What is psr. How the Russian nuclear industry is being ruined by the introduction of the RPS. Inside view of specialists. - The question is - actually, what has changed with the introduction of the RPS

The Engineering Division is one of the leaders in the implementation of RPS among the enterprises of the State Atomic Energy Corporation Rosatom.

The production system "Rosatom" as a tool for increasing the efficiency of production processes has been successfully applied in JSC ASE EC since 2009. In 2010, the company introduced a system for motivating employees for introducing RPS into their activities, in particular, for submitting proposals for improvements (PPM).

Since 2016, the process of working with employees' ideas in JSC ASE EC has been automated - an industry information system has begun to work for employees to make suggestions for improvements "Idea Factory". In 2016 alone, about 2,000 PPU and PSA (proposals for cost reduction) were submitted with a total economic effect of about 9 billion rubles.

The implementation of a production system at NPP construction sites is aimed at improving the controllability of the construction process according to uniform standards, reducing costs, eliminating losses, and increasing labor safety and productivity. At the construction sites of the Belarusian NPP, Kursk NPP-2, Novovoronezh NPP-2, Rostov NPP and in all contractors involved in their construction, work is being built strictly in accordance with 8 RPS standards of JSC ASE EC - a unique set of lean production standards , created for the first time in the world. Since 2016, the implementation of the RPS standards has begun at other foreign sites.

The tools of the production system are used not only at the construction site, but also to optimize office and business processes. The company's managers open and successfully implement personal RPS projects aimed at optimizing activities. In particular, the use of RPS tools in day-to-day work allowed the project and commerce units to achieve results that are an example for the entire nuclear industry.

Novovoronezh NPP-2: an exemplary platform for the implementation of RPS


In 2015, the management of the State Atomic Energy Corporation Rosatom set the task for JSC ASE EC to create an exemplary RPS-site on the basis of the construction site of NV NPP-2 power unit 2. As a result of the work done, the following were created:

· Algorithm for implementation of RPS in all contractors;

· System of end-to-end training;

· The system of distribution and control over the implementation of the RPS-standards;

· Transparent and clearly built system of visualization of the construction progress;

· Exemplary storage facilities;

· Comfortable construction site and exemplary territory;

· Reference areas of labor culture, production life, organization and management of production, etc .;

· The system of planning and control of work execution has been optimized.

As a result of the work done in May 2016, the commission of the State Atomic Energy Corporation Rosatom awarded the site the status of exemplary.

The General Director of ROSATOM made a decision to extend the experience of NV NPP-2 to all construction projects in the industry.

Process Factory

“Process Factory” is a unique form of training that simulates real work using RPS tools, carried out on a construction site. Participants perform timing of the total cycle time when assembling formwork elements, during observations determine losses, identify causes, exchange experience gained on the use of production system tools, discuss proposals for improving the formwork assembly process and implement them to increase the time and economic indicators of the process.

Knowledge transfer


RPS specialists of JSC ASE EC conduct training on RPS standards and tools of the Rosatom production system for employees of both the company itself and contractors. All training is carried out in accordance with the license of the Ministry of Education.

In accordance with the instructions of the General Director of ROSATOM, in 2016, a seminar “Implementation of RPS Engineering Standards” was developed to train all industry organizations on the basis of the reference power unit 2 NV NPP-2. The purpose of this seminar is to acquire knowledge and skills on building an effective management system at an enterprise, mastering techniques to reduce all types of losses and costs in production.

The status of the Rosatom Production System has been finalized - it has been recognized as a culture of continuous improvement. How to raise the level of culture of the AKP in the industry, what role is assigned to managers in this process and what are the prospects for lean production, were discussed at the forum “AKP Leaders”.
The RPS Leaders Forum is a discussion platform for lean manufacturing professionals. They do not agitate here, do not explain the principles of the production system, do not tell how to use the tools - in general, they do not chew on the methodology. Participants in the RPS and PPU contests, RPS employees, methodologists, managers of RPS enterprises, and activists of change support teams - about 200 people in total - gather once a year to discuss strategy, goals and objectives. It was at this site that a decision was made several years ago to systematically deploy the RPS.

RCC

Until recently, there was no consensus in the industry as to whether the RPS was a system or a culture. This year, everyone seems to agree that RPS is more than just a collection of projects and tools to improve the manufacturing process. “AKP is, of course, culture. That legendary Hayashi (Nampachi Hayashi is a former vice president of Toyota, a consultant for lean manufacturing. - "CP"), who comes and regularly scolds us, for me a symbol not so much of specific practices, how to decompose stocks, how to organize chains, but of spirit and belief that there is no end to improvements, "said Rosatom CEO Alexei Likhachev.
What is the meaning of the concept of culture of the AKP was explained in simple words by the first deputy general director for operational management Alexander Lokshin: “Culture is a set of rules, norms of behavior, patterns that are considered the norm. A cultured person is one who is irritated by deviation from such norms and who has a need to comply with these norms. AKP culture is about the need to do well. Force to force to come to this, from my point of view, is impossible. When we manage to create a culture in which continuous improvement is a need for everyone, we will achieve our goals. ” Alexander Lokshin even suggested changing the abbreviation of the AKP to RPC - “The production culture of Rosatom”.
For several years now, members of the AKP movement have been puzzling over how to increase involvement in the AKP, what needs to be done to make everyone believe in it. Here are the most popular answers of the forum participants: be patient and wait for the results of the RPS deployment, explain, convince; train immediately upon hiring, for this to attract authoritative people. The logic of the answers is clear: shaping an AKP culture in the industry is not a quick business. A special place is given to the head of the enterprise - he must become a role model. Every leader should be a mentor.


Nikolay Solomon, First Deputy General Director for Corporate Functions, Chief Financial Officer of Rosatom, also expressed his opinion on how to change the culture: “We need to clearly show what we praise and scold, whom we promote”. At the same time, it is necessary not only to declare these principles, but to follow them, otherwise people will not believe. Nikolai Solomon noted that through the application of the principles and tools of the AKP, the values \u200b\u200bof the state corporation are manifested and brought up. The forum participants agreed that the main focus of the next year is the creation of exemplary flows in production, office and engineering, education and development of employees, building long-term relationships with suppliers.

Lean AKP protects

RPS Development Director Sergei Obozov briefly spoke about the implementation of the Lean Polyclinic federal project, in which RPS specialists from Rosatom participate: “Replication is carried out in 23 regions. There are no longer two polyclinics, as in pilot projects, but sometimes three, sometimes four, sometimes five. We provide basic training. We offered the Ministry of Health to create its own RPS project office ”.
The activities of the AKP office were highly appreciated by the Presidential Administration of the Russian Federation. Further more. The authorities have involved Rosatom as a general partner in the work on the program, which is being implemented under the leadership of the head of the Ministry of Economic Development Maxim Oreshkin, to increase labor productivity in industry and construction.
“We are taking two budget-forming enterprises in each pilot region. Our main condition was “not a single person on the street”, so we took away the factories whose production volume in 2018 should grow sharply. The second condition is that the owners and management really want to improve the results. We will show them a master class on how to make an increased volume with the same number of personnel, ”Sergey Obozov shared his plans.
In this project, interaction will be structured differently than in the Lean Clinic. Rosatom invites students to its place. Sergei Obozov calculates: “Seven regions, two factories - 14 factories, we are ready to accept 28 people in our teams, to work on the exemplary flows of Rosatom. Sometime before mid-December, I think we will complete these teams, and from January 10, 2018 we are waiting for them at our factories. " The program will be implemented in Tyumen, Tula, Nizhny Novgorod, Perm and Samara regions, Bashkortostan and Tatarstan.
The head of the Rosatom Academy, Yulia Uzhakina, added that nuclear-powered closed cities can become lean cities. “The mayor of Zarechny starts to do something, Ozersk joins. We need to help them understand this matter: how it is done, what examples are there, ”she said.
As Nikolai Solomon noted, the best practices of Rosatom must be presented in a very simple and understandable form so that people who have never heard of the RPS become interested in this system. “We are discussing with the Ministry of Economy and VEB the creation of a platform in which these cases will be publicly available,” he said.
“Next year we will have a year of expanding our practice, our experience will be replicated. But we ourselves must not forget to continue to replicate it within the industry - for this it is necessary that each AKP-director, AKP-leader has two or three sponsored directors, ”concluded Alexey Likhachev.

AKP as a way of thinking

Nikolay Kmitto
Chief Engineer of the Directorate at Kursk NPP, NIKIMT-Atomstroy branch
- An unfavorable situation developed during the construction and installation work during the construction of the Kursk NPP radioactive waste processing complex: at the time of the start of the installation of metal structures, the backlog of the schedule was 90 days. We had to eliminate this lag at all costs. According to the schedule, the installation and application of a fire-retardant coating on the supporting metal structures of the storage frame takes 240 days, and we had to be in time for 150. According to the classical scheme, work at height is provided, the protective coating is applied to the already mounted metal structures - somewhere it turned out to be underpainted. Plus gusts of wind and other unfavorable weather conditions led to overruns of fire retardant when spraying.
The RPS tools and common sense helped to cope with the task. We paralleled the installation and coating processes, began to apply the composition during the enlargement assembly in the workshop, at the construction site - only on non-painted and welded elements. The backlog was eliminated. We saved on scaffolding, increased safety, as we practically excluded work at height. In addition, the quality of the applied coating has improved due to dedusting and degreasing of metal structures in workshop conditions. Now it is possible to control the thickness of the coating, which is why the material consumption has decreased. Previously, the composition was applied in 20 minutes, now - in five. The economic effect of the offer amounted to more than RUB 13 million. But the main thing is that this solution can be replicated to other capital construction projects.
RPS for us is a production necessity. The desire to use RPS tools must come from within. Instilling a culture of lean work is difficult. I believe that it will not take long before every employee will understand that RPS is a science that explains how a culture of continuous improvement works.

Vladimir Rogozhin
Advisor to the General Director for Prospective Production Planning, OKBM im. Afrikantova
- We have prepared a project to optimize the workflow in the manufacture of a pipe system for ship reactor plants, which is assembled from modules. The goal is to reduce the manufacturing time for pipe systems from 494 days to 442 days. Before proceeding with the assembly of the module, you need to form a set of parts and prepare a package of relevant documents, draw up documentation after the delivery of the finished product.
We have set ourselves a goal - to reduce the time of paperwork during the manufacture of a module from 20 to five days. With the help of barcodes, processes were automated: if earlier documents were prepared by sampling, an inventory was made, it took up to 90 minutes, now the entire package is formed by simple scanning of barcodes in just a minute. Labor productivity increased by 30%, economic effect - 6.4 million rubles per year. At the beginning of the year, we launched two more projects aimed at streamlining document flow. By the end of the year, we will reduce the time it takes to form a package of documents in the manufacture of modules to three days and reduce the volume of documentation by almost half.
I have been doing RPS since 2009. At first, many of us were skeptical about the AKP, no one understood what it was for. It took me a while to realize that this is an effective tool. But after several successfully implemented projects, people got used to it and started using it. Today we can say that OKBM has a culture of constant improvement. I am motivated to use the RPS by an understandable methodology, a systematic approach to identifying inconsistencies, deviations and eliminating them with proven tools.

Sergey Trofimov
Locksmith-repairman, UEHK
- Since 2015, about 500 of my PPUs have been sold. This year, in our workshop, we prepared an rationalization proposal for the reuse of the grease, since it did not lose its properties. The amount turned out to be small, only 70 thousand rubles. But still savings. The use of the RPS is motivated by constant improvement of their work. I have been working at UEHK for 25 years and have been systematically engaged in rationalization even before the implementation of the RPS. When in 2012 the production system began to be actively implemented in our country, it became easier to draw up your proposals.
The AKP culture can only be promoted through training, explaining the principles and advantages of a systems approach. And only by personal example, and not in an order or as an obligation. I instilled in my brother a culture of constant improvement. This year, in our workshop, he took the second place in the supply of PPU after me, he has about 70 PPU. People are already beginning to look up to him.
When you get used to working in a new way, you see what else can be optimized. Whenever possible, I try to help colleagues from other areas.
Sergey Mikheev *
Engineer 1st category, ASE
- The project is aimed at reducing the cost of forming an artificial foundation for the Kursk NPP-2 hydraulic structures. After evaluating the soil replacement scheme for the foundations, our team proposed replacing the material adopted in the project, sand and gravel mixture, with sand. The fact is that in the Kursk region there are no problems with the delivery of sand, but the sand and gravel mixture would have to be transported from other regions. After changing the configuration and evaluating how rationally it will turn out to perform the artificial foundation from the point of view of the organization of construction, we recalculated the strength. We concluded that our solution meets all the requirements. The total economic effect from the introduction of the proposal amounted to 275 million rubles.

Evgeny Ratz *
2nd category engineer, ASE
- The idea of \u200b\u200bsoil replacement came up with Sergei Mikheev in the process of designing the organization of construction of the Kursk NPP-2. We asked ourselves why such a solution was chosen and whether it can be optimized. We actively use RPS tools in our work. With their help, you can solve any issue, including arguing for cost reduction in front of the designers, who are often not ready for criticism, and consider their decisions to be optimal. Any project can always be optimized, if there is a desire. There are no perfect projects.

Andrey Salnikov
Assembler of building structures, "RossSEM"
- We had to mount 118 eight-meter columns weighing 300 kg each at the zero mark of the reactor compartment of the Belarusian NPP. These columns support the reactor process equipment. Previously, we fed the columns into an opening with a diameter of 1 m from the eighth mark, then moved them horizontally with the help of improvised means to the installation site, lifted, secured, and erected scaffolding. The mounting loop for fixing the column had to be cleaned, welded, then the column was mounted - this is work at a height, it is inconvenient. Then disassemble everything and repeat 117 times.
Therefore, a device for the vertical movement of columns was developed and implemented - such a star-shaped trolley was obtained, on which the column was fixed. Three installers calmly roll the cart with the load to the place of installation. We have significantly accelerated the process: if we installed all the columns on the first block in the old way in 59 days, then on the second block we completed it in 18 days. It would seem like a simple cart, but the effect is colossal.
This is not my first project. Laziness is the engine of progress, and I guess I'm a big lazy person. When I see a problem, I immediately think about how to solve it or how to simplify the process. Everyone helped, I wouldn't have done anything alone. The economic effect amounted to about 780 thousand rubles. The main thing is that the experience will be replicated for other construction of units under the NPP-2006 design. I have a lot of groundwork, and I plan to implement them at the next construction sites.
We began to implement the production system at the end of 2014 at the Belarusian NPP. I immediately connected, as it is an understandable working tool that makes work easier, saves resources and develops a person. Today it is already a culture of constant improvement.

Sergey Sachkov
Head of VVER-440 Fuel Rods and FAs Manufacturing Section, MSZ
- When I was working in another section, we created a device that allows using scales to determine the number of removed process tips when assembling a bundle of fuel elements for RBMK reactors. In the process of assembling a bundle of fuel elements, three pieces are inserted into the cells of the frame. So that they enter strictly in the center and with minimal friction, technological tips are used - they are put on the fuel rod before assembly, after assembly they are automatically removed. An assembly fitter observed whether all the tips were removed. Since three fuel rods are inserted into the frame in 100 seconds, the locksmith waited all this time instead of starting to prepare the next bundle, then he counted the tips and only then gave a signal to continue the operation. With such an organization of labor, in order to assemble 30 beams per shift, two locksmiths had to work at two assembly stands.
We suggested determining the number of removed tips by weight. The balance accurately detects if all handpieces have been removed and signals to continue working. The locksmith does not need to be present all the time near the beam assembly stand and count the tips, at this time he can assemble the frame of the next beam. As a result, the same amount of work can be done by one locksmith at one stand. The freed assembly fitter became a production planning engineer.
I think this practice can be replicated for another type of fuel. It is interesting for me to engage in self-development and benefit the enterprise. Therefore, I do not divide my activities into AKP and job responsibilities. It's a working tool for me. At first, people perceived the AKP negatively, but now I see that the attitude is changing. Previously, they believed that it was imposed, but now they see how I implement my ideas, see the result and get involved. A good example is contagious.
Production system "Rosatom" (RPS)
What is RPS?

The Rosatom production system is a large-scale industry project designed not only to raise labor productivity to the level of foreign competitors of Rosatom State Corporation and reduce costs, but also to raise wages and form new rules for career growth.

The development and implementation of the RPS began in the second half of 2008, when the General Director of the State Atomic Energy Corporation "Rosatom" Sergei Kiriyenko set a goal to quadruple labor productivity in the industry by 2020, cut costs and, as a result, reduce the cost of manufactured products. On December 29, 2008, an order was signed “On the implementation of the Rosatom production system in industry organizations”.

At the heart of the RPS is the NOTPiU of the USSR Ministry of Medium Machine Building - a system of scientific organization of labor, production and management. In addition, the best achievements and tools from other modern systems, in particular, the principles of the Japanese Toyota Production System, are included in the RPS and adapted to the industry specifics.

Japanese 5S Principle: Quality - Safety - Performance


Sort - SEIRI Separate the necessary from the useless

Indicate rarely used
Leave only what you need

Keep order - SEITO Identify a place for each item
Every thing in its place

Keep it clean - SEISO Wash equipment
Clean up the workplace
Identify sources of pollution
Eliminate sources of pollution

Standardize - SEIKETSU Mark places requiring special
attention
Create visual standards

Improve - SHITSUKE Observe discipline
Follow the 5S rules
Improve standards


BEST PRACTICES AT FSUE ATOMFLOT:

year 2014:

A project was implemented within the framework of the enterprise and the NWC division “Increasing the productivity of SFA separation”, the target was achieved - the separation of 5 SFA units in one shift, as well as an ambitious indicator - the separation of 6 SFA units in one work shift.

As part of the optimization of procurement activities, an information system for preparing applications for the purchase of goods / works / services was put into operation. This project took first place in the Rosatom RPS project competition in the nomination "Best Project for Optimizing Office Processes (Debureaucratization)". The author of the work - rhead of the group of new equipment and technology of the RPSAlexander Melitonov.

2015 year:

“Optimization of the LRW processing process”. Targets achieved:

Reduced by 10% the processing time of 90 m 3 LRW;
- labor costs have been reduced by 60% for processing 90 m 3 of LRW.

“Optimization of the nuclear fuel reloading process for reactors OK-900, KLT-40, KLT-40M using the refueling equipment of the 1314 complex”. Targets achieved:

Reduced by 10% (4 days) time spent on reloading nuclear fuel.

2016 year:

- "Implementation of the 5C system at the special section for the repair of ship nuclear power plants and ATU (RTK 6 span western side and 7 span)", as a result of the implementation of this project, a complete modernization of the NPP and ATU repair site was carried out. The equipment necessary for the repair of special equipment and special equipment for nuclear icebreakers and anti-terrorist operation ships was purchased and installed in accordance with the developed layout scheme. Shelves, workbenches, cabinets were also purchased and installed. As a result of the project implementation, 100% of workplaces were covered in accordance with the requirements of the 5C system;

- “Use of the SRW CPS container as a reversible one for loading the cores and cores from the reactor plant of nuclear ships”, which allowed saving, in advance, over 150,000 rubles;
“Reducing the time spent on preparing information and documents for placement in the UIS”, the time spent was reduced by 69.8% from 5776 hours to 1746 hours per 572 contracts, which made it possible to save more than 1,500,000 rubles.

2017 year:

Rosatomflot has started personnel training at the RPS course under the guidance of the company's internal trainer Alexander Melitonov. The Regulation on motivating employees for the development of production facilities of Rosatom is in effect.

If you have a proposal aimed at improving the efficiency of production processes, reducing wasted time, please contact the group of new equipment, technology and RPS - group leader Alexander Melitonov tel .: 55-33-01 (ext .: 6269), Group Leading Specialist Valery Romanov tel .: 55-33-01 (ext .: 6168).

For questions about registering for the RPS training, please contact the HR department - the manager for training and development Elena Tkachenko, tel .: 55-33-59 (ext .: 7359).

Polysemous abbreviated terms formed from the first letters of words are often difficult to decipher. This is especially true in cases where the surrounding text does not give reason to assume multiple options. What can the acronym AKP stand for? Deciphering such a letter combination will become the subject of the review. Let's analyze the most common options.

What is RPS: decryption

According to reference publications, this combination was used to abbreviate the Party of Socialist Revolutionaries. This association no longer exists. But now there is another party in politics - A Just Russia. In another context, this can be called the silver solder PSR in combination with two-digit figures characterizing the percentage of this metal in it.

This designation is often used when explaining the management principles of the Rosatom Production System. When it comes to natural disasters or natural disasters, the AKP is usually understood as search and rescue operations. It can also be called a comprehensive training program and testing the level of preparedness (sports) of specialists of this profile.

Application options

There are a few more less common, but still occurring abbreviations of the AKP. Deciphering them can lead to the most unexpected combinations. It should be noted the pneumatic sporting rifle, which was produced at the Izhevsk Arms Plant until 1946. This also means a complete balanced diet in feeding farm animals.

In technical texts, this can be called a drill chuck (self-tightening) threaded or a detachable connecting profile. In preparation for construction, RPS is understood as the design (pre-design) cost of work (reconstruction, repair), including topography, plans, grounds, etc.

AKP: Rosatom

What is the main message of this? Many structures have tried to develop similar methods: Sberbank (PSSS), KamAZ (PSK) and other concerns. The creators of the RPS (Rosatom) argue that in defining the methodology, they took into account the experience of proven industrial giants. So, part of the TOYOTA production system developed into the basic model. But the basis remained from the domestic labor organization. True, everything superfluous that did not belong (came into conflict) with a rational management approach was swept aside.

The most valuable was taken, starting from the organization of the employee's place and ending with the most thorough analysis of the key products of the concern with the identification of their competitiveness. The emphasis was placed on the creation of universal approaches to the management of production processes and their approbation at the main and subsidiaries of Rosatom.

Key goals were set, methodologies for the use of tools were developed.Clear diagnostics of processes and labor resources were established, so that in the end it was possible to fully satisfy the needs of consumers, ensuring product quality at the highest possible level.

Rescue work

In this context, AKP is most often understood as a sports tourism competition. Applications for participation are submitted not only by teams of registered mountaineering clubs, search engines and rescuers and units of the Ministry of Emergencies. Delegations of educational institutions, groups of athletes can also compete. It should be understood that this is not a simple tourism, but a special extreme type of team competition at distances with combined obstacles. The busy schedule, the continuity of the fulfillment of the task conditions, the complexity of passing the stages - all this makes the competition as similar as possible to real search and rescue operations.

Such trainings teach how to act in situations where there is not enough information, there is no premeditated action plan, there are no proven routes, and there is a real danger to the health and even the life of the participants. For some it is extreme, adrenaline, risk and a game, but not for the sake of the championship and the podium. They teach how to navigate rough terrain using the available orientation aids. On the way, one has to overcome natural and special obstacles, survive in harsh conditions, find "victims", provide them with first aid, and transport them to the place of possible evacuation.

Soldering work

PSR is used to repair various metals and their alloys. The most widely used are three-component compounds (silver, zinc and copper) in various ratios. The solder usually has a number. It depends on the amount of silver in the total mass (PSr-40, PSr-50, etc.).

Usually the products are produced in strips or wire in small coils. When used, the solder connects the parts well and firmly, seals the cracks in the joints. It is equally good for ferrous and non-ferrous metals. In addition to zinc and copper, it is possible to add phosphorus, cadmium, nickel, manganese. The melting point of the solder should be less than the temperature of the processed materials.

The formed seams, in addition to strength, are resistant to corrosion. It is also important to note their high resistance to vibration, shock and various kinds of deformation. Due to these characteristics, silver-based solders can be used for conductive joints in the electrical industry and for various types of adhesions in mechanical engineering.

Party

The revolutionary activity of the "Social Revolutionaries" is known from the history of the last century. The name of their political force in an abbreviated form is the abbreviation AKP. The decoding is clear and understandable: the Party of Socialist Revolutionaries. In 1917, they were unable to retain power, although in February they had maximum support. At that time, the total number of party members exceeded 1 million. But the revolutionary-minded masses already in October rewrote history anew.

"Fair Russia", formed in 2006, also has the abbreviation AKP in an abbreviated form. The party is not a follower of the socialist revolutionaries. However, some of its members are called "Social Revolutionaries" for a similar ideology and declared principles.

The goal of political education, according to the leaders, is to build a just state on the basis of social equality, where the result of the country's economic development is correlated with the real well-being of ordinary citizens. Among the vivid and memorable slogans are: progressive tax, an increase in interest payments for luxury goods (expensive cars, yachts, real estate), as well as a harsh punishment for bribery.

 

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