The number of cars in Russia is steadily growing every year and such a fast pace is clearly not going to slow down soon. It is logical that car service services are currently extremely popular, which will definitely remain in the future. Owners of new cars practically do not visit service stations - they only need to change tires twice a year and purchase consumables.

However, with a competent approach, you can make good money from this. And there is no need to talk about the old cars that ply the vast expanses of our great Motherland in abundance - there is always something to repair and something to replace. It is also worth noting that with the rapid development of technology, vehicles began to be equipped with complex devices and systems, which not every person can handle on their own. Thus, opening a car service is a profitable business idea that allows you to provide yourself with a decent life.

The success of any business largely depends on the right choice of niche.

Today the most popular types car service are:

1. . The peak demand for the services of such service stations occurs at the end of autumn - beginning of spring, when all vehicle owners, without exception, need to change summer tires to winter ones or vice versa. It is worth noting that problems with tires arise among car enthusiasts much more often, since everyone knows that roads are among the main problems in our country.
2. Repair work. Such establishments include a wide range of services for repairing and replacing all kinds of car parts, assemblies and components.
3. Bodywork. Unfortunately, road traffic accidents are not uncommon today, and after such unpleasant situations it is almost always necessary to correct body defects. It also happens that a person for a long period dreams of changing grey colour of your car in a snow-white one. And here you are.
4. Diagnostics and correction of identified defects electronics.
5. Cargo service. Service trucks.
6. Pre-sale preparation. Have you decided to say goodbye to your old lady and get a new “iron horse”? In order to sell an old car at a decent price, you need to give it a marketable appearance - diagnose all the equipment, repair all faults and clean it to a shine.
7. Tuning. It is very popular among young people. Includes installation of additional options, reconfiguration of equipment, changes in internal and external appearance.
8. . It is very popular at any time of the year.

Opening a full-fledged car service involves combining all of the above services into a single whole. If your financial capabilities are limited, but you are not ready to give up the idea of ​​such a business, choose a couple of directions or even one and become the best in this area - you will definitely not end up with clients.

Production plan

Building a new car service center is not an easy task, as it requires an incredible investment of time, effort and money.

It is better to opt for a spacious garage or production facility.

For small car service with 5 workstations, a room for storing spare parts and Supplies, rooms for clients and an office will require about 300 square meters. If possible, parking should be organized - it will be relevant both for repaired cars and for those waiting for their time.

It will be great if you manage to get a place to open a service station near a place with a large crowd of people - a highway, a gas station or a garage complex.

Despite the fact that opening this business does not require obtaining a license, do not forget about certain rules requirements for such establishments:

1. It is not permissible to have a car service center in a residential area.
2. The minimum distance of the service station to residential real estate is 15 meters, to schools, kindergartens, and medical institutions - 50 meters.
3. During the cold season, the car service area should be warm.
4. A ventilation system is required.
5. Lighting must be completely safe.
6. The inspection pit and walls must be lined with ceramic tiles
7. One employee must have at least 5 sq. meters of working space.
8. A shower and toilet must be present.
9. All employees must be provided with clothing and personal protective equipment.

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Recruitment

Finding highly qualified employees, true professionals in their field, is very difficult in our time, and every employer knows this. The automotive repair and maintenance industry is no exception. It is possible that you will have to poach good mechanics from your competitors. In this matter, the main thing is to offer them conditions that they cannot refuse.

Don’t be alarmed by the costs of personnel - with a high degree of probability, the famous guru will bring with him more than a dozen clients and will more than recoup all expenses. Often, car owners prefer to use the services of trusted people, going almost to the other end of the city to do this. Over time, try to attract new people to the car service and train them - this way you will be calm if suddenly the best employee is forced to leave you for some reason.

For a car service, literally a few people will be enough - one per workplace, as well as a person who will work with clients and place orders.

Wage In the vast majority of cases, workers' compensation is formed by adding a small fixed amount and a percentage of the work performed, which can reach half of the monthly income.

Selection of suppliers

Every car service center, regardless of its type, needs to regularly replenish supplies of spare parts and consumables. It is best to decide on suppliers of all the things necessary for work before opening a service station, since in order to arrange supplies, you need to sign a considerable number of documents and resolve many organizational issues.

At the very beginning of your entrepreneurial journey, you can try to cooperate with “made-to-order” suppliers if they are able to deliver all the necessary parts to the destination in the shortest possible time. However most requested parts It’s better to always have it with you, at least with a small supply. Otherwise, you will lose all the customers who need to change the light bulb, and you will ask them to wait a couple of days. Also, do not forget about the seasonality of such a business and prepare in advance for a boom in consumer demand. If during the work process there are extra parts left after purchasing, it’s okay - open a small store.

Financial plan

Main expenses for opening a car service are:

• rent for premises;
• purchase of equipment.

Do you have plans to open a full-fledged car service center with a wide range of services? be ready spend on your idea from 3 to 5 million rubles. A more modest service station will cost the entrepreneur approximately 1.5 million. Income similar establishments that provide several of the most popular services are about 200 thousand rubles, and this is far from the limit - it all depends on the businessman’s acumen, his ability to deal with this area and a little luck.

To open a very small auto repair shop, say a tire shop, you will only need 350 thousand rubles. However, the income in this case will be an order of magnitude lower than in the cases described above - about 30 thousand rubles monthly.

Car service costs range from 20 to 40%, and the maximum payback period is 3 years.

Marketing plan

Without advertising, a newly opened car service, like any or, is practically doomed to failure. Outdoor advertising in the form of banners and small bright signs gives excellent results, attracting the attention of potential clients and all concerned. In the case of opening a car service center, it makes sense to place advertisements in places where there are large concentrations of car owners - for example, in parking lots, in garage complexes. Advertising in print publications and on the virtual network is no less effective.

If possible, you can make a couple of hundred business cards with contact information for your service station and leave them in large stores and nearby offices.

Drivers listen the most radio– take advantage of this and submit an advertisement to one of the popular radio stations in your locality.

Makes a good impression on potential clients image– take care of your employees, develop a bright and easy-to-remember car service logo.

There are fewer and fewer people among us who prefer public transport to a personal car. The number of motorists is steadily growing, and with it the need for volumes of maintenance and repair of “iron horses”. The demand for car service services is always stable; even the most advanced modern cars invariably need them. In order to successfully open a car service and service station, you need a competent business plan. Its main task is to develop the optimal option for organizing a car service center designed to service passenger cars.

Car service market

The development of the car servicing market directly depends on the number of cars in Russia. Over the past ten years, the domestic vehicle fleet has more than tripled, and these figures are increasing every year.

The structure of the car servicing market currently includes:

1. Authorized car services that specialize mainly in servicing only a specific brand of car. Entering such a business is quite difficult, since official dealers and car manufacturers choose their partners very carefully.
2. Network car services that have their representative offices in a wide variety of regions. Currently, this market segment is not yet sufficiently developed.
3. Single car services. Such services do not have accreditation, but are in fairly high demand among car owners, since the price for the services of such car services is usually 20-30% lower.
4. Personalized car servicing. Such services can hardly be called a business, but in Russia they are in good demand.

Example of a car service business plan

If you don’t know how to open a car service center from scratch, then the ready-made service station business plan given below will help you organize this business.

Description of the enterprise

The success of an organized car service is determined by the following criteria:

• range of services provided;
• the target audience;
• production area;
• qualified personnel.

It is necessary to take into account the legislation, according to which the premises of a maintenance company are located no closer than 50 m from residential buildings and are equipped with a centralized sewerage system. Coordination with the traffic police, SES and fire service is required.

You need to know where access roads and competing service stations are located. 300 square meters– optimal area for car service centers for passenger cars. It is important to analyze the work of competitors in advance and take into account the preferences of car owners regarding car brands. Pledge successful work Service station – qualification and professionalism of auto repairmen. Form of organization – individual entrepreneur(IP), taxation - UTII.

Services provided

A car service business plan should include the provision of a wide range of services. The most profitable types of work: repairing the engine and gearbox, replacing the steering gear and clutch and other machine parts. Among the most unprofitable is repair of the brake system, but it must be included in the list of work performed. It is advisable to choose a narrow specialization for the service station: tuning, xenon installation, glass tinting, or others. You can also concentrate on servicing specific brands of cars.

Analysis of the car repair and maintenance market

A new car service has a great chance of success, because, despite a large number of competitors, in major cities There is a frequent problem with the efficiency of services provided. In the service station business plan, you need to analyze in detail the work of neighboring competitors according to the following parameters:

• list of services provided;
• prices for services;
• the target audience.

Thus, you can find unoccupied niches and weaknesses of operating car services.

Service station production plan

In addition to purchasing or renting production space, the future service station will need equipment, in thousands of rubles:

• lift – 40-120;
• diagnostics – 60-100;
• tools – 100.

Depending on the list of services, other highly specialized equipment may be needed.

The characteristics of the service also determine the staff of the car service center. It is necessary to have 2-3 workers constantly working, which is ensured by daily work hiring 4-6 people. The manager can be a hired employee, or maybe the owner of the service himself.

Car service financial plan

Expenses, in rubles:

Capital expenditures:

• purchase of equipment, its installation – 2,000,000;
• advertising – 30,000;
• approval – 20,000.

Total: 2,050,000.

Current expenses:

• rent – ​​150,000;
• operating costs, consumables – 80,000;
• salary – 200,000.

Total: 430,000.

Income, in rubles:

• Revenue – 500,000 (per month).
• Profit – 70,000.

Proper organization of a car service center will provide a stable profit, but it will take some time for capital costs to be recouped.

Basic business secrets

1. Purchasing spare parts and establishing relationships with suppliers. The necessary spare parts catalogs can be found on the websites of dealers and manufacturers. You can also visit specialized exhibitions and choose a supplier. It is better to prepare applications in advance, taking into account seasonal fluctuations in demand. It is very convenient to purchase auto parts with “reserve”. Although this option requires significantly higher costs, the necessary spare parts are always available. This scheme is most relevant for network car services, when every detail will be in demand in any case.
2. To obtain maximum profit for the owner open car service from scratch it is worth concentrating your efforts on the most cost-effective forms services, which include body repair, tire fitting, car painting, car wash.
3. An increase in the profitability of an enterprise is associated with an increase in the number of customers and a decrease in costs. To this end, you can expand the range of services, reduce equipment costs by ordering certain work from specialized companies, reduce rental payments or reduce advertising costs.

Buying a car service

To save time on organizing and promoting a car service center, you can purchase a ready-made enterprise. average cost such a business is about 60 thousand dollars. When purchasing a ready-made car service, you need to pay attention to:

• validity period and possibility of prolongation of the lease agreement with the owner of the premises;
• maintaining an experienced team;
• the presence of formalized relationships with suppliers of auto parts;
• location of the car service, availability of convenient access;
• quality of available equipment.

All these conditions significantly affect the price of the finished business.

The paint and body shop is one of the most profitable areas of auto repair. As in any other business, having a business plan will help you avoid mistakes. I present to your attention a typical project for organizing your business. A body repair shop requires more than just start-up capital. but also certain knowledge.

Summary

This project is a business plan for organizing an automobile repair enterprise that provides services for body repair and painting of cars, with a payback period of two years.

Project goals:

1. Creation of a highly profitable enterprise
2. Organization of obtaining a stable profit
3. Satisfying the relevant market segment with car body repair and painting services.

Project funding source: own funds or bank loan

Form of doing business: IP

Total cost of the project: 4.6 million rubles

Payback period: 1 year

Interest rate included in the calculations: 24%

The total interest payments will be: 1.104 million rubles

The investor's income will be: 1.104 million rubles

Payments of loan funds and interest on the loan will begin from the first month of project implementation.

Main stages of the project implementation

The start of the project implementation is immediately after the acceptance of the business plan by the Customer, or after receipt of loan funds.

The main stages of the implementation of this project, the conditions and deadlines for their implementation are presented in Table No. 1:

Project stages	Deadlines
Conclusion of an investment agreement	1 month
Obtaining borrowed funds	1 month
Entry into the state register, registration in administrative and tax authorities	1 month
Selection of location and design documentation	1-6 months
Purchase and installation of equipment	1 month
Recruitment	1 month
Conducting a marketing campaign	1-24 months

General description of the project

This business plan for opening body shop auto repair is intended to create a small enterprise that provides relevant services. The proposed business line in the field of motor transport was chosen based on the following considerations:

1. By official statistics analytical agency "Avtostat" in Russia is per 1000 people according to different regions cars:

Table No. 2:

1. In Russia, on average, up to 270 thousand registered road accidents occur per year, and about a quarter of this number are unregistered.
2. The condition of most of the road surfaces in the country and the huge traffic congestion leave much to be desired.

All of the above factors show that the number of calls from car owners to car body repair shops is large enough to make this business profitable and promising at least for the next few decades. So the paint and body shop will provide its owner with a solid profit.

The main strategy of the future enterprise is to provide highly qualified services for body repair and painting of cars, application modern technologies when performing work, using a different form of payment from competitors and using a system of discounts.

Range of body shop services

A paint and body shop for car repairs, as a rule, provides highly specialized services without affecting other types of car repairs, such as repairs of the engine, chassis, and electrical equipment:

• Straightening (leveling) damaged elements of car body parts
• Replacement of those body elements that cannot be restored
• Restoring the correct body geometry damaged as a result of an accident
• Painting of restored and damaged body parts

Despite the fact that a wider range of services provided would at first glance bring more profit than a highly specialized area, it was decided to focus on the latter, taking into account the following factors:

1. Qualified personnel of the repair shop in a narrow specialization will significantly increase the competitive ability of the enterprise. When choosing between a car service center with a wide range of services and a specialized workshop, car owners, as a rule, choose the latter, rightly expecting that a more experienced staff works there.
2. Narrow specialization will allow you to improve the skills of working personnel in a matter of months, unlike a car service, where one specialist often has to perform several types of work. repair work.
3. A small, highly specialized enterprise will make it easier to introduce new technologies and purchase/use modern equipment, which will improve the quality of service delivery and reduce the time spent on them.

Room

A paint and body shop, like a regular car service, requires proper layout of the premises, surrounding area, and access roads. It is necessary to immediately determine the form of acquisition of premises for opening a body repair shop. There are three options to choose from:

1. Construction of a building from scratch
2. Buying a building
3. Lease or sublease

To equip or re-equip the premises in accordance with the required standards of GOST, SNiP, and SanPin, it is planned to contact an architectural office in order to save time on carrying out the necessary work and eliminate the possibility of a negative result of acceptance of the premises by inspection commissions.

Most best option– acquisition land plot and the construction of a body repair shop building on it. Currently, the country is actively using prefabricated metal structures - frames and sandwich panels, which make it possible to construct a building in the most short time. A wide selection of panel colors and flexible installation of the frame make it possible to give the building an attractive appearance, which is very important for attracting customers.

The layout of the room must allow for quick and consistent movement of the vehicle being repaired from the body repair shop to the paint booth. This business plan for opening a body shop provides for a premises with an area of ​​120 to 180 square meters. meters, which will allow you to simultaneously repair 2-3 cars.

Modern multifunctional equipment for auto body repair and painting is a guarantee high-quality execution work. The “standard” kit for such enterprises consists of the following devices:

• Straightening stocks - platform, frame, rolling, and floor type + grips, clamps, and jacks for cars of various brands.
• Two post car lift
• Measuring rulers, 2D and 3D measuring systems.
• Hydraulic body straightening kits
• Kit for straightening dents on the body without painting
• Detectors for determining steel types
• Straightening tool kit
• Welding machine
• Polishing machine
• Painting and drying chamber
• Set of spray guns
• Colorist's special lamp
• Mini camera for spraying tests
• Rotary painting tables for painting body parts
• Thickness gauges

All equipment has rather bulky dimensions, so the correct location of the equipment in the body shop will allow you to “win” additional space without actually increasing the area. However, in order to open a body repair shop, equipment alone is not enough.

Staff

The issue of qualifications of the craftsmen performing the work is extremely important, since the success of the entire enterprise depends on the experience of the personnel. In the first year of operation of the paint and body shop, it is planned to hire 4 people:

• An administrator who performs the duties of an accountant, cashier, and purchasing manager for consumables and tools.
• Automotive tinsmith-body worker – 2 people
• Car painter – 1 person

In the next 2 years, it is planned to expand production, increasing the useful area of ​​the body shop to 350 square meters. meters, and the number of staff is up to 8 people.

Today, the automotive repair market, in particular highly specialized ones - bodywork and painting, includes many companies, however, despite this, there is fairly free competition in the service sector, in which business owners do not have the opportunity to influence the price of the service provided, but form it through their offer .

The number of car owners increases every day by several dozen, the repair time for one car takes from 1 to 5 days, so the demand for the services of body paint shops will be in demand for a very long time.

As a rule, even with the most negative calculations, the payback period for investments will be a maximum of 1 year, which classifies a car body repair shop as a project with a quick payback period.

Analysis of the consumer services market

Having a car today is more an indicator of a person’s success, part of his image, than a convenient and quick way movement. Especially in big cities, where it is much more expedient to use public transport (metro). However, the demand for cars is growing. Of course, the economic crisis in Russia, which began at the end of 2014, and which, according to experts, will last until 2018-2019, has made significant adjustments to vehicle sales.

But there are not fewer cars. In 2015, sales of budget models of new cars increased slightly, and the volume of the used car market increased approximately 3 times. According to the traffic police, in comparison with 2012 and 2013, the number of people who received driver’s licenses for the first time in 2015 increased by almost 2.5 thousand people. And this despite the tightening of exam rules.

The probability of a driver with less than 1 year of driving experience getting into an accident is up to 95%. More than 40% of drivers with up to 3 years of driving experience are responsible for all road accidents on the country's roads. These sad statistics show that the demand for paint and body shop services will only increase over the next few years.

Marketing plan

The decline in real incomes of the population has led to the fact that the main competitors of officially operating car services of various specializations have become “garage” workshops offering lower prices. There are two ways to successfully resist such rivalry:

1. Sufficient investment in the company's advertising campaign
2. Providing quality services by professional craftsmen

As a rule, the formation of consumer opinion is necessary not to convince them of the need for body repair services (all car owners already understand this), but to promote their own auto repair shop and quickly determine its location. This can be achieved:

• Placing outdoor advertising - at busy intersections directly near the car repair shop, signs at car washes, at gas stations, in auto parts stores, in small tire shops, etc.
• Placing advertisements in local media - on TV, in newspapers (preferably with a TV program).
• Distribution business cards businesses in auto shops
• Creating your own Internet resource
• Placing advertisements on the websites of partner stores (those where you will purchase materials)

To create an image, it is planned to create a company logo, come up with an attractive name, determine corporate colors, and sew a uniform for the staff.

A car owner who is faced with the need for body repair or painting for the first time, as a rule, looks for a car service in person, or comes on the advice of friends. One way or another, the main task of the company’s personnel is to provide services at such a level that the client in a similar situation in the future will no longer think about where to turn.

To do this, you need to create comfortable conditions both for the client himself and for his “wallet”. To do this, you can use the following marketing techniques:

• Price determination slightly lower than competitors
• Working with insurance companies. This, by the way, will guarantee an influx of car owners, subject, of course, to the quality of the work.
• Posting information about services on thematic websites and forums in your region.
• Organizing a convenient place to wait for quick work - a small cafe, or a hall with coffee machines, cigarette vending machines, etc. installed in it.
• Organization of “delivery” of visitors who will leave their car for repairs to their destination.
• Issue and distribution of discount cards
• Introduction of a system of discounts for providing several services at once. For example, having brought a car with a damaged front fender in for repair, its owner can order a small dent on the trunk lid, or something similar, to be repaired for half the price.
• Providing services related to existing business. Example: a spray booth can also be used to coat a car with liquid rubber or apply airbrushing. An excellent option would be to organize a reupholstery of the interior.
• Proposal for concluding agreements on mutually beneficial terms for motor transport enterprises.

Production plan

To operate an enterprise with a staff of 4 people, you will need the following tools and equipment:

• Straightening stocks - platform, frame, rolling, and floor type + grips, clamps, and jacks for cars of various brands - 1 of each type
• Two-post car lift – 2 pcs.
• Measuring rulers - 3 pcs.
• 2- and 3-dimensional measurement systems – 1 pc.
• Hydraulic sets for straightening bodies – 2 pcs.
• Set for straightening dents on the body without painting – 1 pc.
• Detectors for determining types of steel – 2 pcs.
• Set of straightening tools – 2 pcs.
• Semi-automatic welding machine – 1 pc.
• Inverter spot welding machine – 1 pc.
• Apparatus for welding plastic elements – 1 pc.
• Polishing machine – 2 pcs.
• Painting and drying chamber – 1 pc.
• Set of spray guns – 2 pcs.
• Special colorist lamp – 1 pc.
• Mini camera for spraying tests – 1 pc.
• Rotary painting tables for painting body parts – 2 pcs.
• Infrared short-wave drying – 2 pcs.
• Thickness gauge – 2 pcs.

When choosing equipment and tools, you should always remember that expensive does not always mean high quality, and it is the latter factor that should be decisive when purchasing.

Organizational plan

Table 3 shows the job responsibilities of body shop personnel:

Each employee has an indefinite term employment contract. There are two remuneration options to choose from for an 8-hour working day of a 5-day working week:

1. Time wages + 15% of revenue for each repaired car
2. 30% of revenue for each repaired car

In any case, body shop employees will be personally interested both in attracting car owners for repairs and in the quality of the work they perform.

To optimize the workload of workers in different specialties, cross-training should be applied so that, if necessary, any of them can replace the other.

Financial plan

The beginning of the company's financial year is January.

The accepted currency for calculations is Russian rubles.

The main types of taxes payable are reflected in Table No. 4:

Type of tax	Tax base	Period	Interest rate
Income tax	Incoming profit	Month	20%
Property tax	Estimated value of property	According to the payment schedule	2,2%
VAT	Added value	Month	18%
Income tax	Payroll fund	Month	13%
Social payments	Payroll fund	Month	34%

The forecast for the volume of services provided and their revenue from payment for them for the first 2 years of the enterprise’s operation is presented in Table No. 5:

Period	Type of service	Volume of sales	Price	Revenue from the provision of services
1-12 month		from 100 cars per post		from 4.8 million rubles
1-12 month	Sales of auto parts			from 1.1 million rubles
13 - 24 month	Providing repair work, including garage workshop services	from 100 cars per post	according to the price list for the provision of services	from 6 million rubles
13 - 24 month	Sales of auto parts	according to the available assortment	according to the available price list	from 2.1 million rubles

Assuming the current state of the market is maintained, the company will reach the break-even point within 1 year. Given the market development trend and an increase in service consumption by 15% per year, this stage will be reached within 9 months of work.

Analysis and insurance of existing risks

The following main potential risks can be identified when running this type of business:

• High dependence on the location of the paint and body shop building. Minimized by the possibility of building a building from scratch.
• Difficulty in recruiting highly qualified personnel. The issue is resolved by offering higher pay and/or more favorable working conditions, taking charge of staff training, and regularly motivating employees.
• Lack of necessary consumables (for example, paint “to match” the body color), long delivery of the necessary body elements. The risk is reduced by the presence of a reliable, uninterrupted supply channel for materials
• The emergence of new competitors in the immediate vicinity. The risk is reduced by implementing a competent pricing policy of the enterprise, constant monitoring of prices, and improving the quality of services provided.
• Unstable ruble exchange rate, economic sanctions as a result of which there will be disruptions in the supply of imported spare parts.

Conclusion

The presented analysis of a business project for organizing a paint and body shop showed that this type of business activity is profitable and promising with a medium degree of risks, most of which can be minimized. The main conditions for the successful functioning of an enterprise are its location, the availability of modern equipment and highly qualified specialists.

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Introduction

1. Research part

1.1 Characteristics of ATP

2.2.6 Determination of the number of services per year

2.2.7 Determination of the daily vehicle maintenance program

2.3.2 Adjusting the labor intensity of maintenance and repair

2.4.1 Determination of the technologically necessary (turnout) number

2.5 Calculation of the number of posts for maintenance and repair zones, diagnostics

3. Organizational part

3.2 Selecting a maintenance method

4. Economic part

4.1 Costs for manufacturing the fixture

4.3 Calculation wages production workers

4.4 Cost of power energy

4.5 Calculation of material costs

4.6 Costs of current repairs of the building

4.7 Payback period for capital investments

5.1 Requirements for the design of small-scale mechanization equipment

6. Scientific organization labor

7. Occupational health, safety, fire safety, electrical safety

7.3 Ventilation

7.5 Security environment

7.6 Electrical safety

Literature

Annex 1

Introduction

Russia's vehicle fleet is growing rapidly not only every year, but, without exaggeration, every day. It is replenished with both domestically produced and foreign-made cars. To ensure the safety of transportation of goods and passengers, it is necessary to keep vehicles in technically sound condition, which is only possible if there are specialized enterprises for the repair and maintenance of vehicles. The huge scale of transportation requires maintaining the vehicle fleet in technically sound condition, creating large motor transport enterprises and their specialization, improving technologies and organizing production, sharply improving the quality of repairs of vehicles and units and reducing their costs. For the next few years, it is recommended to create specialized motor transport enterprises with a well-equipped base, competently trained specialists to carry out repairs of trucks, cars, as well as power units, instruments, electrical equipment and fuel equipment.

In solving the problems of further development of automobile repair enterprises, a decisive role belongs to engineers and technical workers involved in the maintenance and repair of cars, units, as well as the introduction of new technical developments, the latest technologies in the field of mechanical engineering and automobile repair. The constant lack of spare parts for repair production is a serious factor in reducing the technical readiness of the vehicle fleet.

1. Research part

1.1 Characteristics of ATP

OJSC Neftebaza is located in the city of Perm and specializes in transporting cargo within the city and beyond. ATP vehicles operate one shift 365 days a year. The chassis section operates in two shifts. The car is in service for 8 hours. The release of cars onto the line begins at 8:00 am, and the release duration is 30 minutes. The average daily mileage of cars is 205 kilometers. Number of vehicles on the ATP: KamAZ-5410 - 215 units, ZIL-5301 - 115 units. 330 cars with mileage less than the established norm to the Kyrgyz Republic. At the ATP there are no cars with mileage equal to or exceeding the mileage standards to the Kyrgyz Republic. The average actual mileage since the start of operation is 39,458 kilometers.

The total mileage of the park is 13,021,140 kilometers. ATP is equipped with the necessary production base.

Cars are stored in open parking lots. The TO, TR, D zones are available and require modernization by 2015.

Table 1.1.1 Main indicators of ATP

D rg (days) 365	L ss (km) 205
From cm 2 shifts
Tn (hour) 8	D or, days/1000 km 0.55
T nv (hour) 8 00 4	L total, km 13 021 140
T at (hour) 16 30

Table 1.1.2 - Park roster

Automobile model
Main	Reduced
KamAZ-5410

1.2 Characteristics of the design object

The chassis maintenance and repair section is designed to carry out repair and maintenance work on the suspension, frame and wheels of the vehicle. The site operates in two shifts, the duration of the site shift is 8 hours. The first shift starts working at 7:00 a.m. to 4:00 p.m., lunch break from 12:00 to 1:00 p.m., and the second shift from 4:00 p.m. to 1:00 a.m., lunch break from 9:00 p.m. to 10:00 p.m.

The site is provided with equipment, tools, small-scale mechanization tools are available on the site, the condition is operational, technological, guard, operational maps, workplace maps are available, they comply with ESKO requirements.

The method of organizing production work is the production line. The form of remuneration for performers is 2980 rubles. At the site, safety precautions, fire protection, electrical safety rules, industrial sanitation and hygiene, and environmental protection are observed.

2. Calculation and technological part

2.1 Selection and justification for the payroll

I take into account KamAZ-5410 vehicles - 215 units and ZIL-5301 - 115 units.

I define a technology compatible group.

Table No. 1. Technology Compatible Groups

Note:

1. KamAZ-5410 - truck tractor, diesel engine.

2. ZIL-5301 - van, diesel engine.

Technologically compatible group - V.

2.2 Calculation of the annual production program for all types of maintenance and repair

The ATP production program for maintenance is the planned number of services (EO, TO-1, TO-2, SO, D-1, D-2) for the planned period. I accept the annual work plan. Capital work is not carried out in the ATP and is not taken into account in the calculations.

Current repairs are not determined, since there are no regulatory deadlines for current repairs; TR in ATP is performed as needed.

Seasonal maintenance is carried out twice a year in conjunction with the next maintenance-2, and accordingly, with an increase in the labor intensity of the work, it is not planned separately.

Calculation of the production program is the main one for calculating the annual volume of maintenance and repair work, as well as calculating the number of production personnel for the design project of the running gear section.

2.2.1 Determination of standards for the frequency of maintenance and repair work, the labor intensity of maintenance and repair work

Standards for the frequency of maintenance, mileage to the CD, labor intensity of a single maintenance and repair work per 1000 km are determined according to tables 2.1 - 2.3. Standards using special coefficients K 1 - K 5 in Table 2.8. - 2.12. Adjusted depending on: category of operating conditions (EC), K; modifications of rolling stock and organizational work, K 2; natural and climatic conditions, K 3; mileage since the beginning of operation, K 4; number of maintenance and repairs of vehicles at ATP and technically compatible groups of rolling stock, K 5.

To facilitate calculations, the following operating conditions of the vehicle will be considered in the future:

City of Perm;

Road surfaces: asphalt concrete;

Terrain: slightly hilly from 200 to 300 meters;

Average daily mileage - 205 kilometers;

Natural and climatic conditions: moderately cold;

Environmental aggressiveness: not aggressive;

Fleet roster: KamAZ-5410 - 215 units; ZIL-5301 - 115 pieces;

Mileage since the beginning of operation Lne = 19458 kilometers.

2.2.2 Determination of the standard mileage before maintenance and repair

where is the standard mileage for the base car model.

The mileage standard is determined according to table 2.3 and is:

3000 km, = 3000 km,

12000 km, = 12000 km,

300,000 km, = 300,000 km.

2.2.3 Correction of mileage according to operating conditions

K 1 K 3 , (1)

where is the standard mileage before maintenance - 1;

K 1 - correction factor between maintenance

(see Table No. 2.7, 2.8);

K 3 is a coefficient that corrects mileage depending on natural and climatic conditions (see Table 2.10).

K 1 K 3; (2)

K 1 K 2 K 3 , (3)

where K 1 is a coefficient taking into account the category of operating conditions;

K 2 - coefficient taking into account the modification of rolling stock;

K 3 is a coefficient that takes into account natural and climatic conditions.

K 1 = 0.8 - maintenance frequency;

K 1 = 0.8 - KR;

K 2 = 0.95 - to KR (KAMAZ);

K 2 = 1 - to KR (ZIL);

K 3 = 0.9 - before maintenance;

K 3 = 0.9 - to KR;

Table No. 2 Correction of mileage for maintenance and repair work

	Type of mileage	Designations
			Normative	Corrected	Accepted for calculation
	Average daily
				2160:205 = 10,53	205 10,53 = 2158,65
				8640:2158,65 = 4,002	2158,65 4,002 = 8638,9
				205000:8368,9 = 23,7	8638,9 23,7 = 204741,9
	Average daily
				2160:205 = 10,53	205 10,53 = 2158,65
				8640:2158,65 = 4,002	2158,65 4,002 = 8638,9
				216000:8638,9=25,003	25,003 8638,9=215998,4

2.2.4 Determination of the technical readiness factor of the fleet

Determined by the formula:

where L СС is the average daily mileage of the car, km;

D OR - duration of vehicle downtime in TO-2 and TR, days/1000 km;

K 4 - coefficient correcting downtime

in maintenance and repair depending on the mileage from the start of operation (Table 2.11)

D KR - duration of vehicle downtime in the KR;

L KR - vehicle mileage before major repairs.

D OR = 0.5 (ZIL),

D OR = 0.5 - 0.55 (KAMAZ)

2.2.5 Determination of the annual fleet mileage

Determined by the formula:

L year = A and L SS D rg Ј , (5)

where A and is the list number of cars in the fleet;

D rg - days of work per year.

L year (K) = 215 205 365 0.928 = 14 929084.0 km

L year (Z) = 115 205 365 0.933 = 8 028348.3 km

L year (K + W) = 22 957432 km

2.2.6 Determining the number of services per year

where L year is the annual mileage of the fleet, km;

L TO-1, L TO-2 - frequency of TO-1 and TO-2 in the fleet, km;

L ss - average daily mileage, km;

2.2.7 Determining the daily vehicle maintenance program

Determined by the formula:

where Dr.z. - days of the working area of ​​maintenance, technical repair of the production site, days.

2.3 Calculation of the annual volume of work

The annual volume of ATP work is determined in person/hour and includes the volume of work on maintenance (EO, TO - 1, TO - 2, D - 1, D - 2), current repairs. The annual volume of maintenance is made from the annual production program of this type of maintenance and the labor intensity of servicing one car. The annual volume of TR is determined based on the annual production program and the annual mileage of the vehicle fleet and the specific labor intensity of TR per 1000 km.

The volume of guard and site work of the TR is established as a percentage of the annual volume of work of the TR, and the volume of diagnostic work (D - 1, D - 2) is established as a percentage of both the annual volume of work of the TR and the volume of work of the TO - 1 ,TO - 2.

2.3.1 Determination of the standard labor intensity of maintenance and repair

2.3.2 Adjusting the labor intensity of SW

Determined by the formula:

t EO = K 2 K 5, (12)

where is the labor intensity norm SW person/hour.

K 2 - coefficient correcting the labor intensity of maintenance, depending on the modification of the rolling stock, table 2.9;

K 5 - coefficient correcting the labor intensity of maintenance depending on the number of cars and the number of compatible groups, table 2.12.

1.0 = 1.1 K 5 = 0.95

0,45 1,0 0,95 = 0,42;

0,5 1,1 0,95 = 0,52.

Adjusting the labor intensity of maintenance - 1.

Determined by the formula:

t then - 1 = K 2 K 5, (13)

where is the standard labor intensity of maintenance - 1, person/hour.

2,7 1,0 0,95 = 2,56

3,4 1,1 0,95 = 3,55

Adjusting the labor intensity of maintenance - 2

Determined by the formula:

t then - 2 = K 2 K 5, (14)

where is the standard maintenance labor intensity - 2, people/hour.

10,8 1,0 0,95 = 10,26

14,5 1,1 0,95 = 15,15

Adjusting the labor intensity of TR.

Determined by the formula:

t tr = K 1 K 2 K 3 K 4 K 5 , (15)

where K 1 is the coefficient correcting the labor intensity of the TR, table 2.8.

K 3 - coefficient taking into account the labor intensity of the TR depending on

climatic conditions and environmental aggressiveness, table 2.10.

K 4 - coefficient correcting the labor intensity of TR from the mileage first

operation, table 2.11.

K 1 = 1.5; K 3 = 1.1; K 4 = 0.7.

4,0 1,5 1,0 1,1 0,7 0,95 = 4,38

8,5 1,5 1,1 1,1 0,7 0,95 = 10,25

Table No. 3. Labor intensity of a maintenance and repair unit

Automobile model	Quantity, pcs.	Labor intensity
		Calculated	Average by group

Table No. 4. Labor intensity of a unit of maintenance and repair per car

car model	Type of work	Labor intensity
		automobile	trailer, semi-trailer

2.3.3 Determination of the annual volume of maintenance and repair work

Determination of the annual volume of maintenance work - 1.

Determined by the formula:

where is the annual number of maintenance services - 1;

Adjusted maintenance labor intensity - 1, person/hour.

7 971 2,56 = 20 405,8

7 971 3,55 = 28 297,1

20 405,8 + 28 297,1 = 48 702,9

Determination of the annual scope of maintenance work - 2

Determined by the formula:

where is the annual number of maintenance services - 2;

Adjusted maintenance labor intensity - 2.

2 657 10,26 = 27 260,8

2 657 15,15 = 40 253,6

27 260,8 + 40 253,6 = 67 514,4

Determined by the formula:

where is the annual number of SW services;

Adjusted SW labor intensity.

111 987 0,42 = 47 034,5

111 987 0,52 = 58 233,2

47 034,5 + 58 233,2= 105 267,7

Determination of the annual volume of work of the SW

Determined by the formula:

where is the annual mileage of the park;

Estimated labor intensity per 1,000 km.

37 689,4 + 164 895,6 = 202 585

2.3.4 Determination of the annual volume of diagnostic work

According to the recommendation of GiproAvtoTrans, the volume of work performed when diagnosing D - 1 and D - 2 is determined as the sum of the annual volumes of control and diagnostic work TO - 1, TO - 2 and 50% of the volume of control and diagnostic work TR.

Determined by the formula:

T d-1 = ? T then-1 K 1 + 0.5? T tr K to-1 tr, (20)

T d-2 = ? T then-2 K 2 + 0.5? T tr K to-2 tr, (21)

where T then-1 and T then-2 are the annual volume of work for maintenance - 1 and maintenance - 2;

K 1 and K 2 - the share of control and diagnostic work in the scope of TO - 1 and TO - 2;

Kto-1 tr and Kto-2 tr - the share of control and diagnostic work in the scope of current repairs D - 1 and D - 2.

K 1 = 10% (Z) K 1 = 14% (K)

K 2 = 10% (Z) K 2 = 12% (K)

To-1 tr = 1% (Z) To-1 tr = 2% (K)

K to-2 tr = 1%

T d-1 (Z) = 20,405.8 0.1 + 0.5 37,689.4 0.01 = 2040.58 + 188.447 = 2,229.027

T d-1 (K) = 28,297.1 0.14 + 0.5 164,895.6 0.02 = 5,610.6

T d-2 (Z) = 27,260.8 0.1 + 0.5 37,689.4 0.01 = 2,914.5

T d-2 (K) = 40,253.6 0.12 + 0.5 164,895.6 0.01 = 5,654.9

2.3.5 Determination of the annual volume of work of TR (guards)

The annual volume of TR work is divided into post work and local work, carried out at universal (specialized) posts in the TR zone.

T trp (to-1) = T tr C trp (to-1) - T spr (to-1); (22)

T trp (to-2) = T tr C trp (to-2) - T spr (to-2); (23)

where C trp is the share of TR guard work performed in the TR zone;

T spr (to-1, to-2) - the annual volume of associated repairs during maintenance - 1 and maintenance - 2.

37 689,4 0,18 - 3 060,9 = 3 723,2

164 895,6 0,18 - 4 244,6 = 25 436,6

37 689,4 0,18 - 4 089,1 = 2 694,9

164 895,6 0,18 - 6 038,0 = 23 643,2

Determination of the annual volume of related repair work.

Determined by the formula:

T spr (to-1) = C tr ? ; (24)

T spr (to-2) = C tr ? ; (25)

where C tr is the share of related repairs, depending on the age of the car.

According to GiproAvtoTrans and Tsentravtotech, the share of related repairs is 15 - 20%.

We accept 15% in calculations

0,15 20 405,8 = 3 060,9

0,15 28 297,1 = 4 244,6

0,15 27 260,8 = 4 089,1

0,15 40 253,6 = 6 038,0

The distribution of labor intensity of accompanying current repairs is carried out as follows and amounts to:

with maintenance - 1 - 5-7 people/min;

with maintenance - 2 - 20-30 people/min.

2.3.6 Distribution of the scope of work for maintenance and repair

Table No. 5. Distribution of the scope of work for maintenance and repair.

Name of maintenance and repair work	Rolling stock
	Passenger car	Buses	Freight	Self-propelled	Trailers semi-trailers
Cleaning/washing Deep cleaning/washing
Works D - 1 Fastening and lubricating adjusting
Works D - 2 Fastening, adjusting, lubricating
TR guard work Works D - 1 Works D - 2 Disassembly and assembly, adjusting Welding work: Cars with metal-wood body Tinsmith works: Cars with metal body Cars with wooden body Carpentry work: Cars with metal and wood bodies Cars with wooden body Painting
TR local works Aggregate Plumbing and mechanical Electrical Rechargeable Tire fittings Tire fittings Forge-spring Mednetsky Welding Zhestyanitsky Reinforcement Taxi Radio repair Fuel

Determination of the annual scope of work for the undercarriage section

20 405,6 = 34 026,7

32 780,7 = 48 404,2

37 689,4 0,18 = 6 784,1 = 164 895,6 0,18 = 29 681,2

2.4 Calculation of the number of production workers

Production workers include workers in various zones and areas directly performing maintenance and repair work on rolling stock. In the calculations, I determine the technologically necessary (appearance) and regular (payroll) number of workers. When calculating the working time fund and the workplace fund, the Labor Code of the Russian Federation and enterprise instructions were used.

2.4.1 Determination of the technological required (appearance) number of workers

Determined by the formula:

where is the annual volume of work for the corresponding maintenance zone, technical repair area, section, special post (persons/hour);

Annual production fund workplace during single-shift work.

We determine the annual production working time for single-shift work and for a shift duration of 8 hours.

D rg T cm, (27)

where D rg - days of work per year in the TR zone

T cm - duration of shift, hour.

250 8 = 2000

R t = = 15.1 16 people.

2.4.2 Determination of the regular (scheduled) number of workers

Determined by the formula:

where is the annual volume of work in the corresponding maintenance and repair zone;

Annual production fund of working hours.

Table No. 6. Work time balance.

R w = = 19.1 20 people.

2.5 Calculation of the number of posts for maintenance, repair and diagnostic zones

Determining the number of posts for a toilet sink:

P tm = , (29)

where is the daily SW program;

Fleet technical readiness coefficient;

0.75 - peak return coefficient from the line;

Duration of work, hour (accepted by ONTP - 0.1 - 86);

Productivity of washing equipment.

2.8 (400 cars)

We accept 3 posts.

Determining the number of deep washing stations:

P mind = , (30)

where is the annual volume of work of the SW, people/hour;

The coefficient of uneven loading of posts (determined by OPTP 01, - 86);

D rg - number of working days in a year;

C - number of work shifts per day;

Shift duration, hour;

Average number of workers at 1 post;

Post working time utilization rate;

K NEO = 1.15; K NTO = 1.09; K NTR = 1.12; P SR = 1;

0.98 - harvesting; = 0.92 - washing;

P mind = = 22.5

We are accepting 23 posts.

We determine the number of posts TO - 1, TO - 2, D - 1, D - 2, disassembly and assembly and others:

where is the annual volume of work (TO - 1, TO - 2, D - 1, D - 2)

We accept 2 posts.

We accept 2 posts.

P to-1 = = 9.8

We accept 10 posts.

P to-2 = = 13.5

We accept 14 posts.

Determining the number of TR posts when working several shifts:

P tr = , (32)

where is the coefficient of workload distribution across shifts (assuming = 0.6);

Annual volume of TR (guard) work.

P tr = = 13.7

We accept 14 posts.

3. Organizational part

3.1 Selection and justification of the method for organizing the technical process of maintenance and repair

I accept the method of specialized teams of a universal post. Organization this method is as follows: at the ATP, universal maintenance, repair, and repair posts are organized, which specialize in types of work (fastening, lubrication, adjustment, control) and in vehicle units and systems, etc.

3.2 Selecting a maintenance method

Shift program TR.

Number and type of rolling stock ZIL - 5301, KamAZ - 5410 330 pieces.

The nature of the volume and content of work on technical regulations is constant.

The number of working posts for TR is 14 posts.

The time period allotted for maintenance is 36,465.3 people/hour.

The complexity of servicing is based on transaction cards.

The operating mode of the vehicle on the line is 8 hours.

I organize the technological process of TR at specialized posts.

3.3 Calculation of production lines in the UMR zone

Line clock calculation:

where is the adjusted labor intensity of the SW;

Calculated number of UM posts;

Average number of workers per post;

The time it takes for a vehicle to move from one post to another.

Definition:

where is the length of the car;

Distance between cars;

I assume the distance on the conveyor is 1.5 m.

The conveyor speed is 4 km/h.

Calculation of the production rhythm of the UMR zone:

R died = , (35)

where is the duration of the UMR zone change;

Number of work shifts per day;

Daily EO program.

Calculation of the number of lines in the UMR zone:

L died = , (36)

where is the clock cycle of the UMR line;

Rhythm of production in the UMR zone.

L died = = 1.6

We accept 2 lines.

Calculation of time for washing all cars at ATP:

Productivity of the washing plant.

We accept 50 cars/hour

3.4 Organization and maintenance of guard work TR

Work on Tr is carried out during work in the automated workplace, when inspecting vehicles at the control point during the process of D&M. Cars are serviced at special posts in a separate area or when performing EO.

When organizing the production of TR, TO, the following factors are observed:

Technological uniformity of repair work, common use of equipment, the estimated number of posts corresponds to 0.9 or more, specialized work (requiring an increased level of work) is carried out in special production facilities.

3.5 Distribution of workers by positions, specialties, qualifications and jobs

The distribution of workers among work zones is made taking into account the specifics of the work and the approximate labor intensity of the distribution of work for maintenance, repair and maintenance.

Distribution of labor intensity of work by TR zones.

Form 12. Distribution of labor intensity of TR work.

Distribution of working areas of technical equipment by specialty and qualification.

Form 14. Distribution of technical work areas by specialty and qualifications.

Workers by specialty			Number of workers
			settlement	accepted
Motorists
Carburetor workers
Mechanics of TR chassis
TR transmission mechanics
Mechanics of TR wheels, brakes
Mechanics of TR cabins, platforms
Auto electricians

3.6 Selection of technological equipment

Process equipment includes stationary, mobile and portable stands, machines, instruments necessary for maintenance, repair and maintenance work.

Form 15. Process equipment sheet

3.7 Selection of technological equipment

Technological equipment includes tools and devices necessary for performing the technological process of vehicle maintenance and repair.

	Name	Model (type)		Overall dimensions, mm	Power consumption kW	Cost thousand rubles
	Set of hammers
	Set of open-end wrenches
	Screwdriver Set
	Socket wrench set
	Set of spanners

3.8 Selection of organizational equipment

Organizational equipment includes various types cabinets, tables, chairs, workbenches, racks, stands, production equipment, specials. suits, boots, glasses, aprons and other necessary equipment.

Form 17. Organizational equipment sheet.

	Name	Model (type)		Overall dimensions, mm	Power consumption kW	Cost thousand rubles
	Bath for washing large parts
	Instrument cabinet
	Parts rack
	Bath for washing small parts
	Mechanic's workbench
	Leveling plate on a stand
	Wheel chocks
	Special suit
	Gloves
	Safety glasses

3.9 Calculation of production space

I determine the area of ​​the production premises in accordance with the graphic-analytical task, taking into account the work being performed.

Determining the area of ​​the repair area:

Determined by the formula:

where is the area of ​​technological equipment;

Area of ​​organizational equipment;

Equipment layout area coefficient.

Accept = 4

Determining the area of ​​a plot with a car seat:

where is the area occupied by the car.

S uch = = 108.3 [m 2 ]

4. Economic part

4.1 Cost of manufacturing the device

Piece-calculation time of a 3rd category turner: t shk = 10.66 min;

Piece-calculation time of the grinder 4 categories: t shk = 10.5 min;

Piece-calculation time of a mechanic of the 4th category: t shk = 9.17 min.

The wage fund of workers involved in the manufacture of devices:

F op = C od , (40)

where C od is the hourly tariff rate.

Turner 3rd category:

F op = 31.20 = 5.54 rub.

Grinder 4th grade:

F op = 33.40 = 5.8 rub.

Locksmith 4th category:

F op = 28.60 = 4.37 rub.

F zp = F t + F w + F s, (41)

where F t, F w, F s - the wage fund of a turner, grinder, mechanic.

F salary = 5.54 + 5.8 + 4.37 = 15.71 rub.

Additional salary:

F dzp = F zp K, (42)

where K = 15% is the coefficient of additional wages.

F dzp = 15.71 0.15 = 2.3 rub.

Payroll accruals:

F zp = (F ozp + F dzp) p, (43)

where n = 0.26 is the wage accrual coefficient.

F zp = (15.71 + 2.3) 0.26 = 4.68 rub.

Form 19. Costs of materials.

General running costs:

F ohr = F ozp K, (44)

where K = 1.2 is the coefficient of general economic expenses.

F ohr = 15.71 1.2 = 18.85 rub.

Form 20. Cost estimate for the manufacture of devices.

4.2 Calculation of capital investments

K = With ob + With tr + With obm + With cool + With zw, (45)

where C about is the cost of equipment, p;

C tr - transportation costs;

With exchange - the cost of the equipment to be installed;

C kru - costs for redecorating the site;

C building - the cost of building construction;

Calculation of equipment cost:

C ob = C tob + C to + C oo + C tr, (46)

where C tob is the cost of technological equipment, p;

C then is the cost of technological equipment, p;

C oo - cost of organizational equipment, rub.

With ob = 28,300 + 5,000 + 26,800 = 60,100 rub.

Transportation costs:

C tr = C about K, (47)

where K = 10% is the transportation cost coefficient as a percentage of the total cost of the equipment.

C pp = 60,100 0.1 = 6,010 rub.

Costs for redecorating the area:

C kru = S y C krz Ј inf, (48)

where S y - area of ​​the site, m 2;

C KRZ - the cost of cosmetic repairs of 1 m 2 of a building, p;

Ј inf = 1.12 - inflation coefficient;

C kru = 108 64 1.12 = 7,741 rub.

With exchange = 28,300 rub. - cost of equipment to be installed.

From building = 1,422,489.6 rub. - costs of building construction.

K = 60,100 + 60,100 + 7,741 + 28,300 + 1,422,489.6 = 1,524,640.6 rubles.

4.2 Calculation of wages for production workers

Payroll Fund (WF)

Form 14. Tariff rates.

	Number of people	Hourly rate	Tariff coefficient

Basic salary fund:

FZP = T h N mi F pl K r K pd, (49)

where T hour is the hourly tariff rate of the i-th category;

N mi - number of workers of the i-th category;

F pl - planned working time fund for the year;

Kr - regional coefficient, Kr = 1.2;

K pd - coefficient taking into account bonuses and additional payments, K pd = 1.1.

The wages of workers of the 4th category per year are equal to:

Full salary 4 = 14.4 53 2000 1.2 1.1 = 2,014,848 rub.

The wages of workers of the 5th category per year are equal to:

Full salary 5 = 16 22 2000 1.2 1.1 = 929 280 rub.

Full wages for workers of the 6th category, who change teams, 3 teams per year:

FZP b = T h N mi F pl K r K pd K b, (50)

where Kb is the surcharge coefficient for crew leadership, Kb = 1.1

FZP b = 17.6 3 2000 1.2 1.1 1.1 = 153,331.2

The total wage fund is determined by the formula:

FZP = FZP 4 + FZP 5 + FZP b, (51)

FZP = 2,014,848 + 929,280 + 153,331.2 = 3,097,459.2

Additional salary fund

Determined by the formula:

FZP d = FZP K, (52)

where K is the coefficient of additional wages, expressed in fractions of a unit, determined by the formula:

where is the duration of the vacation;

Number of days in a year;

Weekend;

Holidays;

Full salary d - 3,097,459.2 0.09 = 278,771.3 rub.

General payroll

Determined by the formula:

FZP total = FZP + FZP d, (54)

Total wages = 3,097,459.2 + 278,771.3 = 3,376,230.5 rub.

Payroll accruals

WIP = FZP total P, (55)

where P is the accrual coefficient, P = 0.26.

WIP = 3,376,230.5 0.26 = 877,819.9 rub.

4.3 Cost of power energy

The maintenance and repair area of ​​the chassis is illuminated by 20 mercury lamps LB - 400, the power of one lamp is 250 W.

C os = T W h C e, (56)

where - days of operation of the zone, section;

T - duration of the work shift;

W h - power consumption of electricity per hour, W h = 20 0.25 = 5 kW/h;

C e - cost of electricity per 1 kW/h, C e = 0.8 rub.

C os = 8 5 0.8 = 8,000 rub.

Heating

The volume of section V is 378 m 3 ;

Heating cost C from - 1 m 3 2.47;

Transportation cost C tr = 45.5 rub.

C mark = (V C from + C tr) VAT, (57)

where VAT is value added tax equal to 12%.

With mark = (378 2.47 + 45.5) 0.12 = 117.49 rub.

C ots = C el N, (58)

where C ots is the cost of heating per season;

N is the duration of the heating season, N = 7.

From ots = 117.49 7 = 822.43 rub.

Domestic water

For the area washing bath

S bv 1 = K Ts bv, (59)

where K is the need for domestic water per day;

Number of working days on site per year;

C bw - cost of 1 m 3 of water including VAT.

With bv1 = 2.6 4.83 = 3,139.5 rub.

For site workers

C bv2 = K bv N C bv, (60)

where K bv is the need for domestic water per day per mechanic;

N is the number of workers on the site.

C bv2 = 0.04 16 4.83 = 772.8

C bv = C bv1 + C bv2

With bv = 3,139.5 + 772.8 = 3,912.3 rubles.

4.4 Calculation of material costs

where - C m - costs of materials;

Standard cost of materials per 1000 km;

Annual mileage of the park;

Participation coefficient of the chassis section in the overall TR.

Calculation of costs for spare parts

With salary = , (62)

where is the cost rate for spare parts;

Coefficient depending on the modification of the rolling stock and the organization of its work TR;

K 3 - coefficient taking into account the natural and climatic conditions of the individual labor intensity of the TR;

With salary = = 476,644 rub.

4.5 Costs of current repairs of the building

C trz = C building K mр, (63)

where C building is the cost of the building;

К mр - coefficient correcting the costs of the building's technical infrastructure;

C pp3 = 1,422,489.6 0.02 = 28,449.8 rub.

Costs for current equipment repairs:

C tr = C about K r, (64)

where C ob is the cost of equipment;

K p - coefficient correcting costs for technical equipment;

Stro = 60 100 0.05 = 3,005 rub.

Calculation of depreciation of fixed assets of the site:

Sa zd = S z z K a, (65)

where K a is the coefficient taking into account the depreciation of the building;

Sa zd = 1,422,489.6 0.05 = 71,124.4 rub.

Sa y = Asd K pl, (66)

where Kpl is the share of the site (by volume) of the entire building;

Sa y = 71,124.4 0.043 = 3,058.3 rub.

Depreciation of technological equipment, technological and organizational equipment:

Sa tob = C tob K a, (67)

where K a is the depreciation coefficient of technological and organizational equipment, technological equipment. K a = 3%.

Sa tob = 28,300 0.03 = 849 rub.

Sato = 5000 0.03 = 150 rub.

Sa oo = 26,800 0.03 = 804 rub.

Equipment depreciation:

Sa arr = Sa tob + Sa to + Sa oo, (68)

Sa arr = 849 + 150 + 804 = 1,803 rub.

Form 16. Depreciation of fixed assets.

Other costs:

S pz = ?S K pr, (69)

where K pr is the coefficient correcting other costs

C = C os + C oo + C tro + C trz + C au;

C = 8000 + 822.43 + 3005 + 28,249.8 + 3,058.3 = 43,135.5 rubles.

With pz = 43,135.5 0.05 = 2,157.7 rub.

Form 17. Estimate of overhead costs.

	Expenditure	Sum. rub.
	Power electricity
	Site maintenance costs
	Costs for technical equipment
	Costs for the technical area of ​​the site
	Depreciation of the site
	Equipment depreciation
	Other costs
Total: overhead

4.6 Payback period for capital investments

where K - capital investments, rub;

Volume of work performed, person/hour;

T o = = 7 years

Cost estimate and cost calculation of TR

Form 18. Cost estimate and cost calculation of TR.

5. Design part

5.1 Requirements for the design of small-scale mechanization equipment

The device must be durable to withstand the loads during operation; should be characterized by simplicity and ease of design, this is necessary in order to reduce the worker’s working time to a minimum.

5.2 Justification of the adopted design

The principle of operation of the locking ring is captivating in its simplicity: it seems that it is not difficult to remove it with any tool, for example, a screwdriver.

Meanwhile, dismantling a capricious part is not so easy. Many people repurpose round nose pliers, pliers, etc. for this purpose. The working (cylindrical) ends of such homemade products are not durable; they often have to be sharpened.

A simple and reliable device for removing retaining rings is shown in the drawings; every repairman can do it.

Pins 5 and 6 are pressed into body 2 and slider 1, respectively. The length of the pins is such that it allows the removal of rings that are deeply seated in the holes. When working with the device, first select the distance between the axes of the pins so that it coincides with the center-to-center distance of the holes in the retaining ring, for which you rotate bolt 4 with a wrench. If necessary, hold the device by another bolt, screwed from the other end of the body or from above.

5.3 Test calculation of the device for strength

The least durable part in this device is the threaded connection. Removing the locking ring will require a lot of force, so when calculating, the force F will be equal to 500N.

Thread diameter M8x1.25 mm.

Tensile strength steel 45.

From the calculation it is clear that the M8 thread can withstand the required load when removing the retaining ring.

6. Scientific organization of labor

6.1 Organization of production management of maintenance and repair

Scheme No. 1. Central production management.

6.2 Responsibilities of departments and their managers

The chief engineer heads the technical service and is responsible for ensuring that the coefficient of technical readiness of rolling stock and working capital is not reduced.

Department (group) of operational management - dispatchers provide planning and operational management of the work of all production complexes, as well as administrative and operational management of the unit’s pre-production complexes.

The department (group) for processing and analyzing information collects and processes analysis of production and economic activities. Once a month, he draws up a schedule of the frequency of TO-1 and TO-2 and transmits it to the head of the TO in the operational management department, the gearbox mechanic and the convoy mechanic.

The maintenance complex carries out all types of maintenance, routine maintenance, related work and repairs, and performs vehicle diagnostics. The maintenance complex includes brigades EO, TO-1, TO-2, D-1, D-2.

The TR complex unites divisions that carry out work on replacing faulty units, components, mechanisms, vehicle systems, and trailers with serviceable ones.

Technical department:

1. Develops plans and measures for the introduction of new equipment and technology of production processes.

2. Organizes and conducts technical training for personnel training and advanced training of workers.

3. Carries out work on drawing up technical standards, instructions, technological and postal maps.

Department (group) for the introduction of new equipment and technologies (teams for the production of non-standard equipment):

1. Puts new equipment into operation.

2. All workers are trained to use the new equipment and pass an exam.

3. Develops and implements the production of small-scale mechanization equipment that reduces hard work.

Chief Mechanic Department:

1. Carries out the maintenance and repair of buildings and structures.

2. ensures maintenance and repair of all communication structures.

3. Ensures the installation of new equipment and the preparation of necessary communications for it.

Technical control department:

1. Carries out quality control of work performed by all departments.

2. Carries out selective monitoring of the technical condition of rolling stock.

3. Carries out technical control of vehicles when they are used or released onto the line.

Supply department - ensures the supply of production with spare parts, materials, semi-finished products and other technical means.

6.3 Organization of the technological process of maintenance, repair and diagnostics

Vehicle diagnostics are carried out as intended. frequency, labor intensity of work performed and is divided into express diagnostics and in-depth diagnostics.

D - 1 is performed with the frequency of maintenance - 1, and D - 2 is carried out 3-4 days before the scheduled maintenance - 2.

When returning from the line, cars pass through a control and technical point, where the mechanic on duty inspects the car using the established technology, if necessary, fills out an application for TR, then the car, as necessary, can be sent to the EO zone, TO - 1, TO - 2, D - 1, D - 2 or current repairs. After performing the appropriate technical intervention, the car is sent to the storage area.

When performing work related to brake systems and steering, vehicles are sent to zones D - 1 for re-diagnosis.

During maintenance - 2, after eliminating the identified deficiency, the car is sent to zone D - 2 for a second check.

6.4 Selection and justification of the work and rest regime

When choosing a work and rest schedule, the requirements are taken into account Labor Code Russian Federation, safety requirements when performing work.

Schedule No. 1. shift time and operating time of vehicles on the line.

7. Labor protection, safety precautions, industrial sanitation, fire safety, electrical safety

7.1 Safety rules at the site, workplace

1. Before starting work:

* Wear the required overalls, lace up your shoes, and tuck your hair under a hat.

* Inspect the workplace, check that there is sufficient lighting, remove foreign objects, and check that the transition ladders in front of the ditch are securely laid.

* Check the serviceability of tools and devices and personal protective equipment.

* Place a sign on the steering wheel with the inscription “Do not start the engine - people are working.”

* Check the cleanliness of the vehicle delivered for maintenance and repair.

* Put the car on the handbrake, engage a low gear.

2. During operation:

* Securely secure workpieces in a vice or fixture.

* Remove metal shavings with brushes and sweepers.

* Place the tool in the tool box with the pointed ends facing inward.

* Do not allow the key to come off the nut or bolt.

* Be careful when working with pullers, do not allow the part to fall.

* Do not use extensions for wrenches and pipes, do not use worn wrenches to unscrew bolts and nuts.

* Use a special knife to cut out gaskets obtained from the tool store.

* Do not wash components and assemblies using gasoline or other flammable liquids.

* Use portable 12 V lamps when there is insufficient illumination in inspection ditches.

* Do not work or carry out installation - dismantling of wheels of heavy-duty vehicles in the field, without releasing air from the chambers.

3. Upon completion of work:

* Clean up your work area, wash your hands, take a shower, change into home clothes.

7.2 Calculation of artificial and natural lighting

In the maintenance and repair section of the chassis, combined lighting is used, in which insufficient natural lighting is supplemented with artificial lighting.

Total luminous power of lamps per year

W osv = R Q F n , (72)

where R is the rate of power consumption of electricity per 1 m 2;

Q is the duration of operation of electric lighting throughout the year for one shift;

F n - field area;

R = 20 W/m2;

The site operates in 2 shifts

Q = Q 2 = 2100 2 = 4200;

W osv = 20 4200 79 = 6 636 000 W

W osv = 6,636 kW.

Electricity power consumed by lighting devices in 1 hour:

W 4 = 20 79 = 1580 W.

To illuminate the assembly area, 20 lamps LB - 400 are required

W 40 = 20,250 = 5,000 W

The actual power consumed by the lighting of the area (working 2 shifts).

W osv b = W 40 Q = 5000 4200 = 2 1000 kW

Calculation of natural lighting comes down to calculating the number of window openings.

Light area of ​​window openings

F ok = F n d, (73)

F n - floor area;

d - light coefficient.

F ok = 79 0.3 = 23.7 m 2;

Building height 3.5 m window opening area

S ok = d h, (74)

where d is the width of the window;

h - window height;

S ok = 4 2 = 8 m 2

Number of windows:

where is the light area of ​​window openings;

Area of ​​a standard window opening;

N = 3 - number of window openings in the area.

7.3 Ventilation

V n = h S n , (76)

where V n is the volume of the area, m 3 ;

h - height of walls, m;

S n - area of ​​the site, m 3 ;

V n = 3.5 79 = 276.5 m 3.

To calculate ventilation, the multiple air exchange method is used:

L = V n K, (77)

where V n is the volume of the area;

K is the air exchange rate of the area, h;

L is the amount of air required for normal air exchange, m 3 /h.

L = 276.5 2 = 553 m 3 / h

Heating and ventilation system APVS 50-30 with an air exchange of 2000 m 3 / h, works only as ventilation.

7.4 Fire prevention measures

In order to avoid creating conditions for such occurrences on the vehicle and in the premises, it is forbidden to: allow contaminated cleaning materials to contaminate the engine and work areas; allow leaks in fuel lines, tanks and power system devices; keep the fuel lines leaking, open the necks of the fuel tanks, wash or wipe the body with gasoline. parts, assemblies, hands and clothing; store fuel and containers for fuel and lubricants; use open fire when troubleshooting; warm up the engine with an open flame.

Smoking on the territory and in production premises is permitted only in specially designated areas.

In production premises, signs should be posted in prominent places near telephone sets indicating the telephone numbers of the nearest fire brigades and the names of the persons responsible for fire safety.

7.5 Environmental protection

The technical condition of machines has a significant impact on the pollution of this environment. As it deteriorates, the atmosphere becomes polluted with carbon monoxide contained in engine exhaust gases, and water and land become polluted with fuel and oils.

Vehicles whose diesel engines operate with increased smoke, and whose carburetor engines operate with a content of carbon monoxide in the exhaust gases exceeding the norms established by state standards are not allowed to be used. For example, the proportion of carbon monoxide in the exhaust gases of carburetor engines should not exceed 1.5 g.

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The most productive workshops are those designed to repair certain types of vehicles, and therefore, when constructing them, it is advisable to consult with the relevant automobile manufacturing companies.

Selection of sites for car service workshops: If possible, the site should be located near a busy highway.

The basic rule of development: 1/3 of the plot is allocated for development, 2/3 is left undeveloped. When designing a workshop, it is necessary to take into account the possibility of its subsequent expansion (Fig. 2).

For larger workshops, an average of 200 m2 of production area per workplace is assumed. To this should be added the area of ​​the sales floor, office, customer reception area, household premises, etc.

When calculating utility networks, it is necessary to take into account the large water consumption for car washing.

Production yard serves as a link between the workshop departments (Fig. 3). Specialized areas of the production yard:

1) a reception area for vehicles coming in for repair;

2) parking of cars awaiting repair;

3) parking for repaired cars;

4) parking for new cars (in some cases - under a canopy);

5) area for disabled vehicles (very spacious);

6) emergency technical assistance point;

7) scrap warehouse (behind the fence).

Areas of the production yard must be clearly marked.

Annual car sales	Number of vehicles serviced annually	Land area, m2	Total construction area, m2	Space requirement per 1 car sold	Workshop area, m2	Number of places for repair	Number of places for inspection	Number of places for technical service	Number of reception stands	Number of washing stands	Number of polishing stands
50	150	2000	480	7,2	360	4	-	1	-	1	-
100	300	3000	835	6,25	625	7	1	1	1	2	-
200	600	4000	1420	5,7	1220	10	1	1	1	1	-
300	825	5000	2150	5,35	1610	16	3	1	1	2	-
400	1000	6000	2620	4,9	1960	19	4	2	1	2	1
500	1250	7000	2980	4,45	2230	23	5	2	2	2	2
750	1725	9000	4500	4,45	3375	32	6	3	2	x	-
1000	2000	10000	5770	4,3	4300	38	7	3	2	x	-

The production process in a repair shop must be clearly organized, from the moment the order is accepted to the delivery of the repaired machine to the client and payment for the work performed.

When designing a workshop, you should pay attention Special attention on correct relationship between rooms(Fig. 4):

1. Current repairs (preventive inspection, replacement of units or individual parts, minor repairs) are carried out for the most part in the presence of the customer.

2. Overhaul - complete engine overhaul, body repair and painting. At modern enterprises, body painting can be completed in 1.5 - 2 hours.

Utility rooms: auxiliary production shops - upholstery, electrical, repair of components and assemblies, washing of parts; as well as household premises. Their minimum height is 3 m.

Office area is taken at the rate of about 6 m2 per person, but not less than 15 m2. Director's office 16 - 20 m2, commercial director's office 12 - 16 m2, reception room 8 - 10 m2, meeting room 8 - 10 m2, production manager's office 10 - 12 m2, warehouse manager's office 10 - 12 m2. In large workshops, the office premises include; order receiving department, settlement department, timekeeping department, card index, cash desk and a separate room for business negotiations.

Spare parts warehouse If possible, it should be visible to clients (Figure 4). It is important to provide for the possibility of expanding the warehouse in the future. Spare parts are delivered to the warehouse only through the yard. The warehouse accounts for 20-25% of the enterprise's built-up area.

Paving the yard: 1) crushed stone pavement on a stone base (cheap); 2) asphalt surface; 3) concrete covering; 4) pavement made of granite or concrete, artificial stones made from blast furnace slag (resistant to oils).

Speedy maintenance (Fig. 6) - the client can remain in the vehicle. The cleanliness of the premises is important, and therefore the floors and walls should be tiled. There must be a two-tier work stand, and not just an inspection pit (Fig. 5). All drains should be equipped with gasoline traps.

Household premises. The size and composition of household premises depend on the number of workshop personnel. The number of administrative and support personnel is assumed to be 40% of the number of workers. The share of purely clerical employees accounts for 30%.

Car wash stations. Unified solutions should be used (Fig. 8), allowing, if necessary, to expand the item. At points with automated production lines, washing, rinsing, canning and drying are carried out in one room. Box length 6.8 m, width 3.8 m, height 3 m (Fig. 8). In such a box it is possible to wash and dry cars up to 5 m long, while servicing up to 150 cars per day. If it is necessary to service more than 200 cars per day, an automated production line is installed, shown in Fig. 9.

1 – workshop office; 2 – receiving orders; 3 – manager’s office; 4 – landing, restroom, etc.; 5 – buffet; 6 – client reception; 7 – oil storage; 8 – pantry; 9 – repair of units. 3. An example of the layout of a small car repair shop.	1. Expedient location of premises corresponding to the sequence of the production process. 1 - area for arrival and inspection of vehicles; 2 - placing orders; 3- issuing orders; 4 - costing of work; 5 - timekeeper's station; 6- jobs; 7 - settlement table; 8 - issuance of spare parts; 9 - spare parts file; 10 - accounting for the consumption of spare parts; 11 - issuing invoices and client records; 12 - cash register. 2. Plan of the maintenance workshop. 3. Body repair and painting department. 1 - spray painting booth; 2 - dryer; 3 - machine room; 4 - paint warehouse; 5 - upholstery shop; 6 - removal of pillows; 7 - installing the pillows in place; 8 - final finishing. 4. Diagram of the relationship between the workshop departments.
5. Two-tier technical inspection post. Dimensions by workplace (left) and aisle (right). 6. Ambulance post with through traffic. 7. Pit under the washing stand. M 1: 200.	8. Washing and drying chambers. 9. Automated washing production line. 1 - entry; 2 - automated washing stand; 3 - drying with hot air; 4 - polishing; 5 - departure; 6 - office. 10. Required area for repairing a small car.

The size of the area depends on the type of car. A length of 6m is sufficient. For body repairs, a width of 3.5 m is required, for preparation for painting - 3.5 - 3.75 m. The span of the room is 17.5 or 20 m.

Automotive repair shops are typically designed with single-story, lightweight steel structures using prefabricated structural elements. Preferred workshops are covered without intermediate columns. Further expansion should be provided while maintaining the selected pitch of the covering trusses. Floors in workshops must have a special sealing screed that prevents fats and oils from penetrating into them. Crushed clinker tiles and other ceramic tiles with high compressive strength have proven themselves well. In the middle of the passage, a sewer channel with a cross-section of 30 x 30 cm, 30 cm, should be installed, closed at the top with a grate. Gasoline separators must be provided. Every two workplaces must be equipped with an exhaust hood to remove exhaust gases. An automatically opening gate with a thermal air curtain should be provided. It is recommended to install channels along the longitudinal walls of the building for laying water supply pipelines, supplying compressed air, removing waste oil, and electrical wiring.

4. Plans of the basement and upper floors of the building shown in Fig. 3. 1 - room for rest and eating; 2 - exhibition room; 3 - archive of drawings; 4 - director’s office; 5 - office premises; 6 - drawing room; 7 - toilets; 8 - washroom; 9 - storage of cleaning equipment; 10 - utility shaft; 11 - registration; 12 - meeting room.

5. Cross section along axis 5.

6. Cross section along axis 1b.

3. Industrial workshops for repairing trucks. BASF company. 1966. Plan of the 1st floor. Architect Neufert. 13 - stand for testing brakes; 14 - paint warehouse; 15 - battery charging: 16 - front; 17 - varnishing; 18 - tire repair; 19 - battery repair; 20 - rectifier unit; 21 - sink; 22 - test benches; 23 - master's room; 24 - closed low voltage switchgear; 25 - closed high voltage switchgear; 26 - parking place for electric cars and other vehicles for internal transportation; 27 - parking area for stackers with electric and diesel engines; 28 - motorcycle repair; 29 - repair of passenger cars; 30 - mechanical workshop; 31 - instrumental; 32 - warehouse of parts and assemblies; 33 - settlement department; 34 - car reception bureau; 35 - repair of trucks, tractors and special vehicles; 36 - crane runway; 37 - repair of tank trucks; 38 - repair of trailers; 39 - tire warehouse; 40 - compressor and steam jet installation; 41 - warehouse for large spare parts; 42 - lubrication of parts; 43 - oil warehouse; 44 - installation of engineering equipment.