |
|||
|
Including workers |
|||
|
Average monthly salary: One worker one working |
|||
|
Installed power of pantographs |
|||
|
Energy-to-weight ratio |
|||
|
Production area of the site |
|||
|
Capital investments |
|||
|
Capital-labor ratio |
Thousand sum / slave |
||
|
The amount of costs for maintaining the site |
|||
|
Cost of one standard hour of repair work |
|||
|
Cost of one reduced overhaul |
4. Occupational Safety and Health
The legislation of the Republic of Uzbekistan regulates the basic standards of work and rest of employees of enterprises.
The main task of labor protection is to carry out a set of legislative, technical, sanitary-hygienic and organizational measures aimed at ensuring safe working conditions and continuous facilitation of production processes. As a result of these measures, labor productivity should increase. Maximum improvement of working conditions, prevention of industrial injuries and occupational diseases, full implementation of safety measures and fire-fighting equipment is the main method of work in the field of labor protection.
Labor protection legislatively regulates the following relations:
General conditions of labor activity of workers and employees in production;
Norms and Regulations on safety measures, industrial sanitation and fire prevention;
The procedure for planning and financing measures for labor protection;
Norms and Rules for the special labor protection of women, adolescents and persons with reduced working capacity;
Benefits for persons with harmful and difficult working conditions;
Medical care at the place of work;
The procedure for ensuring workers in case of loss of working capacity due to accidents and injuries at work, as well as occupational diseases;
Responsibility of enterprises and officials, as well as workers and employees for violation of labor protection requirements and for the consequences of these violations.
All employees entering work undergo induction training on the basics of safety and industrial sanitation, as well as on-the-job training. A re-briefing is carried out once every six months.
Safety instructions for workers of those professions who work on the site should be posted in a conspicuous place on the site. In addition to the instructions, posters on safe working practices and warning signs and inscriptions should be posted.
Particular attention is paid to providing workers with personal protective equipment: workwear, safety footwear, protective equipment for hands, eyes, face, respiratory organs, as well as special protective equipment against electric shock and harmful industrial fumes.
The company performs the washing, repair of overalls and replacement of overalls and footwear that have become unusable through no fault of the employee free of charge.
In accordance with the lists of jobs with harmful working conditions, compiled by the administration of the enterprise, workers are given food free of charge - special fats (milk), as well as soap (400g per month).
There must be a first aid kit on the site, complete with medicines necessary for first aid.
Responsibility for compliance with the Occupational Health and Safety Rules at the site is borne by the foreman, and in his absence, the foreman.
4 .1 Safety requirements for ventilation, heatingand lighting
Ventilation of industrial premises serves to ensure proper sanitary and hygienic conditions for the air environment of workers.
The site provides for exhaust and supply ventilation. Exhaust ventilation removes polluted air from the room, while supply ventilation delivers clean air.
Natural and artificial ventilation is provided on the site. Natural ventilation is carried out through the windows of the room. An artificial (mechanical) ventilation system provides for the removal of polluted air by centrifugal fans, the type and brand of which is selected based on the volume of the room and the multiplicity of the air volume according to the formula:
Q v = VTO O; [m 3 ] (5.2.1.)
where, V = FH = 648 m 3 - the volume of the premises of the site
F у = 108 m 2 - area of the site,
H = 6 m - the height of the premises of the site
К о = 5 - the multiplicity of the air volume
then Q v= 648 x 5 = 3240 m 3
We choose a fan EVR-3 with a capacity of 3000 m 3 / hour in the amount of 2 pieces.
In the workplace, associated with the emission of fumes that are harmful to health, i.e. in places where poisonous gases harmful to health can be released, local exhaust-type ventilation is installed with TsAGI-4 fans, which provide lateral suction of harmful vapors at the workbench level and prevent their spread throughout the room.
To comply temperature regime an air heating system is provided due to forced ventilation of heated air. The fans blow the heated air through the heater and blow it into the heated room.
There is also a central water heating system, in which hot water enters the heating devices (radiators or pipes), which give off heat to the room. The calculated air temperature in the room is +18 o C. The heating system should provide for uniform heating of the air, the possibility of local regulation and shutdown. To create normal working conditions in the premises of the site, natural and artificial lighting is provided.
Natural light is provided through windows in the outer wall of the building.
Artificial lighting is provided for combined, i.e. general and local. General lighting is provided by fluorescent lamps along the perimeter of the ceiling. Local lighting fixtures, located directly at the object of work, allow you to control the luminous flux, creating a high level of illumination. The voltage of local lamps is 12 or 36 V.
In addition to the main lighting, emergency lighting is provided at the rate of 10% of the standardized. For the evacuation of people, emergency lighting must be at least 0.3 lux. The value of the actual illumination of the premises of the site must be at least 300 lux.
4.2 Requirementssafety precautions for tools, equipmentanddevices
Reducing industrial injuries largely depends not only on the quality, but also on the serviceability of the tools used.
All tools are thoroughly inspected daily before starting work and, in the event of a malfunction, are promptly delivered to the tool store for replacement. Defective and unnecessary tools should not be stored in the workplace. Workplace tools must always be clean and dry.
The wooden handles of the tools must be smooth, free of knots, cracks and scuffs and made of hard and viscous wood. To avoid injury, tool handles should not be made of soft wood species (pine, spruce, fir, etc.).
The handles of the instruments must be firmly seated and properly secured. Hammer and sledgehammer handles are inserted strictly perpendicular to the longitudinal axis of the tool and wedged with complete metal wedges.
The wooden handles of files, hacksaws, chisels and screwdrivers are fixed to the tools with metal rings that prevent them from splitting.
Hammers and sledge hammers should have a slightly convex, no potholes and cracks, not an oblique or knocked down surface of the striker.
Wrenches must be in good working order and strictly correspond to the size of nuts and bolts, ensure ease of use and be of high strength.
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2 Plan - scheme of the Ussuriysk locomotive repair plant ……. …………………………… .. ……… 1.3 Management structure of the Ussuriysk locomotive repair plant ……. ………………………. 2 General information about workshop where M62 2.1 is being repaired workshops LSC …… …………………. …… ... …………………… 2.2 Plan - scheme workshops LSC ……. ……………… ... ………………………… 2.3 Management structure workshops LSC ……. …………………………. ……… 2.4 The list of equipment, fixtures and tools used in the repair of M62 ……………………………………… 3. Purpose, design and the principle of operation of M62 .........................................................
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Given the popularity of batteries today, many are striving to open their own business, to make money on their manufacture. However, the technology for producing batteries is so complex that it is impossible to do without special education and experience, it can be simply dangerous.
Rechargeable batteries are irreplaceable in modern life. These are additional energy sources that can be recharged, which is very convenient and beneficial. Batteries usually consist of several power supplies that are combined into one that gives more power. In this case, you can get a battery that will give exactly as much voltage as is needed to ensure the operation of a particular unit.
Nowadays, there are several specific types of batteries that are manufactured using special technologies. Not only the type of work differs, but also the materials used. The result is more or less high-quality rechargeable batteries, which vary significantly in price.
Batteries are in great demand these days. They are used in all walks of life. It can be separate batteries for small household or digital devices, and for cars, and for. Manufacturing rechargeable batteries can be a very profitable business, but such a business requires specialized knowledge, sophisticated equipment, reliable product suppliers and a good investment. Only then can you get a highly profitable business that will generate income all year round.
Types of rechargeable batteries
Nowadays, the most popular options are nickel-cadmium, lithium-ion and lead-type batteries. In addition, they differ in the type of electrolytes used, which can be alkaline and acidic.
For each type of device, certain types of rechargeable batteries are used. For example, lithium-ion devices are best suited for digital devices and home appliances. These batteries are considered to be of the highest quality and most durable. But they are more expensive than their nickel-cadmium counterparts. Lead acid batteries are mainly used in the automotive industry. You can earn the most on such products, but the investments will be impressive. Lead-acid batteries are also different in their type. They can be antimony, calcium, hybrid, gel.
In any case, special equipment is required for each separate type of storage battery. Manufacturing batteries in itself is a very complex task that only experienced professionals can handle. Do not forget that many harmful substances are emitted during the manufacture of batteries, therefore the workshop should be located in an industrial area.
If an entrepreneur is going to invest in opening a factory for the manufacture of batteries, he needs to prepare for the fact that this process will be difficult. To organize a business, you need certain knowledge. If a businessman does not have them, he will need to hire experienced specialists for leadership positions. Their work will be expensive, but without proper organization, it will be difficult to set up a battery business.
Battery technology
When it comes to battery manufacturing, experienced entrepreneurs claim that this is a very complex type of business, so it is not worth starting a factory from scratch without any skills in this area, as it is very dangerous.
But even those who know the whole process and technology of battery production well should get reliable partners. This will make it easier.
It is impossible to do without a clear work plan, this is too serious a matter and large investments... In addition, supplying and marketing needs to be established to create batteries and sell them profitably. This is very important, as unreliable suppliers can damage the reputation of the plant. For large clients, timely receipt of goods is one of the main conditions, without which there will be no effective cooperation.
Lithium battery manufacturing
Lithium-ion batteries are the most popular, therefore this type batteries should be given special attention. In this case, it is necessary to cover the active electrodes with a metal foil.
The material that is needed to assemble the battery comes to the workshop in the form of black powder. In this case, the components for the two main elements must be stored separately. Mixing them will render the battery unusable. Most often, various rooms are provided for the manufacture of cathodes and anodes.
Electronic materials should be mixed until a homogeneous suspension is obtained. Then it must be applied to the film and dried. The most crucial stage in this matter is cutting the finished film. If any failure or deviation occurs at this time, this will lead to the closure of the elements. To avoid such troubles, exclusively high-quality and high-precision machines are used. Moreover, a lot here also depends on the human factor, so you shouldn't save on qualified personnel.
All the main work is carried out on special equipment. Large factories use fully automated production equipment. This allows high-quality products to be produced in large quantities. To create lithium-ion storage batteries, it is necessary to equip a workshop:
- a spectrometer-analyzer of the chemical composition of materials;
- an electron microscope for scanning products and elements;
- a calorimeter that allows you to determine the thermal property of the material;
- vibrating tables and climatic chambers to adjust the performance of the cells;
- test equipment that will accurately establish battery life and number of charge cycles.
Lead Acid Battery Manufacturing
As mentioned above, this type of battery is mainly used. This requires special production equipment and materials. All this costs a lot of money, so even at the initial stage, the organization of the production of car batteries will cost a large amount. However, good returns can be expected from such activities.
Equipment for production is the most expensive, but one cannot fail to note the special materials, without which it is impossible to make lead batteries. For example, you will need powerful plastic cases that can withstand the effects of aggressive environments. Such a case is called a monoblock.
The lead plates themselves are current conductors. The grid can be filled with pure lead, but these batteries are of low power. To improve product quality, it is necessary to use metal mixtures. Sometimes lead is mixed with antimony, calcium and other elements that have a beneficial effect on the properties of battery plates.
Most often you can find on sale car batteries made of lead with admixtures of antimony and calcium. The first type is considered worse, since here the plates weigh more and serve less. If lead with calcium has been used for the battery, the product will be lighter and more durable. Lead-calcium plates do not crumble over time and are more durable, so the battery will last much longer.
A step-by-step plan for starting a battery production
The launch of battery production can be divided into stages:
- Drawing up a business plan, conducting marketing research.
- Search for investors.
- , obtaining permits.
- Rent and arrangement of the workshop in accordance with SanPiN 2.2.1 / 2.1.1.1200-03
- Purchase of equipment.
- Production launch.
- Advertising and sales of products.
How much can you earn from making batteries
The business profitability is 30%. After drawing up a business plan and implementing the idea, you can expect a payback of the project in the first year of production (when using mechanical equipment, worth 500 thousand rubles).
How much money is needed to start
The organization of a workshop for the production of batteries requires a serious investment. A fully automated line will cost 10 million rubles. The cost of producing batteries depends on the volume of production and the degree of automation of the workshop. Mechanized equipment will cost a little less - 500 thousand rubles. Also, the company's expenses should include the rent and arrangement of the workshop - 50 thousand rubles, obtaining permits - 200 thousand rubles, conducting an advertising campaign - 50 thousand rubles.
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How to choose equipment for the production of batteries
For the production of rechargeable batteries, it is necessary to purchase special foundry equipment. Lead mills, mixers, spreading machines will also be required. To implement a business project, you should contact the equipment manufacturer, who will draw up the necessary line.
What OKVED to indicate when registering an activity
When filling out registration documents to designate the activity, the OKVED code 27.20 is indicated.
What documents are required to create a business
You can open a production workshop both as an individual enterprise and as a legal entity. The most common second form of incorporation. To register an LLC, you will need to provide the company's charter and the decision of all founders to organize activities.
What taxation system to use to make mandatory payments
It is advisable to use the simplified tax system with a rate of 6%. This taxation system can be applied by both individual entrepreneurs and LLCs. To pay mandatory payments under the simplified tax system, you must write an application when registering an activity.
Do I need permission to start a business
The Law "On Licensing Certain Types of Activities" dated August 8, 2001 No. 128-FZ provides for the receipt of a special document for the production of storage batteries. In addition, permits are issued by the SES and the fire inspectorate. The process of issuing a permit package itself is complex and troublesome. That is why it is recommended to contact a professional lawyer for help.
in accordance with the 2TE10U diesel locomotive repair program, we determine the alkaline battery repair program
where n- the number of cans installed on the locomotive, pcs;
- annual repair program, sec
For repair, we accept a program for repairing battery cans equal to 6440 cans.
1.2 Purpose of the battery compartment section. Shape selection
organization of production
The battery compartment is used to form new acid and alkaline batteries, with the introduction of medical charging and repair of operated batteries.
Working with acid and alkaline batteries in the same room is strictly prohibited, so the department is divided into two isolated areas. One contains positions for repair acid batteries, on the other for repair alkaline batteries... On the positions of repairing acid batteries, they are located on the graphic part and the arrangement of equipment.
We accept a stationary form of production organization due to a small repair program.
The main parameter of the production process is the release cycle - the time interval through which the production of products or blanks of certain names, type, size and performance is periodically carried out.
The cycles of the production process h / s are determined by the formula
T i= Fi/M rem where Fi– annual fund of equipment operation time, h;
M rem – the annual volume of production of repair sections.
T i=1984/140=14
The rhythm of the production process sec / h is determined by the formula
Ri= M rem / Fi
Ri=140 / 1984 = 0,07
1.3 Site operating modes battery compartment and calculation of the working time fund
The operating mode of the battery compartment is taken in one shift. The working shift starts at 8.00 and ends at 20.00 with a lunch break from 12.00 to 13.00.
Distinguish between calendar, nominal and effective working time fund.
The calendar fund of working time is established on the basis of the Labor Code of the Republic of Belarus for various operating modes of the enterprise and is published in print in the form of a production calendar.
The calendar fund of working time is used to determine the nominal and effective funds, funds of working time of equipment, as well as the number of employees.
The annual fund of working time of the attendance contingent, h, is determined by the formula
Ф р = Д р t p + d p t n, (2)
where D p - the number of full working days in a year, for 2008 with a five-day working week D p = 246 days;
t p is the duration of a full working day, h, t p = 8 h;
D p - the number of holidays that do not coincide with the general weekend; for 2008 D p = 8 days;
t n is the duration of the pre-holiday working day, h; t n = 7 hours
F p = 246 8 + 8 7 = 2024 h.
The effective working time fund is used to determine the payroll number of employees.
The working time fund of employees of the payroll contingent, h, is determined by the formula
Ф cn = (Ф р - Д о t n) a p, (3)
where D about - the duration of the vacation, days; D about = 25 day;
a p - coefficient taking into account absenteeism for good reasons; a p = 0.96.
Ф cn = (2024 - 25 7) 0.96 = 1775 hours.
The annual fund of working time of the equipment of the site, h, is determined by the formula
F i= F p Si a about, h (4) where Si- the number of shifts of working equipment for the battery section, shifts;
Si= 1 shift;
and about - coefficient taking into account equipment downtime in planned repairs with one-shift operation of the equipment; we take a about = 0.98.
F i= 2024 · 1 · 0.98 = 1984 h.
1.4 Calculation of the contingent of workers in the battery department
We determine the attendance and payroll contingent of employees.
The apparent number of production workers is calculated by the formula
,
(5)
where M rem is the annual program of this type of repair, sec .;
q rem is the laboriousness of the battery repair according to the TR-3 cycle, man-hours;
q rem - 69.8 people h;
F p is the annual fund of working time of the attendance contingent, h;
K - coefficient taking into account overfulfillment of production rates;
people
The listed number of production workers is calculated by the formula
where is the replacement rate, taking into account the absence of people at work
