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Design for Production in Existing Facilities (DPEF)

A study on how to efficiently produce a new product using existing production resources. Includes analysis of production costs, reallocation of production, modification of design, and acquisition of additional resources.

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Design for Production in Existing Facilities (DPEF)

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  1. Design for Production in Existing Facilities (DPEF) Richard A. Wysk The Pennsylvania State University IE550 Manufacturing Systems

  2. Design for Production in Existing Facilities (DPEF) • Given: • a product design, • the expected production requirements for the new product, • a set of production resources and the current configuration (production lines, cells, etc.), and • the expected requirements for the products currently being produced,

  3. Design for Production in Existing Facilities (con’t) • Answer the following questions: • Can the new product be produced in the required quantities given the current production allocation? • if so, what are the expected production costs ? • if not, can the current production be reallocated such that all of the production requirements can be met? • if not, can the design be modified to enable production within the current resource structure? • if not, how should additional resources be acquired to meet the production requirements?

  4. How it’s done today: Parametric-based Feature Information • Feature information (Intra-feature specifics) • Dimensions • Size Tolerances • Surface Finishes • Geometric Tolerances

  5. Product, Process and Production Models Product Engineering Library of features Feature interactions Process Engineering Process / Feature links Inter-feature linkages Inter-process linkages Production Engineering System Specifics Machine Specifics Fixture Specifics Tool Specifics

  6. Production Resource Constaints • Geometric Constraints • Machine Constraints • Jig/Fixture Constraints • Tooling Constraints • Process Constraints

  7. Key Process Planning Features • Plans based on Feature Precedence Graph • Generates AND/OR Graph • Collects the resource data from Databases • Is independent of Decision Table

  8. Example: Threaded hole (.250-20 UNF Class 3) • Process alternatives • Drill -> Tap • Drill -> Thread cut • Drill -> Thread form • Process plans • Drill ---> NxxG00G91X@locY@locZ@locM06 NxxG01Z-@sizeF50 NxxG01Z@sizeF100

  9. Process Planner Process Planning Design Station

  10. SL-20 Turning Center Facing Turning Drilling Reaming Boring Tapping Threading Processes • VF-0E Machining Center • Milling (Face/end-milling) • Drilling • Reaming • Boring • Tapping • Threading • Engraving (Ball-mill)

  11. AND/OR Graph Generator • Creates an AND/OR Graph Representation of a process plan • Fills out Processing Node Information • PNI is used by NC code Generator • Covers MP, MT, MH and AS/RS nodes

  12. Example Part • Cylindrical Part • Center Hole • Bolt Holes • Contour • Thread

  13. Process Plans • Shop level plans Dr Tr1 MT MT MT MT Tr2 Ml

  14. Process Plans • Workstation level plans SL-20 VF-0 MH MH MH MT VF-0 VF-3 Workstation #2 Workstation #1

  15. Process Plans (cont.) • Equipment Level Plans (Drilling) Dr1 Tp1 Tp2 Fx Dr2 Fx Dr3 Tp3 Dr4 Tp4

  16. Decision Maker • Contains the hierarchical constraints • Machine • Fixture • Tool • Process • Feature • Can be updated indendent of Process Planner

  17. Decision Information

  18. IPPE Concept Process Planning System Production Analysis System Design Model Process Model CAD System Resource Model Instance

  19. Machines Jigs/Fixtures Toolings Layout Decision Table Process Planner STEP or STEP-like PSL or PSL-like Feature AND/OR Information Graph Process Planning IBM Compatible IBM Compatible Design Station Manufacturing Resource Model

  20. Multi-facility Planning and Analysis WWW Resource Model Instance Resource Model Instance Resource Model Instance Resource Model Instance Inquiries Production Orders

  21. Technological Hurdles • Process Planning • Given a part design, what are the processes, tools, fixtures, etc. required to manufacture the part. All feasible alternatives should be explicitly represented. • Production Planning and Analysis • Given a set of production resources and a set of production requirements with the associated process plans, how should the production be allocated among these resources in order to efficiently satisfy the requirements.

  22. Resource Model • A set of definitions and symbolic descriptions that are used to completely describe the individual resources in a facility as well as the possible interactions between these resources. • A resource model instance describes a specific facility and its resources.

  23. t =E(t + t ) j j + t + t + t j P m c i setup L/UL A j j t setup j t j t m t c t i the time required for setup for an operation (load fixture, retreive tooling , etc.) the time required to load and unload a product for feature operation j (chuck, fixture, etc..) L/UL the machining/processing time for feature j tool change time/part idle time due to scheduling control

  24. t t t = t t + + + p m ch set l/ul Performance Metrics Production time per piece • The cost associated with new tooling is also a key consideration • for the designer. • For low and medium volume products, the cost associated with • tooling and setup can dominate the total product cost.

  25. Concept of a manufacturing system resource model [ Wysk, R.A., Peters, B.A., and Smith, J.S., “ A Formal Process Planning Schema for Shop Floor Control ” ] • Resource Model - set of definitions and symbolic descriptions that are required to completely describe all of the individual resources in a facility as well as the necessary interactions between these resources

  26. Terminology • Resources (R) : Collection of assets in the facility directed towards the manufacture of the products. Includes equipment, tools, fixtures, transporters, and instruction sets • Locations (L): A precise physical location associated with a port and a part. Locations are used to link the transfer of parts between equipment types. Each location has an owner and a set of clients that can address that location • Ports (P): Ports are nodes in the graph defining the paths parts can follow through the facility (note: Graph shows the connections between the resources in the facilities • Arcs: Show which ports can be directly accessed from a particular port • Facilitator: A device than can move transporters between different ports on the MT system or move parts between a port on a MT system and a port on a MP

  27. Example... MP 3 MT 1 3 3 4 4 1 MH 1 1 MH 1 2 2 MP 2 Ports, Locations : 1,2,3,4 Resources: MP2, MP3 (type MP) MT1 (type MT) MH1 (type MH) Facilitator : MH1 Arcs between : 1-2, 2-1, 1-4, 4-1, 4-3, 3-4, 2-3, 3-2 ( represent connections between the resources )

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