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UEET 601

UEET 601. Modern Manufacturing Overview of CIM and Manufacturing Automation. Manufacturing – a combination of physical and chemical processes through which materials are converted to required products. Value is added to the material.

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UEET 601

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  1. UEET 601 Modern Manufacturing Overview of CIM and Manufacturing Automation

  2. Manufacturing – a combination of physical and chemical processes through which materials are converted to required products. Value is added to the material. • A manufacturing system comprises of a collection of these processes, facilities, people, money and other related subsystems that participate in the “value-adding” process. • Activities: - product design/documentation, materials, PPC, Quality control, management, marketing Manufacturing Automation

  3. Trends in Manufacturing involve issues that address: • product specifications and standards • environmentally conscious design and manufacture • concurrent engineering • high levels of quality • design for manufacture or assemble • All these issues impose the need for automation and integration of computers in manufacturing - CIM Manufacturing Automation

  4. External Challenges: • niche market entrants - reduction of dominance • traditional competition - challenges to stay on top of competitors • suppliers - price vs quality, reliability, predictability, response fast to changes in product design • partnerships and alliances - strategic alliances to win competition in the market • customer - most difficult challenge is to respond continuously and timely to customer needs • internet - information exchange and accessibility • global economy; national economy Manufacturing Automation

  5. Internal Challenges: • reliable manufacturing strategy - reduce the “manufacturing divide” • Changing product life cycles - Kaizen, leaping or innovation • Meeting internal challenges (4 steps: analysis, projection, process capability, modifications) Manufacturing Automation

  6. Characteristics of “Order winning criteria” • optimum set-up times • high quality rates • maximize “manufacturing ratio” • inventory management - WIP, Buffers • Flexibility • Plant Layout efficiency - product distance time • Machine availability • Solution - CIM Manufacturing Automation

  7. Computer Integrated Manufacturing (CIM) – the integration of business, engineering, manufacturing and management information that spans the company from marketing to product distribution • Evolution CIM from the traditional manufacturing has been caused by: • changing trends (e.g. short product life cycles) • need for increased flexibility and productivity • reduced manufacturing operations • increased need for better quality and reliability • competition Manufacturing Automation

  8. The CIM Wheel Manufacturing Automation

  9. CIM Benefits a) Better response to shorter product life cycles, changing markets and global competition b) Better process control – improved product quality and reliability c) Increased utilization of resources d) reduced levels of inventory and work-in-progress (WIP) e) lower product costs due to better scheduling and control of production f) Common data base with data shared across all departments g) uses automation hardware and software to integrate enterprise operations - product data created only once Manufacturing Automation

  10. Key components of Automation to be discussed: • Business/enterprise considerations • Design components : • CAD ; Computer aided manufacture • Manufacturing components: • Numerical control • Robotics • CAPP systems • Manufacturing philosophies: - JIT, GT • Cell manufacture and FMS • Vision applications in Automation • Automated Materials handling systems • Production Planning and control systems Manufacturing Automation

  11. Manufacturing Systems

  12. Differences in the operations: • Product - nature of product will dictate the type of manufacturing operation • Technology - changes in technology causes differences in the manufacturing systems • Each CIM system will therefore be unique to each particular enterprise • CIM solution - important to understand WHY each technology is different and HOW they affect the total integrated system Manufacturing Automation

  13. Classification of Manufacturing systems • Two basic criteria • Method of production • production strategy (e.g. volume) • Five groups • Class activity: In groups • Five products are SHIP BUILDING, SHELF MADE IN FABRICATION SHOP, EGR VALVES FOR AUTO, CAR ASSEMBLY LINE, BEVERAGE PLANT • Identify: product design (simple or complex), possible vol of prod, possible no. of different items, how materials move, how tools and equipment move Manufacturing Automation

  14. Project type:(Ship building) • Fixed layout and long manufacturing types • Job Shop: (e.g. Machine shop) • Process layout, low volume production • Repetitive: (e.g. Assembly process for EGR valves or cars) • Product (or sometimes process) layout, medium to high volumes • Continuous: (e.g. Petrochemical) • Product layout, bulk products • Other classifications: • Job shop, Batch and Mass Manufacturing Automation

  15. Overview of Product Design and Production Engineering Manufacturing Automation

  16. Considerations: • product design - critical design steps • software for drawing, analysis, modeling, simulations, testing and design • Concurrent engineering • design for quality Manufacturing Automation

  17. Product Design • need for automating design process in CIM • generates the initial product data and drawings • Single Enterprise database with a single image of all product information - ENTERPRISE DATA INTEGRATION • Communications:- • LAN - supports inter-departmental design activities • WAN - will link enterprises and their contractors/suppliers Manufacturing Automation

  18. Organization Model • Design team - • product design, analysis, materials selection, documentation (both design and production) • Production engineering • production standards(labor, process, quality) • Integrated Product and Production design – Simultaneous or Concurrent engineering • design and production design considered together • Current trend in the design of complex products such as airplanes (Airbus 380, Boeing 777, 787) Manufacturing Automation

  19. Design Components of Manufacturing Automation Manufacturing Automation

  20. Computer-aided Design – CAD • New parts or alterations to existing parts are designed by means of computer • Definition:- the application of computers and graphics software to aid or enhance product design from conceptualization to documentation • many organizations, CAD is usually introduced as a separate entity Manufacturing Automation

  21. Two broad categories - 2D and 3D • CIM integrates together CAD and all other databases for the organization • Basic CAD system would consist of: • input devices - e.g keyboard, mouse • processing and storage - CPU, storage devices • output devices - monitor, plotter Manufacturing Automation

  22. CAD Data Exchange • Because of the diversity in the various CAD platforms, a need for exchange of data exists • Translators transfers data from one software to another, and CAD to CAM software • Types of formats:- • DXF (Drawing Exchange File) • IGES - Initial Graphics Exchange Standard • STL (steriolithography) format • STEP – standard for exchange of product model data (ISO 10303) Manufacturing Automation

  23. CAD model representations Manufacturing Automation

  24. Current trends in CAD involve • workgroups in which different groups concurrently design different aspects of the product while sharing the data in real time – Concurrent or Simultaneous engineering (Example – Airbus Consortium) Manufacturing Automation

  25. Design Automation : CAE Manufacturing Automation

  26. CAE - analysis, evaluation of engineering design data using computer-based techniques to calculate product OPERATIONAL, FUNCTIONAL, MANUFACTURING PARAMETERS • design process - CAD, DFMA, FEA • production engineering - GT, CAPP, CAM (NC, CNC)

  27. Computer-aided Engineering Evaluation • Evaluation – to determine whether there is a match between the actual design and initial design goals. • Changes can be made based on evaluation • Most commonly used is PROTOTYPING Manufacturing Automation

  28. Group TechnologyComputer-aided manufacturing CAPP Systems Manufacturing Automation

  29. 1. Group Technology – GT • Is not an automation strategy in the strictest sense but provides a framework for implementation of automation • Is a manufacturing concept that justifies small and medium size batch production by capitalizing on design and processing of families of parts • Manufacture centered towards part families selected by code and produced on a set of machines Manufacturing Automation

  30. GT examples Manufacturing Automation

  31. 2. Computer-aided manufacturing • Effective use of computer technology in the planning, management and control of production for the enterprise • Wide range of automation technologies • Started with NC • CNC • Process modeling and simulation • Maintenance automation • Production cost analysis Manufacturing Automation

  32. 3. Computer-aided Process Planning – CAPP • CAPP is the interaction of activities involving the selection of methods of production, tooling, fixtures, sequence of operations and assembly, using computer. • Two types • Variant system – uses pre-existing libraries to create new plans • Generative – uses artificial intelligence to create new plans Manufacturing Automation

  33. Networking • Enterprise network – non-public communications system that allows for data exchange and connect different devices • Can be a few feet to thousands of miles • Production data is essential for control • Electronic communications important for data acquisition • Real time data acquisition the key to effective plant control Manufacturing Automation

  34. Levels of Plant floor communications Manufacturing Automation

  35. Levels - cont • Device - field devices e.g. sensors, valves • Machine - equipment that produce or handle product • Cell - a collection of machines use say for one group of products Manufacturing Automation

  36. Networks • Networks Broken down into • Topology • Star, Ring or Bus • Media or cable type • twisted pair, co-axial cable, fiber optics, radio frequency (wireless) • access method or protocol • Primitive (master/slave), Serial, Ethernet (Internet) Manufacturing Automation

  37. Internet IP addressing • Network devices include: • PCs, printers, sensors, PLCs, etc. • These are NODES • IP address identifies the node • TCP/IP – information (data) movement • TCP – data between applications • IP – data between host computers • IP address is 32 bit numeric written in four segments separated by periods (0 – 255) • E.g 131.256.24.82 Manufacturing Automation

  38. Introduction to Operations Planning, Scheduling and Control Manufacturing Automation

  39. Operating systems: • service • supply • manufacturing • Manufacturing planning and control (MPC): • based on time frames: • Strategic plans - over a year • Aggregate plan - 2 - 18 months • Disaggregate plan - shortest time frame dealing with production issues • A major part of MPC is the last two

  40. Disaggregate planning: • products separated into parts and plans based on these parts for purposes of production • first step is to create a Master production schedule (MPS) from the aggregate plan • braking down production quantities from the aggregate plan into item by item production in the given period of the aggregate plan • A Materials Requirements planning (MRP) translates the MPS into a detailed schedules for RM and parts (usually done by computer) Manufacturing Automation

  41. Board (1) Pressboard (1) Finish (2oz.) Product Structure Tree Clipboard Level 0 Clip Assembly (10) Rivet (2) Level 1 Top Clip (1) Bottom Clip (1) Pivot (1) Spring (1) Level 2 Sheet Metal (8 in2) Sheet Metal (8 in2) Spring Steel (10 in.) Iron Rod (3 in.) Level 3 Manufacturing Automation • Ch 13 - 8

  42. Material Requirements Planning Product Structure File Inventory Master File MRP Inputs & Outputs Master Production Schedule Planned Order Releases Work Orders Purchase Orders Rescheduling Notices Manufacturing Automation

  43. MRP record Manufacturing Automation

  44. Capacity Requirements Planning (CRP) • Computerized system that projects load from material plan • Creates load profile • Identifies underloads and overloads Manufacturing Automation

  45. Capacity Requirements Planning MRP planned order releases Open orders file Capacity requirements planning Routing file Load profile for each machine center Manufacturing Automation

  46. Management of product data • PDM – manage product design and manufacturing data • PLM – Product lifecycle management • Product design data, delivery to customers Manufacturing Automation

  47. The Revolution in Manufacturing – Just-In-Time manufacturing

  48. JIT • Philosophy of manufacturing based on elimination of waste, and continuous improvement • All aspects from design to delivery • Just the required inventory, when needed • Zero defects in quality • Other terminologies for JIT • Short-cycle manufacturing • Stockless production • Zero-inventory manufacturing Manufacturing Automation

  49. JIT Elements Manufacturing Automation

  50. Toyota’s JIT system Objective 2 Objective 1 Manufacturing Automation

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