Factory in Rzhev

Rzhev Factory of Automobile and Tractor Electrical Equipment is a historical machine-building enterprise in the ancient city of Rzhev. It was founded in 1917.
210 km
from Moscow
330
employees
7
workshops
20 000 m2
the territory of the enterprise

Production processes

Plastic injection molding is carried out on 7 modern casting machines of one of the industry leaders - HAITIAN with an injection volume of 66 to 270 cubic centimeters and a clamping force of up to 1200 kg from various types of polymers: polyamide, grodnomide, polyethylene, ABC and others. At the plastic injection moulding section, the SMED quick changeover system has been introduced, which allows you to regulate the actions of personnel and reduce downtime.

In addition to casting machines, there is a blow molding machine, with the help of which washer tanks are made. The workers of the workshop are leaders in providing Kaizen with proposals that allow you to combat all types of losses in production.

The non-ferrous casting, die production and heat treatment workshop is equipped with modern robotic casting complexes with a pressing force of 280 tons to 480 tons. up to 5.5 kg.
The machining workshop is equipped with 35 modern numerical control machines, both well-known world manufacturers from the USA and Taiwan, and modern Russian models. The workshop produces more than 100 different parts, made of aluminum, brass, steel and other metals. The staff is trained and has access to high-tech equipment in accordance with the competence matrix. Uninterrupted operation and timely production of high-quality parts in a three-shift operating mode are ensured by highly qualified adjusters who have been trained in training centers for specialists.
The area where galvanic treatment, zinc coating and chemical phosphating, clarification and etching take place is equipped with a modern ventilation system for baths and rooms, which allows you to work without special PPE for the respiratory tract. Two automatic lines, suspension and drum, for large and small parts, as well as a manual control line, the section operates in a single-shift mode.
On the premises of the mechanical assembly shop, post and conveyor assemblies, as well as high-tech equipment of world brands are deployed. Equipment manufactured by Statomat (Germany), which allows winding and forming of different diameters of stators, as well as various modifications for generators from 70A to 140 A. The workshop produces up to 29000 generators and 10000 starters per month. The work is organized in one shift. Employees are trained and have access to operations, according to competency matrices.

New Product Development Processes

The factory is not only a production site, the Chief Designer Department (OGK) is engaged in the development of new products for vehicles, such as generators, starters, thermostats and their modernization. The department employs high-level specialists with extensive experience in the enterprise, who are fluent in the skills of three-dimensional modeling, mastery of working on a computer with various software.

The tasks of the Chief Technologist Department (GBS) include technological preparation for the production of both new products and modernization of existing ones. This process implies a comprehensive systematic approach, which includes the selection of progressive, modern technological equipment necessary for the purchase, the conclusion of contracts for its supply, the monitoring of all stages of its implementation, the organization and direct participation in the commissioning and acceptance of equipment, and the transfer of the streamlined process to the existing production. Also, in the course of production preparation, the design of technological tooling is carried out (both in-house and with the involvement of third-party organizations). In parallel with the development of technological processes, a whole set of documents is developed that meet international quality standards, which is necessary for the presentation of finished products to the Consumer and is a prerequisite for the possibility of starting serial deliveries after obtaining approval from him. This work is carried out on the basis of the requirements of international engineering methods.

The Chief Technologist's Department carries out the design of tooling, such as molds, dies, working and control devices, and means of admission control. The work is carried out using modern, domestic software, including 3D modeling. GBS specialists constantly monitor compliance with technological discipline in production units, timely adjustment of technological documentation aimed at continuous improvement of processes.

The PRAMO-ELECTRO factory has its own central research laboratory, it is officially accredited by the Tver CSM. The laboratory is equipped with modern equipment that allows you to carry out all types of climatic, resource and periodic tests of finished products. In addition, the Incoming Control Laboratory is actively working, chemical analysis of raw materials is regularly carried out using the Found-Master optical emission spectrometer for chemical analysis. In the laboratory, it is possible to measure the accuracy of geometric dimensions up to 0.001 mm