It is believed that heavy industry in St. Petersburg, as well as throughout Russia, is in a tailspin, and the main enterprise of the northern capital — the Kirov plant — has long been split into several low-performing organizations, barely making ends meet. But it turns out that it is not so …
On the "Soviet legacy" does not go
After the collapse of the Soviet Union, many legendary in Soviet times, plants have repeated the country's destiny: Once in unusual market conditions, hundreds of companies have gone to the bottom, having lost the lifeline of the state order. Brought up in a planned economy, a powerful but noble, powerful, but working under government contracts industrial giants were not ready for independent swimming.
Kirov plant — the main manufacturing plant north of the capital — many of you know on the achievements of the Soviet era. For the factory walls in an area of 1.2 million square meters of working steel production, were made T-80 tanks, self-propelled guns, power units for nuclear submarines and icebreakers, plant and equipment for the oil and gas industry, as well as the world-famous tractors "Kirovec." In the early 1990s, government orders dried up, new contracts did not appear, and the western rivals like the giant "John Deere" easily led away under the nose of large orders …
In the twenty-first century Kirov plant entered without imperial scale, with obsolescent facilities, which are now not loaded and a half. The company was expecting a conflict with shareholders and vague prospects, against which many predicted the imminent bankruptcy of the Kirov and goes under the hammer. Nevertheless plant survived and retained production — thanks largely to steel capacity: they do not require constant investment and somehow received orders. Metallurgy and now brings the main income of the holding. Those areas that were unoccupied — and this is a huge shop, land and office buildings — have begun to lease, the proceeds from which greatly helped the plant to survive not only a dashing nineties, but the crisis of 2008.
Now Kirov Plant, who in 1990 turned into a holding comprising 20 subsidiaries (actually former factory shop), took the course of modernization. The company's management understands that to go to the "rich heritage of the Soviet" without a gradual upgrade of production is impossible. Even more so — after Russia's accession to the WTO, which at times will toughen the competition in the market. Technical obsolescence of equipment can put an end to any enterprise — an effective competitor with economical and more productive modern machines always win the customer more attractive price.
Production of the Kirov factory, as well as dozens of other industrial giants of the Soviet era, needs to be updated. For example, metallurgical enterprises are still using outdated open-hearth furnace. Thus nowadays only one percent of the world's steel produced by this technology. And if there is a serious competitor Petersburg steelworkers at risk of losing customers. Significant funds, which require large-scale renewal of metallurgical production, the plant yet. However update workshops plant has already started — all the profit of the holding is the gradual modernization of the energy production and metalworking, machinery equipment, as well as expanding the range of products, which is the highlight of this year's tractor "Kirovec" Series K-9000.
Management expects the Kirov factory, in 2012, the consolidated revenues of the group of companies will increase by at least 40 (!) Percent — from last year's 14 billion to 20 billion rubles. Net income for the first half of 2012 amounted to 238 million rubles — against 123 million rubles for the whole of last year. For years, all earnings are going to upgrade the capacity and energy efficiency of enterprises.
Tractors — sight for sore eyes
A month ago, the company has upgraded the main tractor-conveyor.
— It helped liberate more than 40 million rubles in working capital and reduce the time of collection of the tractor from eight to four and a half days. It has already paid the money invested in the reconstruction — said the first deputy director general and head of the engineering direction of Sergei Kirov factory Zanozin.
The plant plans that given the volume of orders from the conveyor month will go to at least 120 "Kirovtsa" in 2013 edition will reach 150 cars per month. All in all, this year in the development of tractor production will invest 100 million rubles, which will be used mainly for training facilities for the production of a new generation of innovative "Kirovtsa" Series K-9000. Their serial production will start this fall.
Tractor drivers will appreciate the benefits of the new machines: they are equipped with air conditioning with climate control, GPS and camera angle trailed implements, as well as the economical use of fuel system. Previously on such equipment agriculturists and never dreamed of. Thus the cost of a new "Kirovtsa" 30 percent below the prices of their foreign counterparts. In 2013, the Kirov plant will release about 300 tractors of the last generation who can buy farms under special conditions — with the help of state-owned companies "Rosagroleasing." Machinery purchased on credit from 30 to 60 months, with initial paid only 20 percent of its value. In the first half of 2012 in the framework of the state program of the Kirov plant sold 240 cars for a total of $ 1.2 billion.
Government order demanded facilities renewal
In 2012, the Kirov plant has received a major order from the defense of the state. The contract price — 4,000,000,000 rubles. According to him plant "Universalmash" (one of the "daughters" of the holding) 2015 should produce 40 chassis for the latest anti-aircraft missile systems S-300. The production capacity of the factory, who had served only a few orders and was repairing the chassis for C-300, required for the reorientation of production. In order to accomplish this major state order, you need to update and reorganize the plant equipment.
This is aimed at the 400 million rubles — half of them will be put into the case later this year. It is important to be on time, not to let the customer and perform a quality job — depends on, whether the plant will get similar contracts in the future. Especially as the demand from the State conducting large-scale renewal defense, for such products will grow steadily. Experts estimate that in 2015 the volume of public procurement may reach 72 chassis per year.
On energy saving of money is not enough
The need to conserve energy — both at home and at work — not just talking at the highest level. Back then Russian President Dmitry Medvedev urged the country's enterprises to switch to energy-efficient production, thereby reducing their own costs. But this call seriously apprehended, not all businesses — in order to start saving, you need to invest in the modernization of power systems, pre-analyzed their effectiveness.
Since 2011, the Kirov plant is analyzing energy efficiency of buildings, heating systems, heat generating equipment, power supply systems and water supply, which has helped to find out: well you can save by replacing the lighting system and the huge halls of the perimeter buildings. In addition, the funds will help keep the reconstruction of the heat generating complex, which resulted in fuel consumption for heat generation drops to 25 percent.
— Energy-efficient production — is not just a fashionable term, and the logic of business survival. On the scale of a large company slightest improvement over the year could save millions, but a few mistakes at the same time put the company on the brink
of bankruptcy — the head of the Kirov factory George Semenenko.
The plant has enough money is not everything — energy-saving equipment is expensive, and the pace of its implementation are far from desirable. Priority is given to projects that quickly pays for itself. For example, the plant updated tractor-belt, and with it, and the lighting system, which was replaced by energy-efficient. With the current demand for "Kirovtsa" it will pay for itself very quickly.
Pending orders Kirov factory invests in other directions. In 2012, the Company invested 150 million rubles for the modernization of forging production. Modern equipment will reduce production time, expand the range and improve the quality of products. In this holding is planning to increase the number of orders from the automotive industry, agricultural machinery, oil and gas industry.
Another 100 million rubles Kirov plant sent in 2012 to modernize the power engineering industry. At the factory confident that the project will expand the company's participation in state programs of the Navy in 2020 and Atomic Energy of the Russian Federation until 2030, as well as to compete for contracts Power Industry giants Siemens and Alstom.
"Kaizen" on the grounds of St. Petersburg
To optimize the production of the enterprises of the Kirov factory introduce the principles of so-called "lean production" and of the "kaizen", who was born in Japan. This practice involves the continuous improvement of production processes and management, as well as all aspects of the life of the enterprise. Incidentally, this approach has helped to lift Japan out of the ruins of their industry after the Second World War.
East experts have noticed: the extra employee actions at times reduce productivity. Delayed and too low table, a hard-socket, an uncomfortable position working at the bench, lost instrument takes time and energy of the staff and, therefore, affect the economy of the company. And even if you just move the table, move the socket, put the markup for the optimal location of the employee and legs spread instrument clearly as in the operating room, it is possible to achieve productivity growth by at least 20 percent, and non-production costs are reduced by a third.
The concepts of "kaizen" and "lean production" workers "Kirov-Energomash", St. Petersburg Tractor Plant "Petrostal" and other "daughters" of the Kirov factory is no longer a surprise. The last years of holding introduces modern production system and adopts the experience of Eastern companies, including automakers, who for decades have honed skills "kaizen" to perfection. The company has attracted domestic and Korean experts who teach managers and workers to work efficiently and without losses, including the supply, service interaction and warehouse operations. At the plant say that at first the production system has increased productivity by 15 percent, but it is believed that this is not the limit, and the company will continue to further introduce Japanese technology.