Huseyin OZDOGAN

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How Does CIM Improve Process Planning and
Scheduling

• Huseyin OZDOGAN
• Kivanc DONERTAS
• Kani Furkan KACAR
• Gulsen SILAYDIN
• Mehmet DEMIRKIRAN

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What is CIM

• A full computer integrated manufacturing
• system is one that would, or could, originate
• from design through to some sort of CAM
• that would set the machine, set batch sizes if
  you like and organize the tooling
• automatically

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INTRODUCTION

• Computer Aided Process Planning(CAPP) aids in
  creation of process plans in manufacturing.
• Process planning can be defined as the function
  which establishes the sequence of the
  manufacturing
• equipment and/or machine tool selection.

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• CAPP systems helped to reduce the labor
• And required of process planners.
• Today - CAPP systems serve to integrate all
• functions within process planning.
• computer-aided manufacturing applications
• such as CAD and CAM.

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Group Technology (GT)

• Product classification system

Product Family
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• Methods to computer aided process planning
• Computer aided process planning is carried out
  with utilization of two major methods
• - variant method,
• - generative method.

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• The variant method
• each part is classified. The code and the process
  plan for each part are stored in a data base.
• family of parts
• The variant approach might be useful in a case
  where there is a great deal of similarity between
  parts.

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Variant Process Planning
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• The GENERATIVE method
• there are no process plans stored in the data
  base. Instead, the data base contains information
  about parts, machines, tool, and process planning
  rules.
• Ideal for processes that may produce wide
• varieties of parts.
• Usually, generative methods input such as CAD.

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Generative Process Planning (Contd)

• Decision tables provide a convenient way to
  document manufacturing knowledge.
• Decision making logic and algorithms
• Decision trees

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Variant CAPP vs. Generative CAPP

• Variant
• Standard process plans for part families
• GT code used as key in retrieval
• Human modification needed
• Easy to develop but not suitable for new parts
• Generative
• No standard process plans
• No human intervention (Movie)
• Part data transformed into computer by GT code
• Process plans generated by built-in decision
  rules
• Difficult to develop but new parts easily planned

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SAP
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• Sales forecasting is managed by the Demand
  Modeller (DM), Business Optimizer (BOP) and Order
  Negotiator Availability-To-Promise (ON-ATP)
  products, which receive sales information from
  SAP R/3 with details of sales orders that have
  been taken. The Business Optimizer for example,
  determining the best time for blast furnace
  maintenance etc.
• In the Planning phase, the Production Planner
  (PP) controls the loading of the plant and
  allocates sales orders to each resources
  constraints and the customer due date. Material
  Planner (MP) then allocates the required
  materials for each stage of the process and the
  Production Planner will then ensure that it
  builds intermediate stocks to take account of any
  expected down-time event. This allows the plant
  to fit the best order to the best in-process
  material leading to major stock reductions. Plate
  Combinations (PC) provides an optimized plan for
  the cutting pattern for plates, leading to
  reductions in scrap, improved output and better
  deliveries.
• Outputs from Planning components feed into the
  Scheduling phase

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• Production Scheduler (PS) uses a combination of
  simulation and optimization techniques to
  synchronize the scheduling of all machines to
  achieve the optimum balance of operational
  constraints with commercial priorities.
• Caster Scheduler (CS), Hot Mill Scheduler (HS)
  work together to provide detailed scheduling for
  the caster plant and the hot mills, leading to
  reduced costs, increased productivity, and better
  customer service through balancing liquid steel
  making with casting, rolling and finishing.
• On-Line Co-ordinator (OLC) takes process data in
  real-time from the caster and other production
  equipment so that this can be fed back into the
  scheduler and make on-the-fly adjustments to
  reflect what is actually happening in the
  production process. The OLC can resolve conflicts
  by re-scheduling liquid steel production to
  ensure continuous caster operation.
• Dispatch Scheduler (DS) manages the dispatch
  process taking into account the outputs from the
  production line and warehouses, type and
  availability of transportation dependent on
  product, destinations and delivery times. The
  Dispatch Scheduler exchanges data with the SAP
  R/3 system which is responsible for raising
  transport orders, issuing tax receipts, and
  managing the execution of the delivery process to
  the customer.

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Planning and Scheduling

• Demand Modeller (DM)
• Business Optimizer (BOP)
• Order Negotiator Availability-To-Promise (ON-ATP)
  products
• Production Planner (PP)
• Material Planner (MP)
• Plate Combinations (PC)
• Production Scheduler (PS)
• Caster Scheduler (CS) and Hot Mill Scheduler (HS)
  
• The On-Line Co-ordinator (OLC)
• Dispatch Scheduler (DS)

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What is scheduling?

• In factory scheduling, resources are machines and
  activities are operations that can be processed
  in those machines.
• In a manufacturing facility, the input to a
  scheduling system is generally derived from the
  current location of jobs in the system, the
  process plans describing the sequence of
  operations each job needs to undergo, due dates
  for the jobs and the state of the machines to
  process them (e.g., up or down, current setup
  status) , together with some estimates of
  uncertain events that may occur over the time
  period in the future covered by the scheduling
  decisions to be made. The output from the system
  will be the set of job / machine / time
  assignments for a given time horizon.

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taken from Lecture note
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CIM cannot occur until this process is automated
consequently, automated process planning is the
link between CAD and CAM.
CAM
CAD
Process design Process planning (CNC codes) Tool
selection Facilities management
Conceptual design Mathematical analysis Geometric
data (graphical representation)
CAPP COMPUTER AIDED PROCESS PLANNING
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A computer-aided process planning framework
(CAD-CAM)
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Calandering Machine
Example of Real Case
An Example from Training
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Before GT, and Integration of Computer
Production
Production Manager
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After GT, and Integration of Computer
Production Manager
Production
Sales Department / Marketing
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Conclusion-CAPP Benefits

• Reduces process planning times
• Enables faster response to engineering changes
• Lowers costs
• Increases effiencies
• Enhances quality and clarity
• Reduces confusion and errors

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THANK YOU!!!