Digital Practices at Rostov NPP Studied by Kursk Nuclear Specialists
Specialists from the Development Department of Kursk Nuclear Power Plant visited Rostov Nuclear Power Plant to study its experience in implementing digital RPS reference models as part of preparations to achieve the status of a "Digital RPS Enterprise."
The Rosatom Production System (RPS) is a set of lean manufacturing tools used across the state corporation's enterprises to improve efficiency and reduce costs. A digital RPS reference model combines lean manufacturing methods with digital management technologies in a specific operational solution.
Digital RPS reference models automate production oversight across a broad range of activities, from work order management and warehouse inventory control to monitoring equipment operation and maintenance performance. Rostov NPP became one of the first facilities in Rosatom's electric power division to validate its digital RPS reference models through an independent peer quality assessment. That means the solutions have undergone external evaluation and are considered suitable for deployment at other sites.
Six Reference Models Under Review
During the visit, specialists from Kursk NPP examined six digital RPS reference models currently operating at Rostov NPP.
The first, Operational Management of Power Unit Operations, integrates information on equipment status, reactor and turbine operating parameters, switching schedules, and current work assignments. Personnel receive a unified view of plant unit conditions while the system automatically alerts them when operating parameters deviate from established limits.
The second, Inventory Warehouse, is a digital inventory management system that tracks stock levels, generates replenishment requests, and controls the distribution of materials to plant departments. That reduces search time and minimizes downtime caused by missing components.
The third and fourth reference models support manufacturing activities: Component Manufacturing and Production of Equipment Sealing Elements. These systems schedule machine utilization, monitor production deadlines, and verify product quality throughout every manufacturing stage.
The fifth reference model, Equipment Maintenance and Repair, generates maintenance and repair schedules, assigns work crews, tracks task execution, and records maintenance results.
The sixth reference model complements the others by covering additional operational processes across the power plant.
Measured Results at Rostov NPP
Over the past five years, Rostov NPP has implemented more than 200 RPS projects. Its primary performance indicator, process speed, has increased by nearly 40%, while internal customer satisfaction has risen by 17%.
The production system delivers measurable benefits not only at the level of individual operations but across the entire enterprise. Faster processes reduce equipment downtime, shorten maintenance outages, and lower operating costs.
Rostov NPP applies RPS tools throughout the organization, from scheduled outages and modernization of major equipment to routine daily operations. Plant employees regularly submit improvement proposals, with the most effective ideas being implemented.
Debureaucratization and Wider Deployment
In addition to the digital reference models, the Kursk NPP delegation studied debureaucratization practices introduced at Rostov NPP. These include annual meetings between the plant director, RPS leaders, heads of primary work teams, and young employees, allowing management to receive direct feedback from the workforce.
The plant also places strong emphasis on workplace organization using the 5S methodology: Sort, Set in Order, Shine, Standardize, and Sustain. At Rostov NPP, 5S has been implemented not only in production areas but also across administrative departments.
Kursk NPP selected Rostov as its benchmark because its workforce has accumulated the division's most extensive experience in developing and applying the Rosatom Production System. Adopting these practices will help prepare Kursk NPP to achieve Digital RPS Enterprise status.
Knowledge sharing between nuclear power plants is standard practice across Rosenergoatom. Proven solutions developed at one facility are transferred to other plants within the division, accelerating digital transformation throughout Russia's nuclear power sector.
