Institute of Innovative Design Divnogorsk Low- Voltage Circuit- Breakers Plant 25%

Institute ofInnovativeDesign

Divnogorsk Low-Voltage Circuit-Breakers Plant

25%

Institute of Innovative Design

IID

Products of Divnogorsk PlantCircuit breakers:

Electrical cabinets:In=100A In=250A In=630A In=1600A


IID

Innovative projects Construction and production technology of lead-in distributor (cost reduction and quality increase)Construction and production technology of electrical cabinet PR 8503 (cost reduction and quality increase)Nonferrous materials economy. Construction and production technology of circuit breakers and electrical cabinets. (cost reduction and quality increase)


IID

Innovative projects Silver contact points of circuit breaker 250A (cost reduction)Construction and production technology of circuit breaker VA-57-43, up to the 1600A. (cost reduction at the design stage)Construction and production technology of circuit breaker VA-57-31(35,39), 100A, 250A

and 630A. (cost reduction and quality increase)

In=1600A

In=100AIn=250A

In=630A


IID

EconomyP

roje

ct V

A 5

7-4

3

8 million Rub.

Ele

ctri

cal

cab

inet

PR

850

3

Pro

ject

sil

ver

con

tact

p

oin

ts

7 million Rub.

Pro

ject

VA

57-4

3

3 million Rub.

10 million Rub.

Pro

ject

le

ad

-in

d

istr

ibu

tor

8 million Rub.

Pro

ject

non

ferr

ou

s m

ate

rials

eco

nom

y

Pro

ject

VA

57-3

1,

35,

39

20 million Rub.

100 million Rub.


IID

Lead-in distributorProject goal:

to reduce the prime cost

in 50%

Prime cost – 38966 Rub.

Market price - 15417 Rub.


IID

Costs

996

1921

1166 983

0

3599

2124

292

909

6606

2175

0

1000

2000

3000

4000

5000

6000

7000

Name Sheets Frame Panels Doors Docs Devices Apparatuses Buses Clamps Main leads Wires

Prime costs 996 1921 1166 983 0 3599 2124 292 909 6606 2175

Material 861 416 208 739 0 3393 2002 269 857 3067 47


IID

Supporting InformationGathering Supporting information

Supporting InformationGathering Supporting information

Analysis of the ObjectFunctional and Flow models, Evolution Trends, Key Disadvantages, Contradictions

Analysis of the ObjectFunctional and Flow models, Evolution Trends, Key Disadvantages, Contradictions

Problem SolutionEngineering Solutions

Problem SolutionEngineering Solutions

Data GatheringBackground information

Data GatheringBackground information

Function BasedInformation Gathering Function orientedinformation

Function BasedInformation Gathering Function orientedinformation

CONCEPTUAL STAGEINFORMATION STAGE

ANALYTICAL STAGE

Concept substantiationConcepts, Ideas for Further Development

Concept substantiationConcepts, Ideas for Further Development

Problem StatementTrimming problems,Feature transfer problems, Key problems

Problem StatementTrimming problems,Feature transfer problems, Key problems


IID

STATEMENT OF KEY PROBLEMS

GENETIC ANALYSIS

COMPONENT-STRUCTURAL ANALYSIS

FUNCTIONAL-PARAMETRIC ANALYSIS

PARAMETRIC ANALYSIS

DIAGNOSTIC ANALYSIS

INTEGRATION OF ALTERNATIVE SYSTEMS

-CAUSE-AND-EFFECT CHAINS ANALYSIS

Problems

Undesirable effects

Denotations:

STATEMENT OF PROBLEMS DIRECTION OF

SOLUTION OVERMODELING


IID

Functional model


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Results of functional analysis

Basic15%

Auxiliary59%

Harmful26%


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Cause-and-Effect Chains Analysis

What are the reasons of high labour-intensiveness and materials consumption?


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Convolution results


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Results of analytical stageClass of problem Amount

User defined problems 47

Problems which are directed on increase of useful function performance

95

Problems on exclusion of harmful effects 31

Problems on decreasing of functional superfluity

47

Key problems after partial trimming procedure

17

Root problems after cause-and-effect chains analysis

76

Total (problems after analytical stage) 313


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Conceptual stage

23 basic concepts submitted


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1.Labour-intencity decrease

2.Materials consumption decrease

3.Energy intensity decrease

4.Quality and product appearance increase

5.Ease of use and repair increase

6.Change of package and transportation

7. Lead time decrease

Change wires by bus rods


IID

The saving rate is 1212 Rubles for one item.

Arrangement change


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Clamps

Switchers VDU

Safety devices

Current transformers

New arrangement of devices:

The saving rate is 1476 Rubles for one item.

Advanced fixing elements

High labour-intencity


IID

Galvanized panel instead iron powder coating

High costs on powder coating


IID

Buses of intricate profile

High labour-intencity of wire bonding


IID

Welding points reduction

High labour-intencity of frame manufacture

Bending process applied:

Bras binder change by iron

High costs of brass binder

New light frame design

High labour-intencity and material consumption of

frame

Material consumption decrease

861

416208

739

35

3393

2002

269

857

3067

470

500

1000

1500

2000

2500

3000

3500

Name Sheets Frame Panels Doors Docs Devices Apparatus Buses Clamps Main leads Wires

Material 861 416 208 739 35 3393 2002 269 857 3067 47

Reduction 402 260 170 493 100 3180 2002 350 400 613 35

Labour-intencity reduction

13

231

148

310

00 1 0

524

332

0

100

200

300

400

500

600

Name Sheets Frame Panels Doors Docs Devices Apparatus Buses Clamps Main leads Wires

Labour-intensity 13 231 148 31 0 0 0 1 0 524 332

Reduction 2,6 18 74 15 0 0 0 2 0 52,4 166


IID

Achievements

• Costs reduction on 51%• New attractive design• New modern devices used• Materials consumption reduction• Labour intensity reduction • New technology applied• Energy consumption reduction


IID

Innovative Design efficiency

1 Ruble put into innovative design

works gave more than 20 Rubles


IID

Documents

Institute of Innovative Design Divnogorsk Low- Voltage Circuit- Breakers Plant 25%