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Lean-technology saves Russian Helicopters 70 million roubles

Russian Helicopters (part of State Corporation Rostec) has reviewed its implementation of lean technology across production in 2013. Implementing lean technology pilot projects delivered a saving of about 70 million roubles last year.

Lean technology is a strategy that minimises the volume of energy and material losses in the production process. Russian Helicopters comprises major industrial enterprises across the country. Efficiency and economy in production are two of the key strategies aiming to reduce outlays.

Lean projects are underway in virtually all Russian Helicopters' enterprises. At Rostvertol, the lean technology group has implemented several projects since 2011, such as, for example, the 5S approach to organising the workplace, the SMED system for reducing time taken in equipment changeovers, the Kanban scheduling system for production and procurement, and implementing the TPM approach to maintaining and improving equipment that involves identifying flaws early. In 2013, the direct economic impact of reduced material and labour input in production, and increased energy efficiency at the enterprise exceeded 12 million roubles.

Ulan-Ude Aviation Plant is currently implementing projects in this area, including one to 'Establish an efficient production system at the external fuel tank assembly site'. Thanks to this project, the time an employee spent on producing fuel tanks rose from 125.9 to 275.5 standard hours, the time taken to complete an order fell from 113 to 85 hours, and production rose from 8 to 15 sets.

Projects to boost production efficiency are currently being implemented at Kazan Helicopters, Progress Arsenyev Aviation Company, and other Russian Helicopters companies. Stupino Machine Production Plant has implemented a project to 'Reduce the transfer procedure by which parts are processed using CNC'. This project delivered a reduction of 60,000 standard hours in labour input, also cutting spending on design and the preparation of specialised technological production tooling.

Overall, in 2013 alone, over 800 new pieces of equipment were installed across Russian Helicopters enterprises. Russian Helicopters must achieve an energy saving of 40% on 2010 levels by 2020 by implementing lean technology projects and energy saving initiatives.

Russian Helicopters, (part of State Corporation Rostec), is one of the global leaders in helicopter production and the only helicopter design and production powerhouse in Russia. Russian Helicopters was founded in 2007 and is headquartered in Moscow. The company comprises five helicopter production facilities, two design bureaus, a spare parts production and repair facility, as well as an aftersale service branch responsible for maintenance and repair in Russia and all over the world. Its helicopters are popular among Russian ministries and state authorities (Ministry of Defence, Ministry of Internal Affairs, Emergency Control Ministry), operators (Gazpromavia, UTair), major Russian corporations. In 2013 its IFRS revenues increased 10% to RUB 138.3 billion. Deliveries reached 275 helicopters.

State Corporation Rostec is a Russian corporation founded in 2007 for the purpose of promoting the development, production and export of hi-tech civilian and military industry products. It comprises 700 organisations, nine of which have now been formed as holding companies of the military-industrial complex and five of them are involved in civil industries. Rostec's organisations are located in 60 constituent entities of the Russian Federation and supply their products to the markets of more than 70 countries. The revenue of Rostec in 2013 amounted to RUB 1, 04 trillion, with net profit of RUB 40 billion. The tax deductions into the treasuries at all levels exceeded RUB 138 billion.

Press release issued by Russian Helicopters, JSC on November 6, 2014


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