Rosalkogolregulirovanie proposed instructions for calculating the capacity of enterprises. Methodology for calculating production capacity in continuous chemical production Instructions for calculating the production capacity of existing

Approved

Deputy Minister

Food Industry the USSR

Term of introduction

INSTRUCTIONS

BY CALCULATION OF PRODUCTION CAPACITIES

ENTERPRISES OF THE BEER AND NON-ALCOHOLIC INDUSTRY

FOOD INDUSTRY

TI 18-6-58-85

Developed by the Scientific and Production Association of the Beer and Non-Alcoholic Industry.

I. GENERAL PROVISIONS

The instruction for calculating the production capacities of enterprises in the beer and non-alcoholic food industry was developed in accordance with the “Basic Provisions for Calculating the Production Capacities of Operating Enterprises, Production Associations (Combines)”, approved by the State Planning Committee of the USSR and the Central Statistical Bureau of the USSR on December 8, 1983 N ND-49-D / 04-66.

Calculation of production capacities is the most important part of the feasibility study of the plan industrial production. On its basis, possible volumes of industrial output are established and, in accordance with the national economic need for it, the necessary increase in production capacities is determined through technical re-equipment, reconstruction, expansion of existing enterprises and the construction of new enterprises. Calculations of production capacities contribute to ensuring contingency in the development of interconnected industries.

Production capacity is calculated by all enterprises for the reporting year and at all stages of the development of long-term and current plans.

The calculation of production capacities is used to develop and compile planned and reporting balances of production capacities, to plan existing production and new construction as a whole, to address issues of specialization of enterprises, to develop measures to eliminate intra-production imbalances and bottlenecks.

1.1. Under the production capacity of an enterprise (brewing, malting, soft drinks or mineral water) or a separate workshop is understood the ability of the means of labor assigned to it to the maximum possible annual output of products in in kind, calculated on the main technological equipment, based on advanced technical standards its productivity, with full use of all installed equipment and production areas, taking into account the achievements of production innovators, the most advanced technology and labor organization.

1.2. The production capacity of the enterprise is determined by the entire range of products it produces, and in the planning period by the products envisaged for release.

1.3. For enterprises, workshops, the capacities of which have been put into operation, but have not been mastered, the commissioned design capacity is taken as the available production capacity.

1.4. The production capacity of a brewery, as well as soft drink factories, is determined in terms of finished products, a mineral water bottling plant - in the number of bottles. The capacity of a malting plant or workshop is determined in tons of air-dry malt.

When calculating production capacity for the reporting year, the capacity at the beginning of the reporting year is taken in the product range of the year preceding the reporting year, and the capacity at the end of the reporting year (beginning of the planning period) - in the product range of the reporting year. When calculating the planned capacity at the beginning of the planning period, the capacity is taken in the product range of the reporting year, and the capacity at the end of the planning period - in the product range of the planning period.

1.5. The production capacity of the enterprise is set according to the capacity of the leading workshops (departments) and technological equipment, a list of which is given in Appendix 1. The performance of all other equipment is not taken into account when calculating power. The leading ones include workshops, departments and installations of the main production, where the main technological processes are carried out and which are of decisive importance in ensuring the release of finished products.

Production capacity for this period is taken:

for malt - according to the capacity of the malt drying department;

for beer - according to the capacity of the brewhouse or fermentation shop;

for soft drinks - in the blending shop (department) in the production of commercial syrups, in the bottling shop in the production of bottled products;

for kvass - for the fermentation department;

for mineral waters - in the bottling shop;

for carbon dioxide - for the compressor department;

for dry yeast - for drying plants;

for kvass wort concentrate - for the filtration compartment;

for concentrate of kvass of various names - through the bottling line.

The production capacity of an enterprise (association) in the presence of several main industries (workshops, departments) for the production of homogeneous products (malt, beer, kvass, etc.) is determined by the sum of their capacities.

1.6. The capacity of the remaining links of the main production should be proportional (conjugated) to the capacity of the leading workshop (department) or process equipment. If there are bottlenecks, they are not taken into account in the calculation of production capacity.

A bottleneck should be understood as those workshops, departments, units and groups of equipment of the main and auxiliary production, the throughput of which does not correspond to the capacity of the leading link, according to which the production capacity of the enterprise is established.

When the discrepancy is clarified, measures are developed to eliminate bottlenecks, which are an integral part of the plan for organizational and technical measures, technical re-equipment and reconstruction of the enterprise and should be aimed at ensuring a more complete use of production capacities and their increase.

1.7. Conformity bandwidth leading workshops (departments), equipment and other parts of the enterprise is determined by calculating the contingency coefficient K c according to the formula:

K c \u003d M1 / ​​M 2 + P y

M 1, M 2 - the power of workshops, departments, equipment, between which the contingency coefficient is determined in the accepted units of measurement,

RU - specific consumption products of the first workshop for the production of products of the second workshop.

K with more or less than 1 indicates that the shops are not conjugated.

Example. The capacity of the brewhouse for the brewing unit is 3163 thousand decalitres per beer, the capacity of the separation, clarification and cooling of the wort is 3140 thousand decalitres per beer, P y is equal to 1. Then the contingency coefficient between the brewhouse and the department for clarification and cooling of the wort will be equal to:

K c \u003d 3163 / (3140 x 1) \u003d 1.007

1.8. The calculation of the production capacity of the enterprise includes all the equipment of the main production, as well as the equipment of experimental and specialized areas for vocational training.

Equipment of the main production, temporarily inactive due to malfunction, repair, modernization, insufficient load, as well as equipment that is in the process of installation and in a warehouse, intended to be put into operation in the billing period, is taken into account when calculating production capacity.

Equipment similar to the equipment of the main workshops, installed in auxiliary workshops and sections in excess of the standard, should be included in the calculation of the enterprise's capacity.

1.9. The production capacity when using raw materials and materials that meet the requirements of the standards is calculated according to progressive norms and standards or design (passport) indicators, if they are not achieved at the enterprise.

The norms and standards, on the basis of which the production capacities of enterprises are calculated, are periodically updated taking into account the use of advanced equipment, technology, the most modern organization of labor, an increase in the level of mechanization and automation of production, and the achievements of production leaders.

The main indicators by which the production capacity of the plant is calculated are: for a brewery - the turnover of brewing units, the mass of a one-time bill, the duration of beer fermentation, etc.; for a malt plant - the productivity of dryers, etc.; for a plant of soft drinks and mineral waters - the useful volume of fermentation tanks in the production of kvass, the hourly removal of bottled products from the bottling line, etc. (Appendix 2).

1.10. Normative performance indicators for equipment of the same design using raw materials and fuel of the same quality and production of the same types of products on this equipment should be the same for all enterprises in the beer and non-alcoholic industry.

For enterprises in which the technical production standards or design indicators of the productivity of equipment, units and installations, the use of space and the norms for the output of products from raw materials are exceeded by a significant group of production leaders, the production capacity is calculated according to newly developed progressive indicators and standards based on the sustainable achievements of production leaders.

As sustainable achievements, the results achieved in the quarter of the reporting year, which has the best performance, by the leaders of production, constituting 20 - 25% of all workers employed in the same production processes, or 20 - 25% of the best achieved output volumes from the unit, area unit or volume.

The normative performance indicators of the equipment are given in Appendix 2.

1.11. The normative annual fund of working hours of equipment is established when determining the fund of working hours in hours and days based on the "Regulations on the system of planned Maintenance and repair of equipment of enterprises of the beer and non-alcoholic industry”, approved by the USSR Ministry of Food Industry on December 15, 1982, and on the basis of “ Sanitary regulations for enterprises of the brewing and non-alcoholic industry, approved by the USSR Ministry of Food Industry and the USSR Ministry of Health on April 15, 1985, and the current technological instructions - when determining the working time fund in months.

The annual fund of working time in days is taken minus the normalized time for all types of repairs and technological shutdown of equipment, as well as minus weekends and public holidays in discontinuous production.

For specific production sites, the normative annual fund of working hours is calculated based on the following:

For the malt drying department - from a continuous production process, a shift ratio of 3, 24 working hours per day, a shift duration of 8 hours and 330 days of dryer operation per year;

For the brewhouse - from a continuous production process, a shift ratio of 3, a shift duration of 8 hours and 325 days of operation of the brewing unit per year;

For the after-fermentation shop - from a continuous production process, a shift ratio of 3, a shift duration of 8 hours, 24 working hours per day and 338 days of after-fermentation tank operation;

For the blending shop for the production of commercial syrups - from a discontinuous production process, a shift ratio of 1.4 (two-shift operation during 4 summer months, the rest of the time - one-shift operation), shift duration 8.2 hours with a 5-day working week and 232 days work of the blending department in a year;

In the non-alcoholic beverage bottling shop - from a discontinuous production process, a shift ratio of 1.4 (two-shift operation during 4 summer months, the rest of the time - one-shift operation), a shift duration of 8.2 hours with a 5-day working week and 232 days of operation of the bottling line per year;

For the fermentation department for the production of kvass - from a continuous production process, a shift ratio of 3, a shift duration of 8 hours and 100 days of fermentation department operation per year;

In the mineral water bottling shop - from a discontinuous production process, a shift ratio of 1.5 (two-shift operation during 5 summer months and one-shift operation for the rest of the time), shift duration 8.2 hours with a 5-day working week and 232 days bottling line operation per year;

In the compressor department when receiving carbon dioxide - from a continuous production process, a shift factor of 2.6; shift duration 8 hours and 338 days of compressor operation per year;

For drying plants for the production of dry yeast - from a discontinuous production process, a shift ratio of 2, the duration of a shift with a 5-day working week - 8.2 hours and 232 days of dryer operation per year;

According to the filtration department in the production of kvass wort concentrate, it is similar to the normative annual fund of working hours of the brewery of the brewery;

In the workshop for bottling kvass concentrate into bottles and cans - 2660 hours, similar to the normative annual fund of working hours of the non-alcoholic beverages bottling workshop.

The calculation of the normative fund of the operating time of the equipment of the leading workshops (departments) is given in Appendix 3, the normative annual fund of working hours - in Appendix 4.

1.12. The time for equipment repair and the duration of the overhaul period is determined by the standards that establish the degree of wear and technical condition of the equipment. These standards are periodically updated based on the indicators achieved by advanced repair teams. At enterprises with a continuous production process with an overhaul period of more than one year, the time for overhaul of equipment is taken into account in the year in which the repair will be carried out. When determining the capacity of enterprises with a seasonal nature of production (kvass department), the time for overhaul is not taken into account. Downtime due to repair is also determined in accordance with the above provision in paragraph 1.11.

Equipment downtime caused by a lack of raw materials, materials, semi-finished products, fuel, energy, work force or due to organizational and technical problems, as well as the loss of time associated with the release or correction of defects, are not taken into account when calculating production capacity.

1.13. The production capacity of the leading workshops (branches) of the enterprises of the beer and non-alcoholic industry is calculated according to the formulas given in Appendix 5. To calculate the quarterly capacity of the enterprise, the monthly capacity of the leading workshops is multiplied by 3 if no repairs were carried out with equipment shutdown in the reporting quarter.

In the case when repairs were carried out in a separate quarter, the capacity is multiplied by 3 minus the duration of the equipment shutdown for repairs (in months).

Examples of capacity calculations for enterprises in the beer and non-alcoholic food industry are given in Appendix 7.

1.14. The production capacity of enterprises for the reporting year and for the planning period is calculated taking into account its growth due to technical re-equipment (including organizational and technical measures) and reconstruction; commissioning of new capacities due to the expansion of existing enterprises, retirement of capacities due to wear and tear of equipment, changes in the assortment, dilapidation of buildings and equipment, transfer of fixed assets in the prescribed manner to other enterprises, natural disasters.

The increase in production capacities for the production of specific types of products is determined for each enterprise, based on the measures planned or carried out in the reporting year, based on changes in the qualitative and quantitative composition of equipment taken into account when calculating capacities, improving the operating mode of the enterprise, reducing the labor intensity of products and other factors. At the same time, plans and reports do not include measures related to the achievement of the design capacity of an enterprise that is under development.

1.15. The reduction (retirement) of the production capacities of operating enterprises and workshops, approved in the prescribed manner, is documented at the level of the industrial association by drawing up the appropriate protocol of disposal and submitted to the Republican Agroprom until December 20 of this year. and in the Agroprom of the USSR until January 5 of the year following the reporting period.

The form of the production capacity disposal protocol is given in Appendix 6.

1.16. The average annual production capacity of the enterprise is determined by adding to the capacity at the beginning of the year the average annual increase in capacity and subtracting the average annual decrease (retirement) of capacity.

The average annual commissioning or retirement of capacity is calculated by multiplying the commissioned or retired capacity by the number of months remaining from the moment of commissioning or retirement of capacity until the end of the year, and dividing the resulting product by 12. If the commissioning or retirement of capacity is carried out in parts during the year, then each part is multiplied by the number of months remaining, the resulting works are summed up and the result is divided by 12.

When calculating the average annual capacity, the increase (decrease) in capacity due to a change in the range of products (reduction or increase in labor intensity) is taken into account in full.

When developing a five-year plan, the average annual commissioning of capacity in the year of commissioning is taken based on the current standards for the development of new capacities.

1.17. When establishing the production program, the utilization factor of the average annual production capacity for the reporting year is taken into account, which is determined as the ratio of the actual output to the average annual capacity of the given year.

For the planned period, they are guided by the utilization factor of the production capacity of operating enterprises, taking into account the seasonality of consumption, based on the full capacity utilization in the II-III quarters and the full satisfaction of applications trade organizations in the I and IV quarters.

1.18. For newly commissioned new volumes at reconstructed and expanded enterprises, the norms for the duration of the development of design capacities are determined by:

a) for facilities for the production of products that were not previously produced at this enterprise - according to the norms for the duration of the development of a new facility;

b) for facilities for the production of products similar to those manufactured at this enterprise - according to the norm of the duration of mastering the capacity of a new facility, reduced by 50%.

For reconstructed and expanded objects, enterprises, the norms for the duration of the development of design capacities are established according to the approved norms for new enterprises (objects), reduced depending on the magnitude of the increase in existing capacities:

by 30% if the increase in power is more than 70%;

by 40% if the increase in power is 50-70%;

by 50% if the increase in power is less than 50%.

With an increase in the volume of output at the reconstructed and expanded enterprises (objects) up to 20%, the period for mastering the capacity of these enterprises is not established, and the volume of production is established in the amount of the design capacity.

When designing new enterprises, the volume of production is taken into account seasonality, as for existing enterprises.

1.19. The production capacity of the enterprise is one of the most important indicators indicated in the Passport of the enterprise.

The director of the enterprise, as well as the heads of departments and services that carry out these calculations and prepare the corresponding regulatory framework at enterprises.

1.20. In connection with the approval of this instruction on the calculation of production capacity, the instructions approved earlier become invalid.

Under production capacity industrial enterprise understand the maximum possible annual output of high quality products or the volume of processing of raw materials (in the nomenclature and assortment provided for the planning year) with the full use of production equipment and production facilities, taking into account the use of advanced technology, improving the organization of production and labor. The planned production capacity of an enterprise, calculated for a certain planning period, should be distinguished from the design capacity of an enterprise, which is a predetermined value of output, taken as a starting indicator for designing an enterprise under construction or reconstruction.

In the very general view production capacity (M pr) can be expressed as follows:

M pr \u003d Pr about F vr (4.1)

M pr \u003d F vr: Tr d, (4.2)

where Pr about - equipment productivity per unit of time, expressed in pieces of products (parts); Ф vr - the actual (working) fund of the operating time of the equipment, h; Tr d - the complexity of a set of products (parts) manufactured on this equipment in standard hours, man-days.

In the assignment for the design of the enterprise, the program for the production of products is a given value, and the composition of the enterprise, technological process production of products under this program, the structure of the equipment fleet, its quantitative and qualitative composition, the size of production areas, the nature and dimensions of buildings and structures, energy and transport facilities, etc. are the desired values. They should be established in relation to the use of the most advanced methods of organizing technological processes and with the optimal mode of operation of the enterprise.

In contrast, the planned production capacity of operating enterprises is determined on the basis of the applied technological processes, the available fleet of equipment and the available production areas as values ​​already set, and the volume of output according to the planned nomenclature is the desired value, established under conditions of full use of fixed production assets.

Formula (4.1) is used in cases where the productivity of the equipment is known, expressed in the number of manufactured products (parts) per unit of time. At enterprises of multi-product production, which is the majority of machine-building plants, due to the lack of such data for the entire fleet of technological equipment, formula (4.2) is usually used. In these cases, data on the complexity of manufacturing products are used.

Basic provisions and initial data for determining production capacity

The production capacity of an enterprise is a calculated value, determined in accordance with the methodological provisions common to enterprises in all industries, specified in industry methods. Thus, a unified intersectoral instruction has been approved for enterprises in the engineering and metalworking industries.

The main methodological provisions in calculating the production capacity of the enterprise are as follows.

1. The production capacity is calculated for the entire range of products manufactured by the enterprise with the mandatory allocation of products, for which the annual summary balances of production capacity are compiled. For products that are not specialized for this enterprise, productive capacity

is calculated only in the presence of specialized capacities, otherwise the capacity for this product is taken into account among other products. The production capacity is determined in those units in which the production of this product is planned.

2. The capacity of each of the production units of the enterprise is expressed by the ratio (coefficient) of the actual (working) fund of the operating time of the equipment of this unit to the progressive labor intensity of the corresponding annual calculated production program. The determination of the value of production capacity in physical terms is carried out, as a rule, only for the enterprise as a whole, by multiplying the estimated production program for each nomenclature position by the value of the specified coefficient.

3. The production capacity of the enterprise is determined by the capacity of the leading divisions (workshops, sections, units), taking into account the existing cooperation and measures to eliminate bottlenecks. The leading subdivision is considered to be one in which the main technological operations for the manufacture of products are carried out, where the largest share of total living labor is expended and where a significant part of the main production assets of this subdivision is concentrated.

The “bottleneck” is understood as a discrepancy between the capacities of individual workshops, sections, groups of equipment and the capacities of the relevant departments, according to which the capacity of the entire enterprise, workshop is established.

The calculation of capacity is carried out for all production units of the enterprise in sequence from the lowest production level to the highest: from groups of technologically similar equipment to production sites, from sites to workshops, from workshops to the enterprise as a whole.

4. When determining production capacity, downtime of equipment or underutilization of space caused by a lack of labor, raw materials, fuel, electricity or organizational failures, as well as loss of working and machine time due to defects in production, are not taken into account. Only technologically unavoidable losses are taken into account in the amounts established by the parent organization.

5. The production capacity of the enterprise is dynamic, it changes in connection with the growth of labor productivity, improvement of the organization of production,

improving the qualifications of workers. Therefore, the power calculation is “tied” to a specific calendar date. According to the current methodology, power is determined on January 1 of the planned year (input power) and on January 1 of the next year (output power). It is also customary to determine the average annual power. This indicator is used for comparison with the plan and output report.

When determining the input production capacity, the following is taken into account:

implementation of measures to eliminate bottlenecks” and during the first quarter of the planned year without additional capital investments;

introduction of progressive technological processes that do not require the manufacture of complex equipment;

Improvement of equipment productivity due to its modernization;

· increasing the number of equipment or replacing it with more productive equipment due to the equipment in the warehouse, as well as excessive and insufficiently used in other production units of the enterprise;

redistribution of work between certain types and groups of equipment and between production units of the enterprise;

· the possibility of increasing the shift work of equipment and the use of production areas that limit the output of products (transfer of equipment to a three-shift mode of operation).

Output production capacity is calculated taking into account:

· Measures to eliminate bottlenecks planned when determining the input capacity;

commissioning of new production capacities at the enterprise;

· commissioning of production capacities in the process of reconstruction and expansion of the enterprise;

· increase in production capacity at the operating enterprise through the implementation of measures to improve production efficiency;

· Retirement of the enterprise's capacities as a result of a complete or partial cessation of production, provided that the size of the retiring capacities and the timing of their disposal are approved by a higher authority (ministry).

6. Growth in production capacity by operating enterprises through the implementation of measures to improve production efficiency is determined on the basis of the annual plan of these activities. Measures to improve production efficiency include:

introduction of progressive technology, mechanization and automation of production;

Modernization of equipment, tooling and tools;

· improvement of systems of management, planning and organization of production;

Improvement and improvement of product quality, etc.

An increase in production volume achieved through measures to improve production efficiency aimed at mastering the planned production capacity is not considered an increase in production capacity.

7. When calculating the production capacity, the utilization factor of the average annual capacity is determined, as well as the average load factors of the equipment over time. Load factors are determined by dividing the labor intensity required for the manufacture of products on this equipment by the actual (working) annual fund of equipment operation time in a two-shift operation mode. The calculation of the production capacity of the enterprise is based on the following initial data:

Quantitative composition and technical level of equipment;

the mode of operation of the enterprise;

Progressive technical norms of labor intensity of manufacturing products or equipment productivity;

product ranges.

Quantitative composition and technical level equipment plays an important role in determining the production capacity of the enterprise.

The calculation of capacity is carried out for all production equipment assigned to the workshops. Production equipment includes such equipment, with the help of which the technological process of manufacturing marketable products at the enterprise is directly carried out. The calculation takes into account operating equipment and inactive equipment due to malfunction, repair, modernization, lack of loading and other reasons.

Power is not taken into account:

· equipment (within the standard) of auxiliary shops of the enterprise (repair and mechanical, electrical, tool, etc.), as well as areas of the same purpose in the main production shops. The equipment of auxiliary workshops, similar to the equipment of the main production workshops, which is available in excess of the standard, should be included in the calculation of capacity;

· backup equipment of the enterprise, the list and quantity of which must be approved by a higher authority.

When calculating the power, the equipment is grouped according to structural production departments enterprises, and in them - by groups on the basis of interchangeability, i.e. to the extent possible, perform the same technological operations. On the production lines, where the operations are rigidly assigned to certain machines and where, because of this, the equipment is not interchangeable, it is grouped in the order of the sequence of technological operations. Unique equipment stands out separately.

For workshops of a number of enterprises (for example, for some workshops of machine-building, woodworking plants, enterprises light industry and other industries) the main factor determining the amount of production capacity is the area. In these cases, production areas are taken into account in the calculation of capacity, i.e. areas where the technological process of manufacturing products is carried out. These include areas occupied by:

production equipment; workplaces (including workbenches, assembly stands, etc.);

Backlogs (blanks, parts, assemblies) at workplaces;

Passages between equipment and between workplaces (except for main passages).

When determining the power, auxiliary areas are not taken into account. These areas include:

tool and repair shops;

shop warehouses and storerooms;

premises of the technical control department;

departments for the preparation and distribution of coolants;

Other ancillary facilities

· fire and main passages.

The dimensions of the areas are taken according to the production and technical passport of the enterprise, and in the absence of passport data - by measurement. The measurement is made along the inner perimeter of the building or along the axes of the columns, taking into account the protruding parts of the building.

Business hours directly affects the value of production capacity and is set on the basis of specific production conditions. The concept of "working hours" includes the number of shifts, the length of the working day and the length of the working week.

Depending on what time losses are taken into account when determining the power, there are calendar (nominal), regime and actual (working) time funds for the use of fixed production assets.

The calendar fund of time is equal to the number of calendar days in the planned period, multiplied by 24 hours, i.e. for a non-leap year - 8760 hours (24 365).

The regime fund of time is determined by the regime of production. It is equal to the product of the number of working days in the planned period by the number of hours in work shifts. With a five-day working week, the regime fund is determined in accordance with the accepted mode of production, with obligatory observance of the total duration of the working week established by law.

The actual (working) fund of equipment operation time is equal to the regime minus the time for scheduled preventive maintenance, which should not exceed the established norms.

In calculations of production capacity, the maximum possible real (working) fund of equipment operation time (use of production space) should be taken into account. Wherein:

1) for production and areas with a discontinuous production process, the annual fund of equipment operation is taken, based on three-shift (or four-shift, if the enterprise works in four shifts) work and the established duration of shifts in hours, minus the time for scheduled preventive repairs, weekends and holidays days, as well as reduction of working hours on pre-holiday days. The working time fund for enterprises whose leading workshops work in two shifts (or less than two shifts) is calculated on the basis of a two-shift mode of operation. (The discontinuous process includes the production

products, the stoppage of production of which at any moment of the technological process does not lead to the loss of products or raw materials, and the technological process can be timed to the duration of the work shift or working day);

2) for production and sites with a continuous production process, the annual fund of equipment operation (use of space) is taken, based on the number of calendar days per year and 24 working hours per day, minus the time for repairs and technological shutdowns of equipment, if these shutdowns are not included in the norms its use. (The continuous production process includes such a technological process of manufacturing products that is continuous, and the stoppage of the production process is associated with long downtime and leads to the loss of raw materials and damage to equipment or is associated with other large economic losses);

3) for unique and limiting equipment, a valid time fund is accepted, based on a three-shift operating mode. An approximate nomenclature of such equipment is given in industry instructions;

4) if workshops, sections and workplaces are equipped with equipment that does not require scheduled repairs in work time, the actual (working) fund of the operating time of the equipment (use of production areas) of these units is taken equal to the regime fund.

Calculation of the production capacity of the enterprise is carried out on the basis of technical or design norms for the labor intensity of manufacturing products, output, equipment productivity, use of space, norms for the output of products from raw materials, taking into account the use of advanced technology and labor organization.

If the design norms are taken into account when calculating the power, they are accepted according to the data of the current project for the reconstruction or construction of the enterprise or according to the technical data sheets for the equipment.

The output rates adopted for calculating the production capacity should not be lower than the actual output achieved by the leaders of production. In cases where technical or design standards for output, equipment productivity, space use, etc. are missing or surpassed by the industry leaders, the production capacity is calculated according to the newly developed progressive technical standards based on the sustainable achievements of the industry leaders. The norms obtained in this way are the output norms of a worker or a group of workers who have mastered the advanced technology and organization of production to perfection.

When determining the production capacity of an enterprise, the nomenclature of manufactured products and the quantitative ratio of products established in the plan of the billing year are used.

In multi-product industries (engineering, metalworking, production of rubber products, plastic products, clothing, knitwear and other industries), the production program of output established by the enterprise can only in rare cases be directly included in the calculation of production capacity without preliminary processing. In order for the production program to give a clear idea of ​​the profile of the enterprise and be sufficiently “foreseeable”, i.e. did not contain an excessively extensive range of products, it is brought into a form that would allow the volume of calculations to be reduced to a reasonable minimum. The program transformed in this order is usually called the calculation program.

The calculation program should use the same units of measurement (pieces, tons, linear meters, square meters, rubles, etc.) that are accepted for certain products in the production program for output. The calculation program does not include small one-time non-recurring orders, supplies through cooperation that are not sustainable, overhaul of own fixed assets, production of spare parts for own equipment, execution of works and services on the side, etc., since enterprises do not and should not form capacities for the execution of random orders. "Clearing" the program in this regard is one of the ways to specialize production and strictly adhere to its production profile.

At enterprises producing products of a large range, when compiling a calculation program, the product range is enlarged by combining different products into groups according to design and technological similarity and bringing each group to one basic representative product. At the same time, it is necessary that the structure of the labor intensity of the given products be, perhaps, closer to the structure of the labor intensity of the representative product and that the latter should have the highest output and the highest total labor intensity in the group. It is also obligatory that the referenced products and representative products are manufactured on the basis of mastered technological processes.

The Scientific and Production Association of the Beer and Non-Alcoholic Industry has developed Instructions for Calculating the Production Capacity of Enterprises in the Beer and Non-Alcoholic Industry of the Food Industry TI 18-6-58-85

The Federal Service for the Regulation of the Alcohol Market recommends that breweries be temporarily guided (available at the disposal of the Union of Russian Brewers) developed by the Scientific and Production Association of the Beer and Non-Alcoholic Industry.

This is stated in a message posted on the official website of the Federal Service.

At present, the Federal Law "On Amendments to the Federal Law "On State Regulation of the Production and Turnover of Ethyl Alcohol, Alcoholic and Alcohol-Containing Products and on Limiting Consumption (Drinking)" alcoholic products"(hereinafter referred to as the Federal Law) approved by the Federation Council of the Federal Assembly Russian Federation(Decree of July 10, 2013 No. 297-SF) was sent to the President of the Russian Federation, the message says.

“The federal law provides, in particular, for the exclusion of the requirement to equip with automatic means for measuring and recording the volume of finished products (hereinafter referred to as ASIiU) in relation to the main technological equipment for the production of beer and beer drinks, cider, poiré, mead with a production capacity of not more than 300 thousand decaliters in year.

At the same time, organizations engaged in the production of beer and beer drinks, cider, poiret, mead and having the main technological equipment for the production of beer and beer drinks, cider, poiret, mead with a production capacity of not more than 300 thousand decaliters per year, submit to the authorized government of the Russian Federation federal executive body calculation of production capacity in relation to this equipment.

The calculation of the capacity of the main technological equipment for the production of beer and beer drinks, cider, poiré, mead is sent to the central office of Rosalkogolregulirovanie.

Until the Rosalkogolregulirovanie issues an order establishing the procedure and form for calculating the capacity of the main technological equipment for the production of the relevant types of alcoholic products to these organizations in order to exercise the right granted federal law, when calculating the capacity of the main technological equipment for the production of beer, it is recommended to be guided by the Instructions for calculating the production capacities of enterprises in the beer and non-alcoholic industry of the food industry TI 18-6-58-85, developed by the Scientific and Production Association of the Beer and Non-Alcoholic Industry.

Form N 4. Use of production facilities

In the named form, the production capacities necessary for the production of products are determined, ensuring the fulfillment of the concluded contracts for its supply.

Production capacity is understood as the ability of an industrial enterprise to maximize possible release products per year (day, shift) or the volume of processing of raw materials in the range provided for the planned period, with full use of production equipment and space, taking into account the use of advanced technology, improving the organization of production and labor. The calculation of production capacities is carried out in accordance with industry guidelines.

Depending on the nature of production, the production capacity of organizations in processing industry characterized by the release of finished products or the processing of raw materials per year, season, day, shift.

The production capacity of organizations is determined by the entire range of products they produce or in the range reduced to one or more types of homogeneous products taken as a unit. When determining the production capacity of an organization, all production equipment assigned to a workshop, plant, section, department (including equipment that is inactive due to malfunction, repair, modernization) is taken into account. In addition, the equipment that is in the process of installation and in the warehouse, intended for commissioning in the main production in the accounting year, is taken into account.

The production capacity of the organization is determined by the capacity of the leading technological equipment of the main production shops or plots. The leading technological equipment includes machines, devices and units on which the main operations of the technological process are performed.

The production capacity of the enterprise is calculated according to the technical standards for the productivity of equipment and product yields from raw materials, which must be systematically reviewed taking into account best practices, the use of the latest advances in technology and the organization of production and labor.

Technical norms for the productivity of the main technological equipment and the annual fund of working hours are taken into account in accordance with industry instructions for determining the production capacities of enterprises.

To determine the degree of use of the organization's production capacity, the calculation of the average annual capacity for each type of product is made, taking into account the input and disposal of capacities during the year.

The average annual input capacity is calculated by multiplying the input capacity (replaceable) by the number of months of its operation until the end of the year and dividing the resulting product by 12. The average annual retired capacity is also determined by multiplying the retired replaceable capacity by the number of months remaining until the end of the year from the moment of its retirement, and dividing the result by 12.

The annual production capacity (column 7) is determined by multiplying the average annual shift capacity (column 5) by the number of work shifts per year (column 6).

Capacity utilization (in %) is determined by dividing the annual planned output (column 8) by the annual production capacity (column 7) and multiplying the result by 100.

For organizations, workshops, sections, units, installations that are in the planned year at the stage of development of design capacities, their utilization factors (normative coefficients for the development of design capacities) are established in accordance with the norms for the duration of development of the design capacities of organizations, facilities put into operation as a percentage of the annual design capacity.

Planning for increasing the utilization factor of the average annual capacity can be carried out according to the following factors: increasing the interconnection of the capacities of workshops, sections, units, installations, providing the capacities of the main production with the capacities of auxiliary services; improvement of material and technical supply; reduction of terms of development of design capacities; increasing the shift ratio of equipment operation; improvement of the organization of production and labor, etc.

The calculation of the use of production capacity is compiled for all types of products produced by the organization.

Form N 5. The need for raw materials and materials

The power of continuous devices operating at chemical enterprises is calculated on the basis of technical standards for the use of equipment over time and the intensity of equipment operation.

The general formula for calculating production capacity (M):

M \u003d a * (T - T o) * b,

where a is the number of homogeneous devices (machines); T - calendar time, hour; T o - regulated stops of one device (machine), hour; b - performance of one device (machine) per hour.

The number of apparatus and machine hours T mh, which should be used per year, is calculated by the formula

T mh \u003d (T - T o) * a.

When determining the fund of working time (or the number of device-days of work in the planned year), as indicated above, downtime of equipment in connection with current and major repairs, as well as technological shutdowns, can be provided.

Let's say that five devices are installed in the shop; in the planned year, it is planned to stop the workshop for 10 days (in connection with the repair of communications) and the time for current and major repairs and technological shutdowns of one apparatus is 504 hours, or 21 days (504/24). The working time fund will be (365 - 21) * 5 = 1720 device-days. (The repair of equipment coincides with the repair of communications. Therefore, 10 days are not included in the calculation).

After determining the number of device-days of work of the planned period, the amount of raw materials entering the processing is calculated. The calculation can be carried out per unit of time (hour, day).

If the intensity indicator is defined as the amount of raw material supplied to the apparatus per unit of reaction volume per unit of time, then to calculate the power, it is necessary to take into account the output of products from a unit of raw material, or the consumption coefficient.

The production capacity (M) of continuous devices can be calculated by the formulas:

M \u003d (T - T o) * a * L * I n i * V p,

where L is the useful volume or area of ​​the apparatus; And n i - the standard amount of raw materials per unit volume or area of ​​the i-th apparatus per hour; In p - the coefficient of output of finished products from raw materials; p k - consumption coefficient.

If the performance indicator is determined in units of finished products (production volume from one cubic meter of volume per day), the capacity of the continuous apparatus for the planned period will be:

M \u003d (T - T o) * a * L * I p,

where I p - the amount of finished products per unit volume.

For continuous processes, you can use the following formula:

M \u003d (T - T o) * a * V * C * 10 6 * V p,

where V is the volumetric velocity, m 3 / h; C * 10 6 - concentration in terms of a ton of the substance in the apparatus.

Methodology for calculating the production capacity of batch equipment (general calculation scheme)

The power of batch machines depends on the number of revolutions, or cycles, for a given phase of production, the amount of raw materials consumed per revolution or cycle, and the output of finished products from a unit of raw materials.

The duration of the cycle, or turnover, includes the time spent on performing all operations, from turning on the apparatus and loading raw materials to unloading finished products. At the same time, for operations occurring simultaneously, the combined time costs should not be included in the cycle duration.

The production cycle usually consists of technological time and maintenance time spent on auxiliary operations. To reduce technological time, it is necessary to improve the production schedule. The reduction of service time is planned on the basis of the development of organizational and technical measures aimed, in particular, at combining service time with technological time.

The power of this type of equipment of periodic action is calculated by the formula:

,

where I n j is the amount of raw materials consumed in one j-th cycle; In n - the planned output of products from a unit of raw materials; T c - the duration of one cycle (turnover), hour.

When raw materials of several types are loaded into the apparatus, the output is determined by the main raw material and a coefficient is introduced into the formula that characterizes the ratio of the weight of this main raw material to the weight of the total load.

The power of batch equipment can also be determined based on the planned rate of intensity (or productivity), expressed in units of finished products.

The productivity of the equipment in units of finished products is equal to:

.

Thus, power can be expressed by the formula

M \u003d (T - T o) * a * I n * L.

The power indicators of the apparatus-aggregates, expressed in units of products manufactured by the workshop, and arranged in sequential order on the diagram according to the passage of the production process, are called the power profile of the workshop. Drawing up such a profile makes it possible to visually identify bottlenecks, the elimination of which will make it possible to increase output.

Based on the profile data, the capacity of the workshop is calculated. Let us give an example of calculating the capacity of an ammonia shop under the conditions of a stepped work schedule during the planned year (Table 3).

Based on the given data, we calculate the capacity of the workshop. From Table. it follows that due to repairs, not all installed units will operate simultaneously during the year, as indicated by columns 9, 10 and 11. Units will be repaired in turn. With the established duration of repairs and the hourly productivity of the units, it turns out that the synthesis units will have the lowest productivity - 15 t/h of ammonia. This unit is one of the main ones.

The repair of four ammonia synthesis units will take 28 days (7 * 4), and during this period the capacity of the shop will be 15 tons / hour. The next limitation arises from the repair of cleaning units; productivity 16 t/h. It will take 60 days (10 * 6) to repair the cleaning units. Therefore, in the next 32 days (60 - 28), the productivity of the entire workshop cannot be higher than 16 t / h, although the capacity of the synthesis units after repair increases to 20 t / h . Further, 36 days (96 - 60) will be limited to compressors, the repair of which will take 96 days (24 * 4) and the minimum productivity of which is 16.5 t/h of ammonia. After the compressors, it is the turn to repair the air separation units. This repair will take 205 days (41 * 5), so in the next 109 days (205 - 96) it will be possible to produce only 18 tons / hour of ammonia.

In the remaining 155 days (360 - 205), the capacity of the shop is limited by the operation of the cleaning units, the productivity of which during the operation of all units is the lowest - 19.2 t / h.

Therefore, the annual capacity of the workshop will be

(15 * 28 + 16 * 32 + 16.6 * 36 + 18 * 109 + 19.2 * 155) * 24 = 155 136 t

So, the actual hourly productivity is 18 t/h, with the minimum productivity of one of the units (cleaning) being 19.2 t/h. The example shows the need for the production and installation of such equipment, for which the terms of the overhaul cycle would coincide or, at least, be close. Fulfillment of this requirement will significantly increase the removal of products and reduce operating costs arising from the underutilization of production capacity.

Obviously, not only will the specific capital investments per unit of output decrease, but the return on assets and labor productivity will also increase.

Tab. Calculation of the production capacity of the ammonia plant

Note.

gr. 4 = 360 days - gr. 3;

gr. 8 = gr. 2 * gr. five;

gr. 10 = 360 days - gr. 7;

gr. 11 = gr. 2 * gr. nine;

gr. 12 = gr. 2 * gr. 4*24;

gr. 13 = gr. 4 * 24 * gr. 8.

Consider simplified examples of production capacity calculations for enterprises in other industries.

There are three groups of machine tools in the workshop of the machine-building plant: grinding - 5 units, planing - 11 units, turret - 15 units. The norm of time for processing a unit of product in each group of machines, respectively: 0.5 hour; 1.1 hour; 1.5 hour.

Determine the production capacity of the workshop if it is known that the regime is two-shift, the duration of the shift is 8 hours; regulated downtime of equipment is 7% of the regime fund of time, the number of working days per year is 255.

Solution

2.
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3.

4.

5.

The weaving factory operates in two shifts, the number of looms at the beginning of the year is 500. Since April 1, 60 looms have been installed, and on August 1, 50 looms have retired. The number of working days per year is 260, the planned percentage of downtime for machine repair is 5%, the productivity of one machine is 4 m of fabric per hour, the production plan is 7500 thousand m.

Calculate the production capacity of the fabric factory and its utilization rate.

Solution

1.
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4.
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Determine the production capacity of the workshop and the capacity factor under the following conditions: the number of machines of the same type in the workshop is 100 units, another 30 units have been installed since November 1, 6 units have been retired since May 1, the number of working days per year is 258, the work mode is two-shift, the duration of the shift is 8 hours, the regulated percentage downtime for equipment repair - 6% productivity of one machine - 5 parts per hour; production plan for the year - 1,700,000 parts.

Solution

4.