JPRS ID: 9118 SUB-SAHARAN AFRICA REPORT

• Document Type: CREST
• Collection: JPRS
• Document Number (FOIA) /ESDN (CREST): CIA-RDP82-00850R000200060004-9
• Release Decision: RIF
• Original Classification: U
• Document Page Count: 36
• Document Creation Date: November 1, 2016
• Sequence Number: 4
• Content Type: REPORTS

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4 MRRCH 1980 CFOUO 3180) 1 0 F 1
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~OR OFFICIAL USE ONLti' -
~ JPRS L/8963
- 4 March 1980
~
Ec~st Euro e Re ort
p p
SCIENTIFIC AFFAfRS
(FOUO 3/80) -
= FB~$ FOREiGN BROADCAST INFORMATION SERVICE _
FOR OFFICIAL USE ONLY _
-I
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JPRS L/8963
_ 4 March 19a0
EAST EUROPE REPORT
$CIENTIFIC AFFAIRS
(FOUO 3/8J)
CONTENTS PAGE
CZECHOSI,OVAKIA
Engine Assembly Line Automated Parts Storage Explained
(Rudolf Kubasta; STROJIRENSKA VYROBA, Nov 79) ........o.. 1 -
- a - . [III - EE - 65 FOUO]
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~ CZECHOSLOVAKIA
ENGINE ASSEriBLY LINE AUTOPIATED PARTS STORAGE EXPLAINED
Prague STROJIRENSKr1 VYROBA i~ Czech Nov 79 pp 835-850
[Article by Rudolf Kubasta, Kovoprojekta in Brno: "Automated In-Process
Parts Storage for Engine Assr~mbly Lines")
[Text] Over a very short period of time, along with the rapid technologi-
cal development, new means of production and handling have entered the
plans oF engineering production. They not only fulfill their basic function,
but can take over the tasks of their programming and technical preparation,
if r_hey receive, within a specific timey certain basic informatioZ that is
either independent or derived from the technological process or from the
material flow in the process of production.
Th~s, the multiplicity of ineans and information during the process of pro-
duction create demands for an accurate and controlled flow of information,
- which may be best achieved only with specifically selected means of produc- -
- tion and handling and of technical equipment for data processing and record-
_ ing and a specific linkage of their deployment.
Tec}inology is the starting point, but at the same time, it must adapt, with-
in the available limits, to the needs of the organization of material aspects
_ in the process of production, and af the control system linked with it. Al1
three of these factors are interrelated and their harmony p~edetermines the
efficiency of the system.
- The plan prepared for the in-process storage of engine assembly lines in the ~
Tatra national enterprise in Koprivnice serves as an example of an arrange-
ment linking three Eactors to the extent required already during the early
stages of planning of the engineering production program for the subsequent
choice of equipment for production and handling, and of technical equipment
for the data recording and processing systems.
The stage preceding the approach to tha technological nlanning of the func-
tian of- pre-assembly in-process storage (PM) in the manufacture of engines
involves the Following:
1
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_ --Analysis of requirements for the design
--Determination of the objectives and prerequisites for the technological -
design R
--Determination of requirements for storage, handling and transport operations
--Detennination of the targets of automation and data bank in the PM -
, ~
_ --Specification and analysis of the limiting factors
--Technical-organizational concept of the design on the basis of gross
_ capacities, calculations
--Concept of the flow of information
~ --Capacity calculations according to the cechnical-oroanizational concept and
to the concept of the flow of information.
The initial data and the resultant values in this stage of planning are
presented in the form of diagrams Figures 1 through 6.
2
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APPROVED FOR RELEASE: 2007/02/48: CIA-RDP82-44850R000200064404-9
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APPROVED FOR RELEASE: 2007/02/08: CIA-RDP82-00850R000200060004-9

APPROVED FOR RELEASE: 2007/02/48: CIA-RDP82-44850R000200064404-9
FOR OFFICIAL USE ONLY
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15
FOR OFFICIAL USE ONLY
~
APPROVED FOR RELEASE: 2007/02/08: CIA-RDP82-00850R000200060004-9

APPROVED FOR RELEASE: 2007/02/48: CIA-RDP82-44850R000200064404-9
FOR OFFICIAL USE ONLY -
[Key for Figure 7 ]
l. Central computer of the enterprise
2. Ass~mbly lines
= 3. Non-self-contained alternative [alternator?]
4. Storage of manufactured parts
S. Identif ication center
6. Storage of subdeliveries
~ 7. Control room
S. Report of rejects
9. DifPerence between the planned and the actual production
~ 10. [Deduction? Reading?] ~
11. Correction ~
12. Yes '
No ;
13. Dispatch room
14. Production shops ~
15. Complete invent~ry list of stored entries of manufactured parts and sub- f
deliveries, and list according to the model of engine ~
16. No of entry of manufactured parts or subdeliveries stored, called by -
the No of the entry chart .
17. Complete inventary list of entries of manufactured parts and sub-
deliveries in supply on assembly lines, and list according to the
model of engine
18. No of pieces, entry of manufactured parts or subdeliveries in supply on ~
assemb ly lines, called by the No of entry chart
19. Inventory outlets
20. Outlets of the self-contained system
21. Parts required for the assembly for a period covered by supply in the -
storage
Plan for removal of parts and subdeliveries from the storage -
22. Subdeliveries required for the assembly for a period not covered by
supply in the storage -?~ITZ dispatch base _
23. Manufactured parts required for the assembly for a period not covered
by supply in the storage - production dispatch base
24. List of free cells in the storage of subdeliveries for one period of
time
Base for storage of subdeliveries, and data on the punched card of the
pallet
25. Kovoprojekta in Brno
26. Pre-assembly in-process storage _
27. Diagram of the flow of information in self-contained system
16
_ FOR OFFICIAL USE ONLY
APPROVED FOR RELEASE: 2007/02/08: CIA-RDP82-00850R000200060004-9

APPROVED FOR RELEASE: 2007/02/48: CIA-RDP82-44850R000200064404-9
- FOR OFl?ICIAL USE ONLY -
Figure 8.
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APPROVED FOR RELEASE: 2007/02/08: CIA-RDP82-00850R000200060004-9

APPROVED FOR RELEASE: 2007/02/48: CIA-RDP82-44850R000200064404-9
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APPROVED FOR RELEASE: 2007/02/48: CIA-RDP82-44850R000200064404-9
FOR OFFICIAL USE ONLY
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FOR OFFICIAL USE ONLY
APPROVED FOR RELEASE: 2007/02/08: CIA-RDP82-00850R000200060004-9

APPROVED FOR RELEASE: 2007/02/48: CIA-RDP82-44850R000200064404-9
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APPROVED FOR RELEASE: 2007/02/48: CIA-RDP82-44850R000200064404-9
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21
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' FOR OFFICIAL USE ONLY
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22
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i
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Desr_ription of the Function of the System
. The function of the PM system is described for that particular stage in
drafting of the plan which precedes the selection of the model oE the equip-
ment (hardware) for the system controlled in real time, its linking in an
arrangement, and the development of programs and instructions (software) for
that control system.
For that reason the specif ication has the character of an assignment for
the hardware and software designers, or of an order for a bid to be sub-
mitted by the supplier of the whole system, including its introduction into -
operation.
- Therefore, the specification does not contain potential variants of the
function according to the selection of the model and arrangement of the
- hardware, and options for its development, particularly in the software ~
department.
The initial data for the specification consist of the concept of the ma~e-
rial flow, and of the conceptual resolution concerning the centers of auto-
mation, the control in real time (.initial information is processed For the
final resolution in the time of the material flow), and concerning the
autonomy of the system (for final resolution in real time, the system pro-
cesses and banks all data required for the processing of the initial informa-
tion) .
Tt;e function of the system is processed as the basis for the specification _
pre~sented in the form of a diagram in Figure 7.
Storage of the Pallet in the System of Sub-Deliveries
'the storage of sub-deliveries represents an organizational formation in
the area of trade operations, where standard punched cards are produced
for pallets received from suppliers or pal.lets transferred from outside
transport as documents accompanying the pallets where records on the loca- _
tion of the pallet in th~ storage (the cell in the rack) are kept; and
where transport operaCions are dispatched to the location of the pallet in
the storage. ~
~3 ,
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_ The only contact of the system of sub-deliveries with the PM system during -
the storage of the pal].et is as follows:
A -
a) From the PM system it received on-line (technical equipment linked with
the PM arrangement) or off-line (instruction by corrected document):
--Survey of vacant storage ce11s as periodic information on the siruation _
of vacancies (specified entry) issued in specific time intervals, which is
, continuously tracked by the PM system;
b) The on-line or off-line will provide the following for the PM system:
- --I;~formation on the contents of the pallet, i.e., the No of the chart of
_ parts and their count in units of quantity;
--Information on the location in the storage, i.e,, the No of the cell in
rack storage freely selected f or the storage of the pallet from the list of
storage vacancies.
- A prerequisite Eor an efficient contact with the PM system in complete
- conformity of information provided for the PM system at the time of the
deposit in the storage, with the information on the punched card accompanying
the pallet, i.e., information supplied at the time of its removal from the
storage.
Pallet Stored in Pre-Assembly In-Process Storage
Placement of pallets in the pre-assembly in-process storage is determined -
= by the type of the pallet, i.f the pallet is to be stored in the racks, by
_ the suitability of the pallet for computerized transport, and by the punched
- card accompanying the pallet, with specific information. about the type and -
amount of the contents of the pallet.
- Every pallet addressed by computerized transport to the PM reaches its
- destina~ion at the window of the identification center (IB).
Here the operatcr removes the punched card (DS) from the pallet, and the
reader of indiv;.dual DS and the tasterer forward the following:
a) Input data in the system--automatically:
--No of the chart, and descr~.~*ian of ~he contents of the pallet--manually
on the tasterer;
--The quantity of the parts in the pallet according to the data from the
last technical inventory entered on the card;
--The impulse for the placement on the floor (P), if the pallet cannot, or
should not, be stored in the racks, and simultaneous command to computer-
ized transport to the location of the storage on the floor.
21~,
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~
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t'VL\ Vl�1'iV1t1L UJL' V1VL1
b) Data in the system--automatically:
--Record ot the input data on the storecf c rcin5~~ort ]oud In the m~~mc~ry (L);
--Record ~f impulse P in the memory of stored transport load, and blocking
of the s~art of automatic collators snd oE the r.ecord on the occupation of
the vacancy ln the storage rack, if tfie pallet is stored on the floor.
--Release of the collator for subsequent automatic storage of the pallet
in the vacancy according to the memory of vacancies (L), and addressing the
computerized transporC to the point of transfer to appropriate collator, if
the pallets are stored in racks;
--Record of the location of the storage (rack cell No) added to the record
of initial data on stored transport load, and deletion of the information on
rack cell vacancy f rom memory L.
c) Data from the system--automatically:
--Printer write-out on stored transport load for the control system, and -
the information for emergency control--of collators.
AEter Eeeding in the initial data, no other data are fed in the system, if
ttie pertinent contents of the transport load have already been specifitd -
for renio~~al from the storage, thus cancelling the priority of the storage.
The operator in the IB, who identifies pallets for impuse P, is notified
of each pallet that, while passing througn profile inspection before the
IB, Eails to meet dimensional standards for rack storage in the PM.
L'stimate of- Parts and Subdeliveries Required for Assembly Lines
The first initial information for the estimate of the parts and subdeliveries
required on assembly lines is based on the plan of production for the assem-
bly of a complete engine, divided into briei intervals of time, and the plan
_ For the production of subsystems in assembly lines, divided into brief inter-
vals of time, with such ~n advance schedule that all assembl.y o~erations be
correlated in time sequence and balanced in terms of capacity. -
The analysis of the requirements in terms of design and technology of pro-
duction in related lines makes possible consideration of two conceptions
of this plan of production, prepared as:
a) Standard plan
i..e., a fi.xed arnount of parts for the assembly of basic models of engines
and their respective subsystems in constant relation of their advance
schedules, prepared for a period after which the quantity of parts and the
relations are repeated, i.e., standardization of the plan.
The brief interval of time for the tracking represents simultaneously a
standard vertical cross section of assembly plans. The non-standard
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factor, i.e., model ~r.odifications, may be determined solely by the model -
modification code for a short interval of time, without any changes in the
quantiey of the parts of the standard plan.
The preconditions for the standard plan are determined by: ~
--Regular cycle of the assembly line for basic models an3 for modifications
of models of engines;
--Routi~iely repeated production of the control unit, i.e., body for 10 V -
_ and 12 V engines on the production line;
, --A constant ration of the number of test rooms for individual basic models
of the engine;
--Routine schedule f~r advanced assembly of subsystems before the assembly -
of the engine, so as to achieve capacity balance between the assembly on -
the line and the assembly of subsystems;
_ --Economic capacities of the production on parts production lines.
b) Non-standard plan
whose variability is given by the changing quantity of the manufactured -
engines and subsystems. This quantity varies in individual planning periods, -
for instance, according to the supply of manufactured parts and stored sub-
deliveries, or according to variable demands on the production of subsystems,
such as spare parts.
The computation of the non-standard plan is repeated for each planning
period; in order to plan it as a program for assigned production of sub-
systems, the following updated infarmation must be made available:
--Standard schedules for advanced assemblies of subsystems before the ~
assembly of complete units;
--Output standards, and the coefficient of their overfulfillment; -
--Limit of capacities of the lines in relation to the model of the engine
assembled on the line.
In an autonomous concept of the PM system this plan must be computed so as
to provide a non-standard vertical cross section of the short-term plan.
_ These tasks of the plan of production scheduled for specific intervals for
the following day may be prepared during the idle time of the control com-
puter, i.e., in the third shift.
The list of parts (K) for the basic model of the engine and lists of parts
_ of its subsystems provide the second initial information for the estimation
_ of the parts and subdeliveries required in assembly lines. Magnetic tape
serves as the medium carrying the infnrro~tion for such lists of parts. -
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FOR OFFICIAL USE ONLY ~
_ Data concerning individual entries present a complete survey of the system
and quantity of parts per [jednice] of the assembled object (engine or its
s~ibsystem) without cumulating entries of identical design.
Direct count ot the list of parts, multiplied by the quantity of parts of the
assembled object determined according to the short-term assembly schedule, is -
fed into the memory of the control computer (RP); for that operation, theo-
retical requirement (TP) of the quantity of individual entries in the list
of parts is available for the next period and for the basic model of the
engine ur its respective subsystems.
The list of parts for modifications (KM) of the model of engine or its ~
respective subsystems marked by nurnerical code provide the third initial
information for the estimation of the quantity of parts and subdeliveries
required on assembly lines.
It is fed into the memory of the RP with the multiple of parts planned for
_ the assembled objects of modified models only for that particular period of
the plan for which the modification code has been ;;tipulated for the quan-
tity of parts de~ermined in the plan.
The list of parts for model modification specifies changes only in those
entries in the list of parts of the basic model that provide other informa-
_ tion concerning model modification.
A sector from the standard plan for assembly lines with supplemental model :
modification, the linkage of lists of parts K and MK, and the estimate of
TP are presented in the form of a diagram of initial data of an autonomous
system (Figure 8).
,
- In addition to the i~er,tification ~.ia capacity data of the entry, the TP
_ data system received from the list of parts also 3..nformation on the address
of the supplier to the PM, the place of the dispatch from the PM--the
address and code for limit information (for example, the maximum quantity
that may be dispatched to an address in one period of time).
The information system conce.rning TP for a short period (one hour) is
appli~~:d in RP ahead of the schedule of the plan of production assigned to
- assembly lines, in order to deduct the information on the quantity of
individual entries fram memory M of sunulies on the assembly line. Entries
demonstrating minus values a~ter the deduction denote parts and subdeliveries
actually needed on assembly lines, and are used liy RP in programming the -
removal from the storage of entries that are not covered by the supply
available on the assembly line.
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Removal of Pallets from the Storage of Subdeliveries and PM
The program for the removal of eneries b~comes a program Lor tt~e removal.
_ of pallets after its comparison with the supplies of transport loads in
memory L.
Entries not covered by the supply in the storage are identified for special
~ tracking on video terminals in the identification center and in the control
_ center for assembly lines, particularly in the dispatch center of the pro-
duction.
- Entries covered by the supply in the storage are fed separately for sub-
deliveries in the printer which thus camputes a short-term program to
vacate specific cells in the storage; this program may be used immediately
by collators operating in the storage of subdeliveries.
The pallet removed from the storage of subdeliveries is deposited by
collators on lifting tables, which position the pallet, signal the opera-
tors of the collators their engagement, and set the computerized transport
to pick up the pallet. -
Entries concerning ma:~ufactured parts covered by the supply in the storage
of the PM are removed from the storage in two ways: -
a) Pallets stored on the floor (indication P in the memory)
are fed separately in the printer in the identification center, and thereby,
the operator is assigned the task to locate the pallet and lift it, by means
of an auxiliary crane, on the table which signals the computerized transport
to pick up the pallet in the same way as in case of pallets of subdeliveries, -
or to place the pallet directl~ on the computerized transport truck.
_ b) Pallets placed in rack storage
are automatically removed from the storage by on-line computerized collators
upon a signal from the RP to the collators by means of data froro the program
for the removal of pallets, i.e., collator code, rack code, x-coordinate
code, and y-coordinaee code. The collators place the pallets on out-feed
tables. Simultaneously with their removal from the storage, the following
processes are automatically completed:
--Computerized transport truck is directed to the out-feed table;
.
- --The truck is addressed to the assembly line;
--The transport load from the supply in the storage is fed into the supply -
in the assembly line (from L to M);
--Addressing, reading and other commands are blocked according to the
limited pick-up code.
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The tasks of the program for the removal of pallets from the storage are
gradually, over the entire short interval of time, projected on video
terminals, ancl after reading the transport load, they are erased from
memory L and fed into memory M.
The deployment of the tPrminals is presented in the form of a graph of -
the hardware concept For the PM (Figure 9).
Computerized Tr.ansport for the PM and Operations at Assembly Lines
Computerized transport is ~et into operation:
- --Subdeliveries upon an impulse following the contact and positioning _
(turning) of the pallet on the out-feed table;
--Entries P in the PM upon an impulse following the contact of the pallet -
witti the out-Leed table, or after manual addressing of the truck to the
checkpoint in the identification center;
--Entries from rhe racks into the PM upon an impulse from the RP, auto-
matically addressing the truck to the out-feed table of that particular
collator that has confirmed by feedback to the RP the transfer of the in-
Eormation from the program for the removal of pallets from the storage.
In their elemental automatic operations related to the removal of the
= pallet L-rom the stora.ge the entries from the PM racks already address the
truck automatically by means of a floor starter or an antenna radiator.
Together with the command to the out-feed table, the trucks with entries P
receive the following address--the checkpoint in the identification center.
Here the reader removes the punched card, the information on the entry is
checked or projected on the video terminal and thus, the accuracy of the _
transport load is confirmed.
Next, the truck receives automatically from the RP the address of the
~~ssembly line, and the transfer Erom memory L to M is completed. After
the pick-up from the out-feed table the entries of subdeliveries are auto-
matically transported on the truck to the address of the checkpoint of the -
identification center, with the DS accompanying the pallet.
At the check point the transport load of the subdelivery is processed in
- the same way as the transport load of entry P, including address to the
assembly line.
The operator may intervene with computerized transport, for example, in
order to sideline the transport of the load to the washer, only before the
_ transfer from memory L to M is completed, After that moment any interven-
tion requires either an additional transfer of the same transport load past
the checkpoint by manual handling of the truck, or a new entry of the trans-
port load into the system past the checkpoint, and correction of inemory M. _
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Computerized transport is conducted by means oF induction-controlled
- autamatic trucks on inducted lines to the destination to which the truck
has been addressed automatically or manually, by a remote control tasterer,
or the tasterer on the truck.
A variant of the design of lines and destinations appears in the chart
(Figure 10) as a layout for the initial situation, because the simplicity
of its installations will lead to empiricaJ. changes and to extensions of
the lines and destinations.
At its addressed destination the truck waits on the sideline for the pro-
grammed period, and if during that time the shop service does not r.eceive
the truck, upon a sound signal the rruck automatically deposits the pallet -
and returns to the so called zero point, i.e., to the PP4.
If the shop service receives the truck, it disconnects the automatic device
- on the truck by switching it off, and then the truck is operated freely as
any other low-lift electric truck.
The presence of the truck on the line makes it available for the removal
of an empty pallet or for the transfer of a full pallet to another assembly
_ line (subsystems on the engine assembly linc}, The removal of the pallet
from the line and the addressing of t'ne truck must be done manually; also,
the truck must be put back on the line and the automatic device switched on
manually. The guide for addressing of empty pallets is the color or sign
of the pallet according to the place of their f illing. Each assembly line -
may use a push button to signal the control unit that an empty truck be sent
to remove the pallet.
To avoid any unnecessary blocking of the truck by operations on the assembly
line, the movements of the trucks are tracked from the dispatch center fol-
lowing either the signal system from the control unit, or the television
monitor used in the dispatch system, whose sound devices may avert delays
of the truck.
Corrections of Information in the PM System and Its Emergency Operation
Memory M contains data on supplies in assembly lines where deviations from
the actual situation may occur for reasons stated below. Such deviations
- must be corrected by appropriate means:
- Planned theoretical consumption is deducted from the inventory, Real con-
sumption, which is identical in the entries, is computed by updating the
lists of parts, K and MK, however, the capacity consumption may deviate also
in the difference between planned production of assembly groups and real
production for a given period (one day).
Correction may be made by multiplying the lists of parts by the plus or
minus difference between the planned and real production. It is presumed
that the correction is based on daily reports from assembly lines during -
the third--free-shift of the RP, -
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r~ux ur~r~iC1AL USE ONLY
--Parts found on assembly lines to be defective are corrected in individual
entries by keying according to the record of defective parts, subdeliveries
and subsystems ascertained at the assembly.
--Lost parts are correctect in individual entries by keying according to the
differences between the record of the RP and the physical inventory.
--Returned parts are corrected according to the documents accompanying the
returned transport load, which are issued by the assembly and used aiso for
the identification in the IB at the time of their replacement in the storage.
- This is necessary when making chaages so as to update the ]_ists of parts as
well; before the change is made, the situation of the entry may be verified
on the basis of inquiries not only on the assembly line but also in the
storage.
The elimination report serves as the basis for the elimination of both
supplies due to changes, and corrections are entered in memory M up to the
moment of the removal of the unneeded supply from the storage upon the -
command from the tasterer and then its feeding into memory A1.
Emergency operations in the automated parts of the system proceed on two
levels:
--Remote control, if the information system remains operative. Remote con- -
trol by Che tasterer, both for collators and for addressing the trucks, is
located in the identification center.
--Manual operations in case of total breakdo~,m of the automatic equipment.
_ Collators are furnished with service booths and trucks are equipped with
auxiliary control steering for drivers. Elemental operations performed by
attendants are based on periodical printouts from the express printer,
- which register changes in the situation as concerns operations completed
prior to the breakdown.
Operations performed by attendants during the breakd~wn must be recorded -
on the slow printer reserved for that purpose, and on the basis of such
records, the data system must be retroactively updated after the breakdown. -
Both segments of the technological design propose a system of preassembly
in-process storage with the application of the automatic control system of ~
industrial production, whose technological plan, including the planned mate-
rial flow, capacities and autdmation, meet the demands on the design, and
the objectives of the design, which is evident from the capacity data, the
design of its technological equipment and data processing hardware, and
Erom the interpretation of the function of the system in the process of
production.
Along with the technological design, the software plan determines the
function wliich must derive its objective and algorithms from a11 components
= 31
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- r~Ult UFr~1CIAL USE ONLY
of the teclinological design, and become a part in the plan for the imple-
mentation of the system, or a part of the delivery.
- Another part of the plan pertains to the survey of the required manpower,
its qualification and training.
COPYRIGHT: SNTL - Praha 1979
9004
- CSO: 2402 ~D
32
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