ME 522Computer Integrated Manufacturing

1
ME 522-Computer Integrated Manufacturing

• Objectives for Today
• Organization and Introductions
• Review Syllabus
• Teams and Times for Labs
• Introduction to CIM and Beyond

2
Computer Integrating Manufacturing An
Introduction

• Manufacturing (or Production) The process of
  converting raw materials into products that have
  value in the marketplace
• With this definition, who's in charge in a
  business design, manufacturing, marketing, ?
• What gives something value in the marketplace?
• What do automation, integration and computer
  systems have to do with adding value

3
Manufacturing Paradigms
Next Generation Systems 1990s and
Beyond Small Low Excellent Short High
High
Craft and Custom Up to Present Small High
Variable Long High Low
Mass Production 1800s to Present Very
Large Low Good Long Low Low
Automated Production 1950s to
Present Moderate Moderate Good Moderate
Moderate Moderate
How What
Timeframe Quantities Unit Costs Quality De
livery Times Flexibility Environmental Conscio
usness
4
Functions of Manufacturing Operations
Finished Product
Designs, Materials and Subassemblies
Processing Assembly Material Handling
Inspection and Test
Receiving
Shipping
Control
5
Some Control Loops and Manufacturing Terms
Max Production Rate
Inventory Management
Product Requirement
Production Schedule
Capacity/ Master Scheduling
Final Product
Work Station
Assembly
Parts
Process
Center
Factory
Cell
Product Quality
Station Performance
Average Tardiness
Inventory
Profitability
6
Classifying Manufacturing/Production
Volume/Variety Matrix
Continuous Flow Processes (paper)
Product Quantity or Batch Size
Mass Production (automobiles)
Batch Production (chain saws)
Job Shop Production (aircraft)
Product Variety or Part Numbers
7
Where the Time Goes In Mid-Volume Metalworking
28 - Plant Shutdown
40 - Incomplete 2nd and 3rd Shift
6 - Equipment Failure 7 - Setup 7 - Tool
Change 4 - Load/Unload, Other
8 - Productive Machining
8
Manufacturing Costs
9
Traditional Functional Organization of
Information and Departments
10
Bring On the Acronyms
11
Acronyms and Abbreviations from A TO ? (Manager's
Guide)

• AGV Automatically Guided Vehicle
• APT Automatically Programmed Tools
• AS/RS Automated Storage and Retrieval System
• BUE Built Up Edge
• CAD Computer Aided Design

• CAPP Computer Aided (or Assisted) Process
  Planning
• CIA Computer Integrated Assembly or Central
  Intelligence Agency
• CIM Computer Integrated Manufacturing
• CMM Coordinate Measuring Machine

12
Acronyms and Abbreviation from A TO ? (Manager's
Guide)

• DFA(M or X) Design for Assembly (or Manufacture
  or Anything)
• DNC Direct (or Distributed) Numerical Control
• EDM Electrical Discharge Machining
• FMS (Flexible Manufacturing (or Machining) System

• GT Group Technology
• JIT Just in Time
• KBS Knowledge Based Systems
• LAN Local Area Network
• MAP Manufacturing Automation Protocol
• MRP Manufacturing Resource (or Requirements)
  Planning

13
Acronyms and Abbreviation from A TO ? (Manager's
Guide)

• CNC (Computer) Numerical Control
• OC Curve Operating Characteristics Curve
• PC or PLC Personal Computer or Programmable
  (Logic)Controller
• QC(A) Quality Control (or Assurance)
• QTAT Quick Turn Around Time

• ROI Return on Investment
• SCARA Selective Compliance Assembly Robot Arm
• SPC Statistical Process Control
• TOP Technical and Office Protocol
• WIP Work In Process
• U V and X - Z Open to suggestions

14
Paradigm Shift to Agile?Some Definitions
Brooke (1993)
A manufacturing concept that goes beyond lean
production.
An organizational strategy that provides quicker
decisions and produces a greater variety of new
products faster and cheaper
In an 'agile enterprise', products will be built
quickly and cheaply for a customer based on
detailed data received at point of sale.
A system that can fabricate different objects
simultaneously, without having to shut down for
retooling.
15
What's Agile?Some Attributes
Flexible tooling and automation
Flexible strategies and relationships with
suppliers and sometimes competitors, to form
virtual companies
Deep understanding of the customer
A multi-skilled, flexible labor force. Where
blue- and white-collar have similar educational
levels
Integration of technology, management and
workforce into a coordinated independent system
Excelling at multi-disciplinary teamwork
Mastery of "lean" production and simultaneous
engineering
16
The Global Manufacturing Environment

• Customer driven global markets customers want
• Innovation
• quality and reliability, and
• they want it NOW!
• Competitive firms have to deliver products
• that both sell and are produced globally,
• using a work force with different experience and
  training, and
• do it QUICKLY!

17
Enabling Technologies
Information, Computing and Networking Technology
Advanced Processes and Equipment
Organizational, Management and Business Concepts
Product, Process and Enterprise Design Tools
Intelligent Controls, Sensors and Actuators
18
Agile Technology

• Responsiveness to customers, markets and
  operational opportunities.
• Technology areas that reduce lead-time may be in
  areas that traditionally were the realm of the
  blue collar skilled trades.
• Underlying these technologies must be
  understanding that can be modeled this an age of
  virtual prototypes.

19
The Practical Problem
Systems Like This Have to Wait
for These
20
Agile Technology
Production Volume Machining Operation Workpiece
Material Workpiece Geometry
Fixturing Features Designed Into the
Part Availability of Standard Fixturing Elements
Surfaces/Points for Locating, Clamping
Supporting Design/Selection of Fixturing Elements
Complete Assembly Clamping Forces Sequence
Fixture Design System
Machining Features Machining Sequence Machining
Accuracy Operator Safety
Analytical Tools Heuristic Rules Expert
System Machining Simulation Optimization
Techniques Finite Element Analysis
Meshing/Remeshing
21
Some of the Issues

• Locating relocating
• Supporting
• Clamping
• Deflections
• Accessible
• Robust
• Prototypes
• Component design

22
Computer Integrated Manufacturing

• How This All Fits Into the Course
• This will be different than most courses you have
  taken, it will really be 2 or 3 courses, where
  the objective is to broaden your thinking.
• you'll learn a little about technologies and
  methodologies (enough to be dangerous) that you
  may want to follow up in more specialized courses
• The project and labs are key part of the course
  you will teach yourself by doing some research,
  design or engineering analysis and doing it as a
  member of a team