Rosatom Production System (RPS)

RPS in ASE Engineering Division

ASE Engineering Division is one of the leaders inintroducing RPS among the companies of Rosatom State Corporation.

Rosatom Production System, a tool for enhancing the efficiency of industrial processes, was successfully introduced in JSC ASE EC in 2009. In 2010 the company introduced the system of employees’ motivation for introducing RPS in their activities, in particular for putting forward proposals for improvement (PFI).

From 2016 the process of work with ideas of JSC ASE EC personnel has become automated — industry information system, “The factory of ideas”, was introduced for employee’s proposals for improvement. In 2016 alone, about 2000 PFIs and proposals for cost reduction (PRCs) were put forward, with the total economic effect of about 9 billion rubles.

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The introduction of RPS at NPP construction sites is aimed at increasing the controllability of construction process on the basis of uniform standards, reduction of costs, elimination of losses, enhancement of labor safety and efficiency. At construction sites of Belarus NPP, Kursk NPP-2, Novovoronezh NPP-2, Rostov NPP and in all contractor’s companies engaged in their construction, the work is performed in strict compliance with 8 RPS-standards of JSC ASE EC, a unique set of lean production standards created for the first time in the world. From 2016, the RPS- standards have been introduced at other foreign sites abroad.

The RPS tools are applied not only for construction, but also for optimization of office and business processes. The company managers launch and successfully implement their personal RPS-projects aimed at activities optimization. In particular, the use of RPS-tools in every-day work made it possible for the design and the commercial units to achieve results that set an example for the whole nuclear industry.

Novovoronezh-2: exemplary site in terms of introduction of RPS

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In 2015 the management of Rosatom State Corporation gave an instruction to JSC ASE EC to establish an exemplary RPS-site on the basis of Unit 2 of Novovoronezh NPP-2 site. The following was achieved as a result of the work performed:

— algorithm of introduction of RPS in all the contractor’s companies;

— system of continuous training;

— system of circulation and control over the implementation of RPS-standards;

— transparent and clear system of visualization of the construction progress;

— exemplary storage facilities;

— a comfortable construction village and territory;

— exemplary areas in terms of production culture, every day life, organization and control of production;

— optimized system of planning and control over works execution.

As a result of the work performed, in May 2016 the commission of Rosatom State Corporation awarded the site the title of an exemplary site.

General Director of Rosatom State Corporation took the decision to share the experience of Novovorinezh NPP-2 with all the construction projects of the nuclear industry.

The Factory of Processes

“The Factory of Processes” is a unique form of training which simulates real works performed at the site, using RPS-tools. The participants perform the time study of the cycle during the assembly of form-work elements, they determine time losses, identify their reasons, share the experience of using the RPS-tools, discuss proposals for improving the assembly of form-work and introduce them for improving the time and economic parameters of the process.

Knowledge Sharing

RPS-specialists of JSC ASE EC teach RPS-standards and tools the specialists of the company and contracting organizations. The teaching is performed in accordance with the license of the Ministry of Education.

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In accordance with the instruction of General Director of Rosatom State Corporation, in 2016 a seminar “Introduction of RPS-engineering standards” was developed for training all the companies of the nuclear industry, on the basis of exemplary power unit No 2 of Novovoronezh NPP-2. The goal of the seminar is obtaining knowledge and skills in establishing an efficient management system at the enterprise, learning methods of reducing all the losses and costs at production.

The unique system makes it possible to teach state-of-the-art system of management of projects and RPS-standards for using them at all the construction sites of the world. Theoretical knowledge is consolidated at the operating construction site of Unit No 2 of Novovoroneah NPP-2.

Over 200 employees of the nuclear industry enterprises that are not part of the engineering division, have been trained within the framework of the seminar, among them directors, deputy directors for capital construction and specialists of third-party organizations.

In 2016 more than 1500 people underwent training (about 50% of them being employees of subcontractors) which is 1.5 times more than in 2015.