Manufacturing Processes for Engineering Materials 5 th Edition

Manufacturing Processes for Engineering Materials (5 th Edition in SI Units) Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Computer-Integrated Manufacturing • Computer-integrated manufacturing (CIM) describes the computerized integration of product design, planning, production, distribution and management. • CIM depends on usage of a large-scale integrated communications system. • Requires extensive database containing technical and business information. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Computer-Integrated Manufacturing • CIM systems consists of subsystems that are integrated as a whole, such as: 1. Business planning and support 2. Product design 3. Manufacturing process planning 4. Process automation and control 5. Factory-floor monitoring systems Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Computer-Integrated Manufacturing Benefits 1. Shorter product life cycles 2. Product quality and uniformity 3. Better use of resources 4. Better control of the processes Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Computer-Integrated Manufacturing Some examples: 1. Computer aided design and manufacturing (CAD/CAM) 2. Computer numerical control (CNC) 3. Adaptive control (AC) 4. Industrial robots for assembly 5. Automatic control 6. Computer-aided process planning (CAPP) 7. Group technology (GT) 8. Just-in-time production (JIT) Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Computer-Aided Design and Engineering • Computer-aided design (CAD) uses the computers to create design drawings and geometric models of products and components. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Elements of computer-aided design systems • CAD system consists of four stages: 1. Geometric modeling • Constructs geometric mode with lines and dimensions. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Elements of computer-aided design systems 2. Design analysis and optimization • Design is subjected to an engineering analysis. 3. Design review and evaluation • Review and evaluation to check for any interference among various components. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Elements of computer-aided design systems 4. Documentation • Detailed, working drawings are developed and printed. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Computer-Aided Manufacturing • CAM involves the use of computer technology to assist in all phases of manufacturing. • CAD/CAM systems allows information transfer from design to planning stage. • Advantages of CAD/CAM are: 1. standardizing product development 2. reducing the effort of designing, evaluation and prototype work Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Computer-Aided Process Planning • Process planning involves selecting methods of the sequence of operations, processing time and methods of assembly. • Computer-aided process planning (CAPP) view total operation as an integrated system, so that individual operations are coordinated with each other. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Elements of computer-aided process-planning systems • 2 types of CAPP systems: 1. Variant System • Computer files contain a standard process plan for a particular part to be manufactured. 2. Generative System • Process plan is automatically generated on the basis of the same logical procedures. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Elements of computer-aided process-planning systems Advantages of CAPP systems 1. Standardization of process plans improves the productivity. 2. Process plans can be prepared. 3. Process plans can be modified. 4. Routing sheets can be prepared. 5. Other functions can be incorporated. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Computer Simulation of Manufacturing Processes and Systems • Process simulation takes 2 forms: 1. Optimizes or improves performance. 2. Analyses multiple processes and their interactions. • Simulation helps engineers to organize and to identify critical machinery. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Computer Simulation of Manufacturing Processes and Systems • Process simulation takes 2 forms: 1. Optimize or improve performance. 2. Analyse multiple processes and their interactions. • Simulation helps engineers to organize and to identify critical machinery. • Able to conduct ergonomic analysis of various operations and machinery setups. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Group Technology • Group Technology (GT) is a concept to take advantage of design and processing similarities among the parts that are to be produced. • Attractive to consumer demand for variety of products which requires batch production. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Cellular Manufacturing • Group technology consists of one or more manufacturing cells. • Manufacturing cell is a small unit consisting of one or more workstations. • Cellular manufacturing used in material removal, sheetmetal forming operations and polymer processing. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Flexible Manufacturing Systems • In FMS all elements of manufacturing are integrated into an automated system. • Different computer instructions can be downloaded for each successive part that passes through a workstation. • Can handle a variety of part configurations and produce in any order. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Flexible Manufacturing Systems Elements of FMS 1. Workstations 2. Automated handling and transport of materials and parts 3. Control systems • System capable of transporting raw materials, blanks, and parts in various stages of completion anytime. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Just-in-Time Production • JIT concept has the following goals: 1. Receive supplies just in time to be used. 2. Produce parts just in time to be made into subassemblies. 3. Produce subassemblies just in time to be assembled into finished products. 4. Produce and deliver finished products just in time to be sold. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Just-in-Time Production • 1. 2. 3. 4. This approach emphasizes: Worker pride and dedication Elimination of idle resources Teamwork Advantages of JIT: Low inventory-carrying costs Rapid detection of defects Reduced need for inspection and reworking of parts Production of high-quality parts at lower cost Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Lean Manufacturing • A systematic approach to identifying and eliminating waste in every area of manufacturing. • 1. 2. 3. Helps identify whether the activity: adds value adds no value but cannot be avoided adds no value but can be avoided Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials

Artificial Intelligence • • • 1. 2. 3. 4. 5. AI concerned with systems that exhibit some characteristics are usually associated with intelligence in human behaviour. Has impact on the design, automation and overall economics of manufacturing operations. AI encompasses the following: Expert systems. Natural language. Machine (computer) vision. Artificial neural networks. Fuzzy logic. Chapter 15: Computer-Integrated Manufacturing Systems © 2008 Pearson Education South Asia Pte Ltd Manufacturing Processes for Engineering Materials