Content
Large volume of product range
Changes every day
Planning and acceleration
What's the bottom line?
MasterFAB
MasterFAB
MasterFAB
A single source of accurate and verified production data in a metal fabrication plant. A solution that connects information, processes and work groups
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Specialists use automatic machines, data exchange between equipment and various programs, actively use software for cutting materials, electronic marking systems, etc.
However, advanced technologies have not spread to many production shops, leaving them “cut off” from the rest of the plant’s departments that are keeping pace with innovation.
A detailed analysis of roles in the production of metal structures reveals even more problems. Thus, the technologist has to spend a lot of resources on the labor-intensive work of selecting the necessary structural elements for production using electronic or paper drawings. Often, during the execution of an order, for example, due to a delay in materials, the technologist has to make changes to the preparation of production, which is time-consuming when working with drawings. Or it turns out that the customer cannot accept the finished metal structures at the construction site. This deprives the enterprise of timely profits on other orders, since precious time was spent on the production of "unnecessary" products.
A digital production management platform using BIM technologies will help to cope with such difficulties.
Such a platform will unite information, processes and people in a single space.
Designers, technologists and craftsmen will be able to work with models, thereby increasing their productivity
Planning departments will improve long-term and operational planning
Managers and owners will receive a complete picture of the progress of orders, resources and costs
This means that all ZMK employees involved in production processes at ZMK will be able to quickly access the order being manufactured, will be able to track all changes in the status of elements and plan their work.
Large volume of product range
The huge range of manufactured metal structures is one of the key factors in modern production, which works with a large number of orders. Where each order consists of unique parts and shipping marks. And it's not even that the technologists do not know how to produce them. The technology of cutting, welding and painting metal is well known to them. The peculiarity is that there are many types of finished structures, the so-called shipping marks and parts they consist of. And therefore the volume of documentation unloaded from the design department is also very large.
Working with such a large data set is very labor-intensive, requires a large personnel reserve and a lot of time. At the same time, there are high risks of making an error, the price of which is double the cost of resources. Let's consider an alternative process. Will we be able to change the organization of work? Replace drawings, electronic documents and tables scattered across different folders with a single digital space of a web platform with the ability to visualize data in the form of reports and a model?
Such a space will allow us to store all information about the order for the delivery of shipping marks in one order log, accessible to all participants of the storage. For example, the order log itself will be implemented as a table indicating the order name, the name of the customer organization, a special order code and its working status.
So we have come to the details of choosing a digital space for ZMK. Are there boxed solutions for ZMK?
MasterFab is a web platform for managing production data at a metalworking plant. The solution was developed taking into account the tasks of all the main roles at the enterprise.
Watch the recording of the webinar “Digital tools at a metalworking plant”, where we talk about how to transfer information to production at metalworking plants 2 times faster without losing data using the MasterFab platform .
List of shipping marks
MasterFab
When creating a new order in MasterFab from the design software, you first need to import the IFC file. Thanks to the detailed 3D information model, you can visualize the structure that needs to be manufactured. After importing the IFC data, an intelligent list of shipping marks (SSM) is generated. KMD drawings and DSTV files are loaded only after this so that they can automatically appear in the SSM according to their belonging to parts and marks. After importing all data, only marks are displayed in the SSM by default. The categories "Parts", "Subassemblies", "Bolts" and "Welds" are displayed after clicking on the corresponding buttons.
With the help of the VOM and reports, managers will be able to plan metal purchases in detail, track the status of each individual grade and plan the workload of the workshop and work groups, notifying them in a timely manner of any changes.
MasterFab
Changes every day
There are three main external factors that influence production:
Availability of metal and the ability to change the place of purchase. Moreover, the information is needed in quantitative, not weight values, with an exact indication of the specific size of the parts
Dependence of different elements of metal structures on each other. It happens that some dispatch marks are already ready for production. But their production is "frozen" because changes have come to another element of the structure affecting the mark
Readiness of fitters and customers to accept structures. When manufactured metal structures cannot be shipped, the plant loses time that it could have spent on production for another customer and the profit that it could have received under the contract
A modern online platform will be a suitable solution to the problems caused by these factors. It will connect all specialists involved in the production, shipment and acceptance of metal structures in a single digital space and provide them with common access to the necessary information. So that managers can manage the purchase of metal and the shipment of finished metal structures, and assemblers are always aware of the status of the production of shipping marks.
Find out more about the MasterFab platform and its functionality from the presentation.
The MasterFab platform has functionality that will help solve most of the problems described. To coordinate all specialists involved in production at ZMK, the platform has a "Workspaces" functionality. This is a digital workspace for one structural unit, which contains an order log and lists of users and orders.
MasterFab
For all participants of the space, you can set up roles: Administrator, Editor, Observer. In the version of the web application with free functionality, available at www.app.masterfab.ru, their number is limited: up to three users are available in the role of Administrator or Editor. But there are no restrictions for the Observer role.
Once you have set up the Workspace and added all the required users, they will be able to perform their duties using the intelligent shipping mark list and BIM model viewing functionality for the steel structure.
Managers
Various managers will receive comprehensive information on the composition and characteristics of the parts of the shipping marks and will plan what metal needs to be purchased taking into account its availability on the market at the moment.
In this case, the assessment of the volume of the required material is not done in tons and kilograms, but in exact values for the length and width of the parts.
Technologists
Using MasterFab, the technologist prepares production from the very beginning, receiving information from the design department in the form of an IFC file. Based on this data, it is also possible to view a 3D model of the entire structure. And when hovering over an element in the customizable VOM table, the corresponding part will be highlighted in the 3D model.
Order evaluation and planning of what needs to be manufactured is also carried out using an intelligent list of shipping marks, which also specifies the production order. Thanks to detailed data on the status and composition of each mark, the technologist quickly reacts to changes in the project without unnecessary costs.
Assemblers
Since the list of shipping marks contains detailed information on the composition of the product and its characteristics, the assembler will accurately form the required design. And free access to the statuses for each part will help to submit them in a timely manner and in accordance with the production sequence.
Master
For the foreman, the MasterFab platform will make it much easier to manage groups of welders and assemblers: he will easily estimate the volume of work and then distribute tasks among the performers, explaining to them in detail what exactly needs to be done.
Based on the data from the VOM, he will also be able to participate in production planning and ask the shop manager about the metal delivery times and the possibility of producing a specific shipping grade.
Planning and acceleration
The success of long-term and operational production planning at ZMK depends on many external and internal factors: from the high workload of each individual specialist to the failure to fulfill agreements by the customer. As a result, production is delayed, and the plant does not receive the required profit.
Or, to work under a contract, it is necessary to provide various reports: a list of brands for EPC, a list of materials for an order, packing lists, etc. In a large production, report files number in the hundreds and take a long time to prepare.
For automated planning and reporting, a digital web platform is the ideal solution. Most modern programs allow you to generate tabular and graphical reports in a couple of clicks, so that you can then quickly move on to discussing the data with managers.
In MasterFab, this functionality is implemented through the order card. By clicking the "Reports" button, the shop manager will go to the tools for creating various reports that can be printed or saved in PDF format. The MasterFab interface is available in two languages: Russian and English.