Computer Integrated Manufacturing Department of Industrial Systems

Computer Integrated Manufacturing Department of Industrial & Systems Engineering

Production System

Four major production types 1) 2) 3) 4) 개별공정 흐름공정 프로젝트 연속공정 (job shop) (flow shop) 공정 (project shop) (continuous shop)

Job Shop Layout

Manufacturing time in Job shop

Robot Centered Cell

Production Types by Quantity • 1) Low production ; Less than 100 item • 2) Medium production ; 100～ 10, 000 item • 3) High production ; greater than 10, 000 item

Production Quantity VS Variety

1) Low Quantity Production • job shop type, customized product, large variety of product type • ex) space capsules, airplane, special purpose machine • maximum flexibility

1) Low Quantity Production • fixed position layout type (big product) • process layout type – functional layout lots of movement and WIP

2) Medium Quantity Production • product range 100～ 10, 000 item • Large product variety; batch production type

2) Medium Quantity Production • Facility changed after I production, order repeatable • production rate higher than single product type • Facility utilized commonly by lines • Batch changing time is required for setup time (changeover time)

2) Medium Quantity Production • Product variety is not large • When setup time is small, various part groups are produced in a facility • Cellular layout type composed with various machines and work stations

3) High Quantity Production • mass production (greater than 10, 000 items) • i) quantity production : production with a single machine • Production with specialized purpose machine

3) High Quantity Production • ii) flow line production • Composed with several workstation • Each workstation composed of special machine • Conveyor belt used • ex) automobile, appliance assembly • Good for single model production

Production Types (discrete product)

CIM Background • Various tastes of customers • Reduction of cycle time • Requesting integrated systems for improving both technology and quality

Computer Integrated Manufacturing? • Integrated systems of functions in factories that are production, marketing, order, design, production control, inventory control, quality control, inspection, shipping, through communication and producing technology

CIM Model

CIM • Computer – database • Integration – Network • Manufacturing – rapid development of new products • CIM; conceptual rather than physical • Island of Automation; partly automated but not integrated • Objectives of CIM; managing enterprises

Elements of CIM • Information technology: Computer, Communication, Control • Manufacturing technology: Manufacturing, Market, Management • 3 Cs support 3 Ms

Elements of 3 Cs • Computer: IT, OS, programming language, database, artificial intelligence • Communication: communication technology, MAP, TOP, LAN, VAN • Control: control technology, algorithm, S/W for control

Targets of CIM • Developing high quality products with low cost • Integration and control of product design and manufacturing processes • Easy financial management • Increasing volume of sales

Benefits of CIM • • • Marketing Engineering design Research and Development Manufacturing processes Financial planning

Manufacturing system • Manufacturing system: facility + production technology + management • Applying GT, CAPP, TMS to Production technology • Applying MRP, JIT to Management • Wide manufacturing system: facility + production technology + management + product design + business plan

Integrated Production System(ex)

Factory automation CIM philosophy automation optimization target unmanned factory rationalize example FMC, FMS Linking CAD, CAM, MRP element processing, material flow, measurement, inspection, assembly, CAD, CAM, CAPP, CAQ, MRP target factory enterprise focus hardware software human origin replacing human Japan reorganization USA, Europe

Function of CIM 1) Order information and automatic scheduling through computer - dealing individual orders of various products - control of due dates - preparing production planning 2) Inventory control through JIT - minimizing raw material, WIP, inventory - utilizing bar code, RFID

3) Statistical quality control - quality improvement 4) Monitoring facility, process - data collection for facility operating - report for producing defective goods - records & analysis of failing facility

5) Data collection for MIS - WIP data - shipment data - direct & indirect labor data - production control data ; defective rate, operation rate, failure rate, production rate - supplier record; quality, acomplishment - defective production data

6) Managing MIS Data - reducing indirect cost - rapid decision making using database 7) Diagnosing failure - minimizing down time - details of failure (problems)

8) Managing Technical Data, Document - managing S/W program - tool life data - quality data - product history - document update 9) Standard

CIM Hierarchy • 1 st Level: production facility CNC, Robot, PLC • 2 nd Level: Work Cell controlling 1 st level activity applying data from 1 st to process, production, quality control

• 3 rd Level: Area level managing several lines production plan, facility maintenance scheduling, assigning material, facility • 4 th Level: Factory level controlling function of whole factory, inter-factory sales control, wages, finance, long term production plan, marketing, customer services

Standardization for CIM • Capability of information transfer for different types of facilities CIM Standard ISO standard – 6 levels: Enterprise, factory, area, cell, station, equipment

Manufacturing Automation Protocol - GM • Communication b/w different types of facility • Factory level network for machine device, robot, PLC, Computer • 7 levels

Technical & Office Protocol – Boeing, NBS • Data communication for different types of devices b/t office and design • Spread sheet, draft drawing, design, business document, e-mail

Initial Graphics Exchange Specification – ANSI, NBS • Data communication b/t CAD system • Neutral data file for data transformation b/t different CAD system

Product Data Exchange Specification – NIST • Transformation of product information for different CAD system • Shape feature – design element • Non-shape feature – processing, inspection, assembly, material, heat treatment, strength

Standard for External Representation of Product Data • ISO Workgroup TC 184/SC 4 • International standard for representing product model and data exchange format

Function of CIM • Upper Level – Planning, management, control – discrete time information slow response time • Lower level – action - continuous time information rapid response time

Upper Level Allocation

Enterprise System • Production planning & control • Information technology management Plant Control System • Scheduling • Material resource planning • Quality control

Optimization at Upper Level • • • Production plan N production center – m types of products B 1, b 2, ……. bm Linear programming • S. t.

Transportation Plan • From L warehouse to k warehouse, • e 1, e 2, e 3, …………, ek transport • Linear programming

Elements of Upper Level of CIM at Enterprise, Factory, Area • CAPP • MRP • Capacity Planning

Computer Aided Process Planning • • • Priority for process Machine tool, process parameter Not consistent for manual planning Retrieval type – GT code Generative type

Generative Type • • • process plan for each part Logic for process planning 3 D model for product information Utilizing Group Technology Logics for process planning and product information are integrated in database system

Material Requirement Planning • Inventory control for raw material, WIP, parts • MRP - master production schedule file - Bill of Material file - MRP software for application

Capacity Planning • Evaluating manufacturing capacity • Allocating machine, facility, work personnel to MRP • Information for Capacity Planning - production plan from MRP - processing order - work order specification - facility - man power

Function of CIM at Lower Level • Cell, Station, Device Level • Cell Controller - production schedule from area level - program selection for task - down load the program

Function of CIM at Lower Level • Station Controller - Managing PLC, Robot, CNC, sensors - Controlling devices - Controlling processes - Monitoring processes

Function of CIM at Lower Level • Devices level - CNCs, Robots, PLCs, Sensors, Conveyors

Constructing Steps for CIM 1) Controlling production processes - automation for order, supply, manufacturing, inspection, packing, shipping - integration of manufacturing and office management 2) Constructing communication network and database

Constructing Steps for CIM 3) Automated processes, assembly, production Reengineering for design 4) Development and manufacture of automated processing facilities Adopting automated recognizing system

Constructing Steps for CIM 5) Enabling CIM for enterprises with business relationships 6) Introducing: Top down Action: Bottom up

Obstacles for CIM 1) Communications b/t various companies of suppliers 2) Automated facilities independently 3) Weak solutions

Investment for CIM • • Marketing: managing customers’ report Engineering Design: using CAD R&D: developing new products Manufacturing process: process planning, scheduling, reducing manufacturing lead time • Financing: costing

Advantages of CIM 1) Reducing developing time for new product 2) Reducing transporting time 3) Optimal inventory control 4) Reducing planning time for production 5) Reducing lead time for production 6) Rapid response for customers’ claim 7) Quality improvement 8) Increasing competitive power

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