TMK Research Center (Moscow, Russia)

Y. I. Kosmatskiy, Dr. Eng., Branch Office Director – Deputy General Director for Research, yaroslav.kosmatskiy@tmk-group.com
D. N. Lysov, Head of the Economic Research Department, lysovdn@tmk-group.com
E. N. Kondratyev, Senior Researcher, egor.kondratev@tmk-group.com
N. V. Gorbunov, Head of the Sector, nv.gorbunov@tmk-group.com
A. A. Tyurin, Head of the Metal Consumption Rates Sector, aleksey.tyurin@tmk-group.com

TMK Pipe Metallurgical Company (Moscow, Russia)
T. V. Dvornikova, Deputy Head of Department, tatyana.dvornikova@tmk-group.com

This article examines the implementation of a computational analytical method (CAM) for regulating metal consumption in the production of cold-formed pipes under conditions of intra-industry cooperation (using Pipe Plant No. 1 and Pipe Plant No. 2 as examples). The relevance of the study is due to the fact that metal costs account for a significant share of the cost of pipe products (up to 90%) and the need for accurate cost planning in unstable economic conditions. The objective of the study is to develop a methodological and software tool for the operational accounting of metal waste and losses, allowing for the establishment of consumption standards at all stages of production. The process flows for manufacturing cold-formed pipes were studied, and waste types (cuttings, shavings, heat losses, and irrecoverable losses) were systematized by processing stage. Research methods include mathematical modeling of waste and metal loss generation, formalization of calculation algorithms in the form of methodological documentation, and the development of specialized software. The software product provides automated calculation of partial metal consumption coefficients (MCC), metal consumption rates (MCR), the structure and mass of waste and losses (SWL and MWL), and the preparation of reports in accordance with corporate requirements. The study resulted in the creation of a mathematical model adapted to the current technologies and equipment used in the production of cold-formed pipes at Pipe Plant No. 2. The model takes into account differentiation based on individual process flow charts and product characteristics, including the use of hot-pressed pipes as the starting material. The developed software enables calculations with detailed breakdown by operation, which improves the rationing accuracy and helps reduce costs. The practical significance of the study lies in the potential for implementing the proposed tools at pipe industry enterprises to improve competitiveness by optimizing metal consumption and increasing cost transparency.

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