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Stability and competitiveness with KOMPAS-3D
The main secrets of JSC "Zavod Phiolent" By Maxim Kidruk and Oleg Zykov

How does one transition to work with electronic tools, especially in the field of 3D design, with influence upon economic indices of an enterprise? The experience of JSC "Zavod Phiolent" (Simferopol, Ukraine), where for more than five years the KOMPAS-3D system has been used, shows that influence can be described not only by general phrases, but also in the efficiency of investments in modern CAD facilities.

Phiolent factory is a strategically important object of the Ukrainian industrial complex. The factory specializes in the manufacture of low-power electric machines, complexes, systems and components of shipboard automatics intended for control of technical devices, NPP control elements, as well as domestic electric tools.

The factory's history began back in 1913 from an ordinary workshop that constructed farm tools.Today "Phiolent" is a multi-product, economically stable enterprise that delivers about 50,000 types of various products on an annual basis. These products are popular not only in Ukraine and CIS but at European and world markets as well. "Phiolent" delivers its products to Russia, Bulgaria, Poland, Germany, China, Vietnam, India, USA and Cuba. In the 1990s with the beginning of market relations in economics, the factory was a study to work in conditions of severe competition. One of the tools for winning in competitive activity that the factory chose to use was complex automation.

Pavel Ivanchenko, chief designer of ?Zavod ?Phiolent.
During several years the stock of computing machinery increased up to 250 computers upon which today a great number of licenses of various software products are introduced and used. Among these are off-the-shelf software of national and foreign manufacturers and self-developed facilities for automation of production scheduling, storage and book-keeping accounting, work with suppliers and consumers, and many other.

Initially, automatic design systems were considered by factory management as the main component in the factory's software initiative. A decrease in the duration of designing new products resulted in a significant reserve for decreased expenditures of labour and time for preproduction and manufacturing. The reduction of designers and technologists became a precondition for the introduction of CAD at factory "Phiolent." In 2001, specialists of the factory, having tested various CAD-systems, chose the КОМPАS system. Reasons that led to the decision were conditioned by strict requirements for preparation of design documentation determined by an automation bureau.

At the first stage of automation, the КОМPАS-Graphic drawing/design system was installed at the factory, and by 2002, the factory moved to KOMPAS-3D, a full-scale 3D design  solution. Thanks to centralized insturction, the КОМPАS-3D solution became the standard for executing all design works at the factory. 

Chief engineer of SDB of JSC "Zavod Phiolent" Pavel Ivanchenko says: "From the first days of КОМPАS-3D CAD application our specialists immediately prized the high quality of the system. Convenient, intuitive user interface allowed designers to easily move to automatic designing, and use of 3Dmodeling allowed to make a qualitatively new step in products manufacturingVarious CAD/CAM/CAE-systems are used at the factory, but enterprise standard assigns common CAD format  KOMPA ."

Construction mixer

Technical capabilities of the graphic editor included in KOMPAS-3D, as well as the specifications editor provides easy execution of drawings and other documentation. The ease of learning the system, the moderate price, as well as the relatively small requirements to the existing stock of personal computers was also a factor in full deployment of the system. KOMPAS "Phiolent" designers gained confindence in the solution in the same way as at thousands of other enterprises in CIS. From 2003 to 2005 personnel from the information technologies department provided more close integration of solutions from АSCОN with ERP-system, as well as with CAM/CAE-solutions used at the factory. In particular, they succeeded in the creation of a series of software products that imports data from КОМPАS-3D documents into databases of enterprise management system, and this allowed the use of KOMPAS functionality.

Fret Saw PM 700e

In 2002, a full range of various domestic electric tools and accessories was developed at the factory with the use of only KOMPAS-3D. "During this time a significant reduction of new products assimilation period was achieved: from 2 years for one product (before introduction of KOMPAS) to 4 products annually today, says Ivanchenko. And in 2003 factory specialists started the development of ОRION-KАТ 1E, a complicated complex ship movement control system, which was made with the use of KOMPAS-3D as well. The assimilation period (that is the time from design idea to delivery of a product) was reduced to one year, and the design process itself took only three months! Today, due to the introduction of KOMPAS, not less than four new products are prepared annually at the factory, and reduction of expenditures for preproduction is over 30 percent.

Fret-Saw parts, optimized after the calculation and modelling in KOMPAS-3D.

All listed indices, in the end, resulted in an increase of earnings, and consequently improvement of economic stability and independence of the factory. Besides the economical effect introduced by using KOMPAS, it has drawn graduates of institutes of higher education, and has highly influenced the motivations of experienced employees for learning of computer technologies. "There are a lot of young specialists in design and technological bureaus of the factory, says Ivanchenko. "With enthusiasm they study and use automatic design, and at all multiplicity of software products they are respectful to КОМPАS, as the basic system of preproduction that solves all problems set before it."

In 2004 a KOMPAS 3DModeling Contest was held by ASCON Company. From this time, factory representatives took active part in the annual Contest. In 2005,  ОRION-KАТ 1E, a complex movement control system was declared to be the best project in the field of instrument engineering, and at the contest of the previous year the project of electric fret saw P М 4-700E became one of the prize-winners. More than two thirds of the components included in the fret saw are unique and were developed exactly in KOMPAS-3D. During the design of the fret saw model, a program was used that had been specially developed by JSC "Zavod "Phiolent" specialists with the use of an API of the KOMPAS system and the Microsoft Windows API. The library realizes rotation of one of the fret saw's parts which resulted in the mechanism to be rebuilt. 

Motion control system model. 3200 parts in the assembly.

Rotation is realized with a definite step, for each value of which the program calculates mass centering characteristics of all assembly and delivers coordinates of product's center of gravity into MS Excel. With the help of such application several variants of parts were developed for the model for the purpose of obtaining of minimum changes of center of gravity, and that gave the possibility to determine the minimum vibration velocity features of the fret saw. At the present moment the commercial product shows excellent noise and vibration parameters of the saw swinging mechanism.

Notching die model.

Upon this example it is shown that KOMPAS has wide capabilities not only for integration with external CAD/CAM/CAE-systems but for extension of its functionality with consideration of real requirements of specific production. At that, this extension can be achieved by the forces of the users themselves. Today not all industrial enterprises are able to evaluate direct connection of CAD with general efficiency of production. Example of "Phiolent" shows how with the help of rational selection of design system one can quickly achieve and exactly control return of investments into new information technologies. Use of KOMPAS at the factory excellently demonstrates how complex solutions on the basis of IT can transform your production. Result is obvious  improvement of products competitiveness, both at internal and external markets, and mainly achievement of long-term economic stability of the factory.

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