The development of a new product is a complex technical task, providing for the implementation of a complex of research work. A feature of the process under consideration is the need to ensure the required technical level of the product, as well as giving it certain properties. They should ensure the minimum complexity of manufacturing and subsequent operation of the product, as well as reduce the consumption of material and energy resources at all stages of the life cycle. Material consumption of production characterizes the costs that the enterprise incurs when developing and launching products in mass production.
Product manufacturability
The main goal of any product is to satisfy customer needs. Moreover, on the one hand, it is necessary to strive for its maximum usefulness, and on the other hand, do not forget about those properties that are associated with the resource consumption of the product. The set of product properties that allow its design to be optimal in terms of manufacturing and operating costs (while ensuring the required level of quality and output volumes) is called the manufacturability of the design.
For manufacturability, a number of indicators are used, which include:
- material consumption of products - characterizes the inherent costs of material resources (manufacturing, operation and repair);
- the energy intensity of the product - the volume of costs of fuel and energy resources;
- specific material consumption - shows compliance with the beneficial effect of the product.
The specified parameters are universal for all produced objects. If it is necessary to compare various design options, in order to select the most appropriate, first of all, an analysis is made of the material consumption of the product.
Characterization and calculation
Material consumption of products characterizes the amount of various resources that is necessary for the creation and subsequent use of objects (systems) in certain operating conditions. There are several varieties of this indicator. Some of them relate to manufacturing steps, others only to repair or maintenance.
In the practice of calculations, quite often use specific indicators of material consumption, which help to trace the relationship with the consumption of material. In general terms, the specific production material consumption (M beats ) is calculated as follows:
M beats = M p / (P * T)
M p is the consumption of material in the manufacture; T - standard operating time; P is the maximum value of the main parameter (beneficial effect, determined by scientific data).
The selected characteristics are closely correlated with the cost of the material. When changing the parameter, the flow rate also changes. Examples of useful effects, depending on the technical system or facility under consideration, can be mileage (for cars, bicycles, freight vehicles), power (for pumping stations), productivity (refrigerators), etc. As you can see, the material consumption of products characterizes complex component when choosing new designs.
To specify the type of material that is combined used in repair technology or in manufacturing, it is possible to differentiate the indicator by type of material - metal consumption, plastic intensity, wood intensity. Analysis of specific indicators allows you to choose the overall strategy and direction of improvement of the developed facilities.
In addition to the characteristics presented, additional assessments of the use of materials are recommended. Material consumption of products is characterized by the following indicators: coefficient of applicability, utilization of materials, etc.
For example, the coefficient of applicability is defined as:
K ol = M ni / M n
M ni is the consumption rate of a particular (i) material; M n - the consumption rate of all materials for the manufacture of the product.
The specified coefficient allows the use of promising grades of materials.
To analyze the degree of rational use of materials, you can apply the appropriate coefficient:
To im = M i / M nΡ , where M nΡ is the nominal value of the mass of material (i).
Determination methods
When conducting an analysis of the design of the product, it is necessary to ensure the following conditions are met:
- the expected operating conditions should be at the same organizational and technical level;
- the most advanced technologies should be used at the time of design;
- products should have almost the same level of labor intensity;
- material consumption values ββare determined by one method for all designs.
The most common determination methods include the calculation and the weighing method. Also used is the method of analogies, the method of mass accounting, the method of specific rationing, etc. In addition to everything else, they determine what indicator characterizes the consumption of materials.
Prospects for use
The results of the analysis of material consumption can be used to improve the design and development of new products. In particular, for:
- receiving new materials;
- advanced manufacturing and repair technologies;
- increase the level of reliability of products;
- optimization of operating conditions;
- use of new quality control methods;
- analysis of the possibility of recycling materials.
Conclusion
Modern approaches to ensuring manufacturability of products should be based on accurate methods for determining the properties of products. Material consumption of products characterizes not only the consumption of materials for a particular product, but also the optimal distribution of resources at all stages of use.