World Class Technologies for Manufacturing

1. World Class Technologies for Manufacturing World Class Technologies for Manufacturing Patrick J. Delaney, CFPIM, CIRM, CPM

2. National Manufacturing Week Chicago McCormick Place February 23-26, 2004 • Manufacturing Enterprise Automation • Manufacturing Process Automation • Product Design Automation • Facility Security & Automation • Data Capture and Data Tracking Automation

3. Computer-Integrated Manufacturing Rehg & Kraebber, Prentice Hall, 3rd Ed. 2004 • Purdue University • 30 Engineering Schools • Manufacturing Technology Program

4. Are You Ready To Go ?

5. The Untouched Processes

6. World Class Technologiesfor Manufacturing • Electronic Commerce [www.com+EDI] • Internet Supply Chain Systems Suite • Enterprise Resource Planning Systems • Advanced Planning & Scheduling Systems • Integrated ERP/CRM/SRM • Wireless WANs [over 30 miles] • RFID Tracking Technology • Global Tracking Systems • Internet B2B Server Applications • Sales & Field Force Automation [SFA] • Mobile Connectivity [MC] • Computer Aided Design CAD/PLM • Computer Aided Manufacturing [CAM] • Manufacturing Automation Controllers • Device and cell controllers

7. DuPont Innovation • Automotive Coatings Technology • Wet on Wet Paint Systems • Rust coating • Primer coat • Color coat • Clear coat • Final stage oven dry

8. Robotic Evolution • Hydraulic in early 1980s • Electric/electronic today • Newer vision systems • Higher accuracy & repeatability • Proprietary controllers [Motorola] • Advanced CAD/CAM • Simulation • Greater path accuracy [0.05mm] • Dual robotic cells • Jig-less manufacturing Betty Boop

9. Manufacturing Software Development Path MES APS SFC ERP/ERO MRP II Inventory control MRP CRM Order Entry SFA DRP Forecasting SCM

11. Supply Chain Event Managers [SCEM] i2 Global Logistics Monitor • Monitor all E-commerce transactions • Business rule based • Create action messages and flags • Check each event for validity and accuracy • Accommodates all trading partners • Order status, shipping, inventory, billing, etc. Computer Associates BizWorks

12. Ford Case Internet CAD • E-commerce graphics application • Internet transfer of engineering documents & graphics • Utilizing a translation software to interface with incompatible supplier applications

13. Daimler-Chrysler Case • Laser based 100% inspection • Automatic collection of SPC data • Line stopping feedback • Machine analysis and preventive maintenance warnings • Bi-lingual inspection instructions • Automated display of ISO 9000 procedures • Intranet sharing of QA data across plant sites

14. Honda Supplier • Inbound items are bar-coded • Outbound items are bar-coded • WIP isn’t bar-coded • Warehouse isn’t bar-coded • Cycle counts daily • Physical inventory every 30 days

15. Old Rand-McNally Publishing Co. Case Cycle Counting Approach • Largest printing plant in the U. S. • Very large warehouses • F.G. Four racks high • Lose signatures • Cycle counters • Flashlights • Binoculars • Computer print out

16. Data Capture Devices • Hand held devices • Pen based devices • Scanner/data input devices • RFID tracking • ERP integrated • Windows CE - OS • Finger size point & scan • Micro-chip theft control • Electronic asset tracking [EAT] • Rackrunners • MicroStamp RFID Technology

17. Voice Recognition Technology InfoWorld 100 Technology Winner 2003 • Warehouse picking application • Headset communications • Belt clip display system • Two-way communications • Improved pick accuracy to one error in 3,000 picks

18. Technology Assessment Team • Technology Assessment • Investment priorities • Integration issues • Benchmarking study • New employee profiles • Technology training • Payback measurements • University relationships • Technology Vision

19. Today’s Typical Systems Environment • Most technologies are only partially implemented or interfaced • Budget constraints constantly cut back deployments • Acquisitions & divestments force major steps backward • E-commerce skill sets are weak • Short term needs interfere with obtaining quality deliverables • End to end supply chain initiatives have overwhelmed the development queue • Outsourcing has built more islands of automation

20. World Class Technologies Assessment A C SOPHISTICATION B D INTEGRATION

21. Today’s Purdue Graduates • Database structuring and administration [Quick BASIC, C+] • Design techniques of Expert Systems [PC Easy & EXSYS] • PC based ERP • Distributed system design & networking • Hands-on PLC programming [programmable controllers] • Apply CAD and CAE software tools • Work in a $10 million CIM laboratory • CIM software • CNC workstations • automated materials handling with robots • automated data capture [RFID] • vision systems

22. PPR Hub Process Planning Robotics Production System Ergonomics Product Process Resource Efficiency HUB Cost Analysis QA Scheduling & Control Factory Flow Simulation System Integrators: Rockwell/ IBM/ Dassault/ ABB/ EDS/ MIT

23. National Manufacturing Week Chicago McCormick Place February 23-26, 2004 www.manufacturingweek.com • What industries are using your product? • What new features have been added to your product since last year? • What are the integration features of your product?

24. Speaker Contact Data • Patrick J. Delaney NWU Research Park • E:mail: SIBCCorp@aol.com • Phone: 1-800-806-5177