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Outline. DefinitionComputer Integrated Manufacturing (CIM)-detailed analysis of the conceptIntegration of the production processControl of the firmProduct planning, design and manufacture (CAD/CAM)CAD/CAM applicationsCAM components Manufacturing plant and production systemsCommunication b

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COMPUTER INTEGRATED MANUFACTURING - Transcript

1. COMPUTER INTEGRATED MANUFACTURING Presented By: Heba Saleh Karim El-Sabahy Mohamed Hussein 2. Outline Definition Computer Integrated Manufacturing (CIM)-detailed analysis of the concept Integration of the production process Control of the firm Product planning, design and manufacture (CAD/CAM) CAD/CAM applications CAM components Manufacturing plant and production systems Communication between applications Advantages of CIM Economic Aspects Case Example 3. Definition Computer Integrated Manufacturing (CIM): A computerized integration of all aspects of design, material selection, planning, manufacturing, production, quality assurance, management and marketing. CIM is a methodology and a goal, rather than an assemblage of equipment and computers. It involves the total operation of a company including an extensive database concerning all technical and business aspects of the operation.CIM is a methodology and a goal, rather than an assemblage of equipment and computers. It involves the total operation of a company including an extensive database concerning all technical and business aspects of the operation. 5. CIM- detailed analysis of the concept Integration of the production process (production control) Control of the firm Product planning, design and manufacture Manufacturing plant and production systems Communication between applications 6. Integration of the Production Process (backbone of CIM) It is composed of information structure: enables every person in the company, at whatever level, to benefit from real-time direct access to all the technical and economic data needed for their work. Production and inventory control (PIC): manages the manpower and material resources of an industrial company to produce the best compromise between three contradictory objectives: Commercial Financial Production-related Commercial: maximum customer service and hence large stocks and great flexibility. Financial: optimum usage of workforce and materials, and minimum work in progress. Production related: maximum efficiency in the use of manufacturing resources through longer runs and production in larger batches. Commercial: maximum customer service and hence large stocks and great flexibility. Financial: optimum usage of workforce and materials, and minimum work in progress. Production related: maximum efficiency in the use of manufacturing resources through longer runs and production in larger batches. 7. Control of the firm CIM Enables managerial decisions to be made: the use of the companys resources should be maximized to achieve strategic objectives. The information system is therefore designed such that: *Key data used for decision making are available, up to date and directly accessible. *The detailed design of the system guarantees that decisions are taken at the appropriate level. The control function in a firm depends on: 1.The master production schedule (MPS) which provides help in medium to long-term planning decisions 2. Manufacturing Resource Planning (MRPII) The master production schedule (MPS): includes data on customer orders, sales forecasts and stocks, associated with strategic data and large scale production schedules, making it possible to simulate the future direction of a company in terms of a production strategy. Manufacturing Resource Planning (MRPII): Controls all aspects of manufacturing planning. It is capable of final production scheduling, monitoring actual results in terms of performance and output, and comparing those results against the MPS. The master production schedule (MPS): includes data on customer orders, sales forecasts and stocks, associated with strategic data and large scale production schedules, making it possible to simulate the future direction of a company in terms of a production strategy. Manufacturing Resource Planning (MRPII): Controls all aspects of manufacturing planning. It is capable of final production scheduling, monitoring actual results in terms of performance and output, and comparing those results against the MPS. 8. Control of the firm 3.Database Product Data Data management attributes Production data Operational data Resources data Input of database Individuals Data Acquisition System (DAS) Database: Consists of up to date, detailed and accurate data (technical and non-technical) relating to: Product data: e.g. part shape, dimensions and specifications Data management attributes: e.g.owner, part number Production data: manufacturing processes involved in making parts and products Operational data: e.g. scheduling, assembly requirements Resources data: e.g.capital, machines, tools, equipment, personnel Data Acquisition system (DAS): various sensors in the machinery and equipment (e.g. microprocessors and transducers) used in production can report for example the number of parts being produced per unit of time, their dimensional accuracy, surface finish, weight at specified rates of sampling. Bar codes are also read. Barcodes are used as a serial number for the individual part. Optical sensors pick up the pattern, decode it and output the information digitally. This is used for inventory and production control. DAS are also capable of transferring the data to other computers which analyze them. Database: Consists of up to date, detailed and accurate data (technical and non-technical) relating to: Product data: e.g. part shape, dimensions and specifications Data management attributes: e.g.owner, part number Production data: manufacturing processes involved in making parts and products Operational data: e.g. scheduling, assembly requirements Resources data: e.g.capital, machines, tools, equipment, personnel Data Acquisition system (DAS): various sensors in the machinery and equipment (e.g. microprocessors and transducers) used in production can report for example the number of parts being produced per unit of time, their dimensional accuracy, surface finish, weight at specified rates of sampling. Bar codes are also read. Barcodes are used as a serial number for the individual part. Optical sensors pick up the pattern, decode it and output the information digitally. This is used for inventory and production control. DAS are also capable of transferring the data to other computers which analyze them. 9. Product Planning, Design and Manufacture. Computer Aided Design (CAD): involves the use of computers to create design drawings and product models Computer Aided Manufacturing (CAM): the use of a computer to generate the data required to configure a production process, for example the parameters needed to set up NC machines and robots Integrating CAD/CAM CAD is a powerful tool that is used in the mechanical design and geometric modeling of products and components. In addition to the designs geometric and dimensional features, other information (such as a list of materials, specifications, and manufacturing instructions) is stored in the CAD database. CAM: It also includes simulating the manufacturing process (e.g simulating the path of a tool during a machining operation), and download manufacturing programs to CNC machine tools.CAD is a powerful tool that is used in the mechanical design and geometric modeling of products and components. In addition to the designs geometric and dimensional features, other information (such as a list of materials, specifications, and manufacturing instructions) is stored in the CAD database. CAM: It also includes simulating the manufacturing process (e.g simulating the path of a tool during a machining operation), and download manufacturing programs to CNC machine tools.

11. CAD/CAM Allows the transfer of information from the design stage into the stage of planning for the manufacture of a product, without the need to reenter data on part geometry manually. CAD database is processed further by CAM into data and instructions for operating and controlling production machinery, material handling equipment, automated testing and inspection for quality control. CAM is capable of machining operations such as describing tool path for various operations Various operations such as NC turning, milling, and drilling.Various operations such as NC turning, milling, and drilling. 12. CAD/CAM Applications Programming for NC, CNC, and industrial robots. Design of tools and EDM electrodes. Quality control and inspection 13. CAM components The mechanical hardware: Capable of moving different parts of the machine in programmed co-ordinate system (machine tool, robot arm, etc.) The power supply system:e.g. hydraulics, electricity, pneumatics, etc.. Actuation devices: Such as stepping motors, DC & AC motors, Hydraulic devices, etc Feedback devices, such as encoders The computer control unit: This part consists of the machine control system, and the machine control software 14. CAM example An example of CAM system is a CNC machine. Its a numerical control machine with a microprocessor as an integral part of the MCU. Data handling, control sequences, and response to input is determined by the integrated microprocessor. The software compiler used by CNC for simplifying numerical control programming is APT; and it is the most widely used processor. 16. Manufacturing plant and production systems Flexible manufacturing system (FMS): host computer organizes the supply of materials, programs for NC machine tools, tooling of machines, etc in a highly flexible manner. Such a system: is automated is capable of manufacturing several types of product can changeover from manufacturing one product to another ideally by overlapping operations FMS: changes in the manufacture of parts and assemblies can occur without costly delays in retooling, reconfiguration, etc.FMS: changes in the manufacture of parts and assemblies can occur without costly delays in retooling, reconfiguration, etc. 17. Communication between applications One of the main aims of CIM is to coordinate exchanges of information between applications such as: Programmable logic controllers (PLC) robots various terminals PLC: a data processing system dedicated to the monitoring or control of actuators and sensors in an industrial environment.PLC: a data processing system dedicated to the monitoring or control of actuators and sensors in an industrial environment. 18. Advantages of CIM Responsiveness to shorter product life cycles and changing market demands Better process control emphasizes product quality and uniformity Support and coordinate exchanges of information between applications. Designing components for machining. 19. Advantages of CIM contd Decrease the cost of production and maintenance through better use of materials, machinery, personnel and the reduction in work in progress (WIP) inventory Save time and effort. 20. Skills Required for using CIM Good understanding of the process involved. Ability to describe and define different computer integrated models. Ability to develop different solutions for same problem. 21. Problems Faced Unfamiliar technologies used. Requires major change in corporate culture. Reduction in short term profits. Perceived risk is high. Present corporate leadership is unfamiliar with tech. and with types of management changes required for effective usage of this technology. Proposed solution strategy requires major changes in corporate culture. Required investment is associated with a reduction in short term profit.Present corporate leadership is unfamiliar with tech. and with types of management changes required for effective usage of this technology. Proposed solution strategy requires major changes in corporate culture. Required investment is associated with a reduction in short term profit. 22. CIM Economy A CIM return analysis could take the following structure: Collect data typical of the present situation Identify the sectors to be improved Estimate the annual profits Evaluate the costs Determine payback time 23. CIM Economy CIM implementation is tailored for specific company requirements, and is done in steps of cell application An educational software package including technical tutorials provided by Ciscos Basics costs $1100 Boeing 777 passenger airplane was designed completely with CAD/CAM software, costing $6 billion. * Hence costs its application are not fixed.* Hence costs its application are not fixed. 24. Case Example 25. Society for Manufacturing Engineering The SME sponsored a conference called AUTOFACT in 1989 to simulate how a mid-size company exploits CIM. The conference was conducted by 25 companies ranging from computer system vendors to consultants worked together to make this simulation. 26. Steps representing CIM Customer ordered a mower deck part on an older model tractor. Dealer used online CAD part catalogue to get part geometry. Dealer ordered four parts from factory. Information received at division office. Inventory system found parts unavailable. A message was forward to material planning system. Production planner reviewed part assembly indicating two assembly components not available. Production planner sent to design engineer to search for similar components on databases. Design engineer modifies the design of the perceived components and saves it on the database. New assembly number was sent to production planar upgrading the catalogues.

27. Production planar releases an order to manufacture parts Production planar selects production schedule and sends it to manufacturing production control system Manufacturing engineering develop NC program and verify it and transfer it to operator Shop floor term loads program to CNC machine After machining is complete, finished parts are grouped and taken to shipping Bar code labels are put on boxes then transferred into main plant A receiving clerk scans the barcode and logs boxes into inventory An order is sent to manufacturing engineer to prepare robot assembly program Assembly engineer requests part geometry and tooling geometry then transmits it to a robot programmer Robot programmer prepares robot simulation program and transfers it to robot controller Robot controller ordered to present parts to robot 28. Robot delivers the completed assembly System creates a barcode shipping label and puts them on boxes Parts are ready to go 29. Questions? 30. Works Cited Groover, Automation, Production Systems, and Computer Integrated Manufacturing. Prentice Hall 2001 Henderson, Mark Richard, Wolfe, Philip, Computer Integrated Design and Manufacturing. McGraw-Hill 1991. Kalpakjian, Schmid, Manufacturing Engineering and Technology. Prentice Hall 2000. Waldner, Jean-Baptiste, Principles of Computer-Integrated Manuacturing. Wiley, 1992.

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