World Class Technologies for Manufacturing Patrick J Delaney

World Class Technologies for Manufacturing Patrick J. Delaney, CFPIM, CIRM, CPM

World Class Technologies for Manufacturing National Manufacturing Week Chicago Mc. Cormick Place February 23 -26, 2004 n n n Manufacturing Enterprise Automation Manufacturing Process Automation Product Design Automation Facility Security & Automation Data Capture and Data Tracking Automation

World Class Technologies for Manufacturing Computer-Integrated Manufacturing Rehg & Kraebber, Prentice Hall, 3 rd Ed. 2004 Purdue University n 30 Engineering Schools n Manufacturing Technology Program n

World Class Technologies for Manufacturing Are You Ready To Go ?

World Class Technologies for Manufacturing The Untouched Processes

World Class Technologies for Manufacturing n n n n Electronic Commerce [www. com+EDI] Internet Supply Chain Systems Suite Enterprise Resource Planning Systems Advanced Planning & Scheduling Systems Integrated ERP/CRM/SRM Wireless WANs [over 30 miles] RFID Tracking Technology Global Tracking Systems Internet B 2 B Server Applications Sales & Field Force Automation [SFA] Mobile Connectivity [MC] Computer Aided Design CAD/PLM Computer Aided Manufacturing [CAM] Manufacturing Automation Controllers Device and cell controllers

World Class Technologies for Manufacturing Du. Pont Innovation n Automotive Coatings Technology Wet on Wet Paint Systems l Rust coating l Primer coat l Color coat l Clear coat Final stage oven dry

World Class Technologies for Manufacturing Robotic Evolution n n Betty Boop Hydraulic in early 1980 s Electric/electronic today Newer vision systems Higher accuracy & repeatability Proprietary controllers [Motorola] Advanced CAD/CAM Simulation Greater path accuracy [0. 05 mm] Dual robotic cells Jig-less manufacturing

World Class Technologies for Manufacturing Software Development Path APS MES SFC Inventory control MRP II MRP Order Entry Forecasting ERP/ERO SFA CRM DRP SCM

World Class Technologies for Manufacturing

World Class Technologies for Manufacturing Supply Chain Event Managers [SCEM] i 2 Global Logistics Monitor n n n Computer Associates Biz. Works n Monitor all E-commerce transactions Business rule based Create action messages and flags Check each event for validity and accuracy Accommodates all trading partners Order status, shipping, inventory, billing, etc.

World Class Technologies for Manufacturing Internet CAD n n n E-commerce graphics application Internet transfer of engineering documents & graphics Utilizing a translation software to interface with incompatible supplier applications Ford Case

World Class Technologies for Manufacturing n n n n Laser based 100% inspection Automatic collection of SPC data Line stopping feedback Machine analysis and preventive maintenance warnings Bi-lingual inspection instructions Automated display of ISO 9000 procedures Intranet sharing of QA data across plant sites Daimler-Chrysler Case

World Class Technologies for Manufacturing Honda Supplier n n n Inbound items are bar-coded Outbound items are bar-coded WIP isn’t bar-coded Warehouse isn’t bar-coded Cycle counts daily Physical inventory every 30 days

World Class Technologies for Manufacturing Old Rand-Mc. Nally Publishing Co. Case Cycle Counting Approach n n n Largest printing plant in the U. S. Very large warehouses F. G. Four racks high Lose signatures Cycle counters l Flashlights l Binoculars l Computer print out

World Class Technologies for Manufacturing Data Capture Devices n n n Hand held devices Pen based devices Scanner/data input devices RFID tracking ERP integrated Windows CE - OS Finger size point & scan Micro-chip theft control Electronic asset tracking [EAT] Rackrunners Micro. Stamp RFID Technology

World Class Technologies for Manufacturing Voice Recognition Technology n n n Info. World 100 Technology Winner 2003 Warehouse picking application Headset communications Belt clip display system Two-way communications Improved pick accuracy to one error in 3, 000 picks

World Class Technologies for Manufacturing Technology Assessment Team n n n n n Technology Assessment Investment priorities Integration issues Benchmarking study New employee profiles Technology training Payback measurements University relationships Technology Vision

World Class Technologies for Manufacturing Today’s Typical Systems Environment n n n n Most technologies are only partially implemented or interfaced Budget constraints constantly cut back deployments Acquisitions & divestments force major steps backward E-commerce skill sets are weak Short term needs interfere with obtaining quality deliverables End to end supply chain initiatives have overwhelmed the development queue Outsourcing has built more islands of automation

World Class Technologies for Manufacturing SOPHISTICATION World Class Technologies Assessment INTEGRATION

World Class Technologies for Manufacturing Today’s Purdue Graduates n n n n Database structuring and administration [Quick BASIC, C+] Design techniques of Expert Systems [PC Easy & EXSYS] PC based ERP Distributed system design & networking Hands-on PLC programming [programmable controllers] Apply CAD and CAE software tools Work in a $10 million CIM laboratory l CIM software l CNC workstations l automated materials handling with robots l automated data capture [RFID] l vision systems

World Class Technologies for Manufacturing PPR Hub Production System Efficiency Cost Analysis Process Planning Robotics Ergonomics Product Process HUB Resource Scheduling & Control QA Factory Flow Simulation System Integrators: Rockwell/ IBM/Dassault/ ABB/ EDS/ MIT

World Class Technologies for Manufacturing National Manufacturing Week Chicago Mc. Cormick Place February 23 -26, 2004 www. manufacturingweek. com n n n What industries are using your product? What new features have been added to your product since last year? What are the integration features of your product?

World Class Technologies for Manufacturing Speaker Contact Data n n n Patrick J. Delaney NWU Research Park E: mail: SIBCCorp@ aol. com Phone: 1 -800 -806 -5177