Team Members Adersh Kunju Arun Ramachandran Bhareth Balagopal Jabil M.

Table of Contents

PDD Assignment CNC Machines

BRIEF HISTORY .................................................................................................................................................................. 2 CNC PROGRAMMING .................................................................................................................................................... 2 CNC MACHINES PROGRAMMED USING OPEN-SOURCE LINUX SOFTWARE .......................................................... 3 PLANNING ......................................................................................................................................................................... 3 Marketing function ....................................................................................................................................................... 3 Design and Manufacturing functions ............................................................................................................................ 3 CONCEPT DEVELOPMENT ................................................................................................................................................. 4 SYSTEM LEVEL DESIGN ...................................................................................................................................................... 6 CNC System Market Potential ................................................................................................................................... 7 DETAIL DESIGN .................................................................................................................................................................. 7 Major Reasons for MNCs being huge players are .................................................................................................... 9 TESTING & REFINEMENT ................................................................................................................................................... 9 SWOT Model ............................................................................................................................................................... 10 PRODUCTION RAMP UP: ................................................................................................................................................. 10

COMPUTER NUMERICAL CONTROLLER (CNC) MACHINE (PROGRAMMED

USING OPEN-SOURCE LINUX SOFTWARE) BRIEF HISTORY
Numerical control (NC) is the operation of a machine tool by a series of coded instructions consisting of numbers, letters of the alphabet, and symbols that the machine control unit (MCU) can understand. These instructions are changed into electrical pulses of current that the machine's motors and controls follow to carry out manufacturing operations on a work-piece. The numbers, letters, and symbols are coded instructions that refer to specific distances, positions, functions, or motions, that the machine tool can understand as it machines the work-piece. A form of NC was used in the early days of the industrial revolution, as early as 1725, when knitting machines in England used punched cards to form various patterns in cloth. Even earlier than this, rotating drums with prepositioned pins were used to control the chimes in European cathedrals and some American churches. In 1863, the first player piano was patented; it used punched paper rolls, through which air passed to automatically control the order in which the keys were played. The introduction of software-based controls in the early 1970s replaced the NC hardware design with complete computer logic that had more capacity and could be programmed for a variety of functions at any time. This made it possible to revise, modify, or update CNC programs or parts of programs at any time on a computer. In turn, CNC machines became easier to use with their menu-selected displays, advanced graphics, and ease of programming. The required input technical information is stored on a kind of input media such as floppy disk, hard disk, CD ROM, DVD, USB flash drive or RAM, etc.

PDD Assignment CNC Machines

CNC PROGRAMMING
CNC Programming is where all the machining data are compiled and where the data are translated into a language which can be understood by the control system of the machine tool. The machining data is as follows: a) Machining sequence classification of process, tool start-up point, cutting depth, etc. b) Cutting conditions spindle speed, feed rate, coolant, etc. c) Selection of cutting tools CNC programming requires technicians to use computers in order to control machine tools for the purpose of repeatedly manufacturing complex parts (usually metal). Using a program written in the complex G-Code notation, technicians ensure that all products adhere to the same precise measurements. CNC Mastercam was one of the first companies to produce the necessary software for this particular industry. Mastercam changed the way we produce and build. In a way, Mastercam helped pave the way for the last 60 years of industrial growth.

Since programming CNC machines was lobbied by a group of companies around the world, it led to an exponential increase in costs for services such as programming, set-up, after sales services, etc. CNC MACHINES PROGRAMMED USING OPEN-SOURCE LINUX SOFTWARE The product that is being dealt with here is Computer Numerical Controller for machining operations, which is programmed using Open-source Linux software. The programming language being opensource will reduce the costs involved in programming the CNC machines to a great extent. Moreover, the programming can be done according to the individual machine operators conditions and criteria.

PDD Assignment CNC Machines

PLANNING
The first phase of the product development process is planning. The planning activity is referred to as Phase Zero since it precedes the project approval and launch of the actual product development process. This phase begins with corporate strategy and includes assessment of technology developments and market objectives. The output of the planning stage is the project mission statement, which specifies the target market for the product, business goals, key assumptions and constraints. The Planning phase consists of a lot of tasks and responsibilities to be carried out with respect to the different key functions involved in launching the product. The key functions and the tasks involved in them include the following: Marketing function There is huge opportunity in the CNC machines market today. Until now, CNC programming has been under control of a lobby of international companies and this was the main reason for the skyward costs associated with purchase as well as programming of a CNC machine. Moreover, these companies issued standard packages and the programming needs of individual machine operators could not be taken into consideration. Therefore, the introduction CNC machine programming using Open-source Linux software would be a perfect solution to counter these problems. Furthermore, the market could be differentiated into different segments such as: Companies that manufacture a product Companies that produce production work pieces for other companies Companies that produce tooling Companies that produce prototypes

A very good marketing strategy would be identify these above and more target segments and market the product accordingly to fit with the expectations of the customers in these segments. Design and Manufacturing functions

The product platform and architecture, which in this case is the Open-source software Linux, should be well researched on and the product should be able to overcome any difficulties which may arise during fabrication. Moreover, new technologies which may arise in the market should be thought about and considerable time should be spent on deciding strategies to cope with future competition that may arise due to newer technologies. Also, production constraints and supply chain strategy should be evaluated. Other major tasks in this phase include:

PDD Assignment CNC Machines

Research
Available technologies should be studied in detail and improvements made

Finance
Financial constraints should be evaluated and financial goals planned

Management
The project resources should be allocated as per requirements
CONCEPT DEVELOPMENT Concept development stage involves determination of the competitors for the product and the identification of lead users for the product. For CNC system expertise is concentrated with Japan and Germany- There are 2 major manufacturers of CNC systems worldwide-FANUC and Siemens, and almost all CNC machines manufactured in India import their CNC systems from these two firms. The lead users for the product are all small, medium and large Indian machine tool manufactures. Concept development stage should be done in an organized and systematic format. The following are the steps involved in concept development stage.

PDD Assignment CNC Machines

6 5 No: of Concepts 4 3 2 1 0 0 1 2 3 4 Time & Iterations 5 6

Concept Generation as such is an iterative process that goes through several filters that acts as checkpoints to analyze and control the quality of ideas that an organization processes. At the end of the Concept development process the team arrives at one or at most two ideas that are worth the time and effort to pursue.
Plan Downstream Development

Identify the customer needs

Establish target specification

Generate, Select and Test product concepts

Final specifications

Identify the customer needs: For a CNC machine controller it should be precise and user friendly, customers prefer those CNCs which can make a precise machining and that which has a low error percentage. They also prefer the user friendliness of the software which acts as an interface between the user and controller. CNC market is dominated by MNCs Germany and Japan which offers precise control over machining activity. But these controllers software cant be personalized or changed according to the user. So the customers also are more tend to purchase a product which offers the precision of these MNCs and that it can be personalized according to user. Establish target specification: Based on the above mentioned needs of the customers the specifications will be obtained by preparing the metrics of needs and specifications and determining the priority of these specs in satisfying customer needs. This process of determine the needs should be conducted by making a complete metric, which is formed by dependent variables. The matrices should also be practical which can be easily evaluated by the team.

PDD Assignment CNC Machines

Generate Select and Test product concepts: The process of concept generation is done by understanding the problem and need thoroughly and breaking it into sub problems and coming up with solution conducting an external and internal search for solution. A good combination of these solutions would generate an excellent concept. There could be a couple of concepts for a problem , the selection of the apt concept is done by evaluating each concept with respect of the customer needs , the selection is also done by conducting a detail strength and weakness analysis. In this case our product has a great strength over its competitors is that it can be personalized and made user friendly. But it lacks a brand name like Siemens which is a drawback for the product. Those concepts which are satisfactory after conducting the analysis would be taken for the testing phase. The testing is planned to be conducted by survey method. Where a survey would be developed which can satisfy the purpose of the concept test. The survey would be conducted among a selected sample of population and the consumer responses would be measured and these results would be interpreted to get the test result about the product. The final selection of the concept would be based on this survey result. Final specifications: The firm would arrive at final specifications by taking those specifications which passed the concept test phases. The firm at this stage would also be aware of the limitations of the product and the solutions to overcome these limitations. The developers should also have to do decide on the tradeoff between the cost and performance so that the product can be made suitable for the target population. Plan Downstream Development: The firm creates a detailed plan for the development processes. The plan includes the strategies that should be adopted to minimize development time and the resource management for the project completion. This phase also involves the economic analysis of the project i.e. the manufacturing cost estimation and the feasibility of manufacturing the product is done during this phase.

SYSTEM LEVEL DESIGN This stage includes the formulation of plans for new products and the future extensions planned in the product family. The industrial design of the product is also planned in this stage. The industrial design should in such a way that it satisfies the ergonomic needs and aesthetic needs. The ergonomic needs involve the ease of use of the product, the maintenance of the product .The product safety and the safety it offers to the user are considered in this stage. The CNC system developed should be well equipped with all safety interlocks like overload tripping relays, heat controlling mechanism so that the users would be safe and they would find it easy to use it. Since the software developed is developed on an open source platform it could be easily personalized and can be operated according to the users wish. These decisions regarding the usage procedure and steps involved in the operation are decided in this phase. The aesthetic needs involve the differentiation the product offers and the pride which gets added to the user. Here for CNC system the product can be differentiated by its cost advantage and high and technology used to manufacture it. The products final assembly line scheme is also decided in this phase.

The Indian machine tool industry depends entirely on imports for all the critical components it needs to build CNC machines. These are products like Antifriction linear guide ways, Ball screws, Precision spindle and ball screw support bearings, CNC controls, Spindle and axes servo motors with drive controllers, Feedback measurement systems. These imports are mainly doe from Japan, Germany and China. These imports constitute to be one of the major factors which increase the cost of the CNC system. The practical issues related to the product manufacturing and using of the product would be identified in the previous phase and this phase involves formulating solutions for these problems. The product review and identification of further issues are also done here. CNC System Market Potential Indian Machine Tool Industry 2010-11 & 201112 (INR Million) Growth 2010-11 2011-12 Rate Production Exports Imports 36,238 1,358 67,033 42,990 1,802 76,454 1,17,642 19% 33% 11% 15%

PDD Assignment CNC Machines

Consumption 1,01,913

(Source: Indian Machine Tool Manufacturers Association, IMTMA) Out of this total consumption 83% of machine tools are CNC machine tools. (Source: IMTMA) Conducting a cost analysis of a machine tool approximately 26% of cost of a machine tool is due to the CNC system installed in it. (Source: IMTMA) So the potential market for CNC system is: Total Consumption of CNC machines is 83% of Rs. 1, 17,642 Million = Rs. 97642.86 Million. Total cost of CNC system is 26 % of Rs. 97642.86 Million = Rs. 25387.14 Million Market potential for CNC system is Rs 25400 Million (approx.) and its growing at a rate of 15% DETAIL DESIGN The next major impetus in the machine tools market in India will be fuelled by the changes bought by increased efficiency, meeting customized demand and reduced costs.

PDD Assignment CNC Machines

Concept Development System Level Design Testing & Refinement Production Ramp-Up

Planning

Detail Design

Since this product development centers on the change in software along with the cost reducing factors that are built along with it, the product as such has a market. With detail design we are trying to bring in various cost factors that are part of the product design process. This also includes the indigenous sourcing of materials, production volume, the number of unique parts that goes into and the development time that it requires (both peak internal & any external).The market has a huge potential to address the gap left by MNCs who address the high cost category leaving out the SMEs that make up a huge chunk. Decide the type of organization Concentrate on the type of design specialized by firm Harping on Mission Values of the organization

Production Ramp-Up Testing & Refinement Detail Design System Level Design Concept Development Planning Initiation 0 50 100 150 200 250 300 350 400

The above Gantt chart displays how important & essential are stages like design & testing, it provides a birds eye view of how a project is functioning on different dimensions time, cost, and error among many other variables. The detail design helps organization to break down the project into smaller integral components that work alone and are allotted to different teams to reduce the workload and speed up the process. Like above displayed activity diagram different processes are done parallelly to reduce cost as well as enhance productivity. Real-time management of the chart helps to identify potential problems & progress. Task Sequencing Components Check Dependency check on individual blocks are done
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PDD Assignment CNC Machines

Major Reasons for MNCs being huge players are Manuals & circuit diagrams were not available leading to problems in operation and servicing Machines cannot be used directly, need total refurbishing, which negates the reasons for buying cheaper second hand machines Machine electronics are outdated and needed total replacement with the latest version

The Market share of Indian Companies in this entire sector is very low due to cost, manufacturing capability, access to capital & technology.

TESTING & REFINEMENT

During the testing and refinement stage, a number of prototypes are built and tested. Even though they are not made from production components, prototypes emulate production products as closely as possible. These alpha prototypes are necessary to determine whether the performance of the product matches the specifications, and to uncover design pitfalls and gain in-the-field experience with the product in use. Later, beta prototypes are built from the first production components received from suppliers. It is also an integral part of the prototyping stage, involves limited distribution of the new product to select stores and end consumers. Marketing people should stay in touch with store managers and evaluate how well the product is selling.

Dev. promotion and launch materials Facilitate field tests Reliability, performance and life tests Get regulatory approvals
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PDD Assignment CNC Machines

Implement design changes Begin supplier ramp-up Refine mfg. processes

SWOT Model

S
Open Source System Customizable

W
Would Need Programming Knowledge Design

T
MNC Cost Cutting Similar Products

O
Large Market Market Timing

PRODUCTION RAMP UP: At the beginning of a new production ramp up, almost all of the investments in research, product development and manufacturing have already been made. Delays in reaching the production at the target volume will also delay the revenues even more into the future. During the initial stages of the production we will cater to key customers who are very much in need of our product and whose involvement is high in the buying procedure. This will ensure proper feedback from the customers which will help us in bringing changes in the production activities and will push us faster towards full production capacity. The product that we are dealing with is a high technology product and as such the rate of product introductions are high in this field .Due to faster product introductions the price falls of these products are also very fast. In order to counter this we suggest the use of faster ramp up strategy. The problem with analyzing and coming up with an actual production number is a very hard process considering the nature of the product; it depends on few factors like... Relative Advantage o Product performance relative to incumbent Compatibility o Consistency with existing values/experiences Complexity
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o Ease of Use Triability o Possibility to experiment with product Observability o Visibility of usage and impact

PDD Assignment CNC Machines

Faster ramp ups will increase the life time sales volume of the product and also will hasten market penetration, potentially raising subsequent market share and deterring competitors. Organizational Model The organizational model that can be implemented in the production and the entire process can be such that there is integration between management team, project team & any other functional member or group involved. The project can be completed by breaking down the processes by functionalities and then grouping them avoiding overlapping and thereby reducing time and cost. Parallel development efforts will help in completing work faster if all the activities required are mapped prior and assigned properly.

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