171903: Computer Integrated Manufacturing P M Agrawal and V J Patel

Thousands of products
A Product - Large number of parts

Thousands of parts and drawings

Parts having different shape, size and function Different processing requirements e.g. Dowel and a small shaft Spur gears of different sizes

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Non-traditional approach to design and control a manufacturing system Decompose a manufacturing system into independent, manageable logical sub-systems by Aggregating parts into part families and machines into cells

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Group Technology is the realization that many problems are similar, and that by grouping similar problems, a single solution can be found to a set of problems thus saving time and effort. Formation of on part families based on similarities in design attributes and manufacturing Family members having some similarities. e.g. in process layout, similar machine tools grouped together form a family. Why are they grouped together?
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Why are they grouped together?

Identify similar parts and group together to take advantage of similarities in design, production planning and manufacturing 1. By performing like activities together 2. By standardizing similar tasks 3. By efficiently storing and retrieving information about recurring problems

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GT in Design
Large manufacturing system decomposed into smaller subsystems of part families based on similarities in Design attributes
1. components grouped into design families 2. information is stored and retrieved 3. a new design can be created by simply modifying an

existing component design

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Design Family

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GT in Design: Benefits
Reduction in new parts design Reduction in the number of drawings through standardization Reduction of drafting effort in new shop drawings Reduction of number of similar parts, easy retrieval of similar functional parts, and identification of substitute parts

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GT in Manufacturing
Cellular manufacturing grouping of similar parts on dedicated cluster of machines or manufacturing processes (cells). Part families are identified such that they are fully processed within a machine cluster.

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GT in Manufacturing
Advantages: reduced setup times reduced in-process inventories improved product quality shorter lead time reduced tool requirements improved productivity better overall control of operations Disadvantages: lower machine and labor utilization higher investment due to duplication of machines and tools
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Implementation of GT
Objectives:
How to classify? What should be the coding scheme? Grouping parts into families based on attributes. Three methods to form part families: Manual visual inspection Coding and Classification Production flow analysis

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Manual visual inspection

Formation of part families by visually inspecting the physical characteristics of the parts Simple

Prismatic Parts Rotational Parts

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Manual visual inspection

Scope limited to small companies having limited number of parts requires thorough knowledge of the entire part spectrum (design and manufacturing requirements of individual part) Inexpensive but least sophisticated May lead to incorrect results - different experts may have differing judgments

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Coding and Classification

Coding for classifying parts into part families process of assigning symbols to the parts The symbols represent design attributes of parts or manufacturing features of part families GT Coding Schemes Monocode or Hierarchical code Polycode or Chain Hybrid or mixed code
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Monocode (Hierarchical Code)

The structure of monocode is like a tree Each symbol amplifies the information provided in the previous digit.

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Structure of Monocode
Total Parts population Sheet Metal Parts (1) Manufactured Parts (2) Purchased Parts (3) Raw Material (4)

Rotational Parts (A)

0<L/D<0.5 0.5<L/D<3.0 (0) (1) L/D>3.0 (2)

Prismatic Parts (B)

W/L ?

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Monocode (Hierarchical Code)

Large amount of information using less number of digits coding scheme Complex and difficult to develop Limited use in manufacturing - difficulty in capturing information on manufacturing sequences in hierarchical manner (all branches in the hierarchy be defined)

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Polycode Chain structure

Each digit of code independent of each other Each digit in specific location of the code describes a unique property of the workpiece
Compact and easier to construct and use Useful in manufacturing Length may become excessive because of unlimited combinations Cannot be as comprehensive as hierarchical

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Polycode Chain structure

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Mixed code (Hybrid structure)

Combination of both monocode and polycode schemes Advantages of both schemes. Code relatively more compact Most coding systems use this coding scheme

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Mixed code (Hybrid structure)

Polycode
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Monocode
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Polycode
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Coding Systems
Over 100 Systems such as: KK-3 OPITZ DCLASS MICLASS CODE MULTICLASS Vuoso-Praha Covering Applications like: Tools and tooling Materials Parts Assemblies Processes

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Popular Coding systems

Opitz Coding system: Mixed (hybrid) coding system
Developed by H. Opitz, Aachen Technical University, West Germany,1970 Widely used in industry Can be applied to machined parts, non-machined parts (both formed and cast) and purchased parts Considers both design and manufacturing information

KK-3: Japanese Society for the Promotion of Machine Industry 1976.

21 digit decimal system, primarily metal cutting and grinding Much greater in length than OPITZ (more information)
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Popular Coding systems

MICLASS Metal Institute Classification Systems introduced by the Netherlands.
Chain structured code of 12 digits Includes both design and manufacturing information 18 digit supplementary code for user specified information One of the earliest Interactive coding systems (use of computer)

DCLASS is a Decision making (D) and Classification system (CLASS) by Del Allen at Brigham Young University in 1980.
Tree structured 8 digit system Each branch represents a condition, a code can be found at the junction of each branch
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OPITZ Coding System

consists of three groups of digits

Form code 12345

part geometry and features relevant to part design

Supplementary code 6789

information relevant to manufacturing (polycode)

Secondary code ABCD

Production processes and production sequences

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OPITZ Coding Scheme

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OPITZ Coding Scheme

OPITZ code:
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1 3 1 0 6
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OPITZ Coding Scheme

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Selection of Coding Scheme

1. Flexibility for various applications such as part family formation, process planning, costing, and purchasing 2. Accuracy: correct information on parts 3. Expandability 4. Unambiguous 5. Concise 6. Ease of learning 7. Computerization 8. Suitability for specific applications

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Production flow analysis (PFA)

Parts that go through common operations are grouped into part families. The machines used to perform these common operations may be grouped as a cell, consequently this technique can be used in facility layout (factory layout)

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Four stages in PFA

Stage 1: Machine classification Stage 2: Checking parts list and production route information Stage 3: Factory flow analysis Stage 4: Machine-component group analysis

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Production flow analysis (PFA)

Stage 1: Machine classification Classification of machines on the basis of operations that can be performed on them A machine type number is assigned to machines capable of performing similar operations Stage 2: Checking parts list and production route information Record information on each part - operations to be performed and the machines required to perform each of these operations
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Production flow analysis (PFA)

Stage 3: Factory Flow Analysis micro-level examination of flow of components through machines allows the information to be decomposed into a number of machine-component groups Stage 4: Machine- Component group analysis manual method to form cells analytical approaches to handle large problems systematically
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Matrix-Based Algorithms
transforming the initial matrix into a structured matrix may or may not result in separable clusters clustering efficiency Algorithms:
Rank-Order Clustering (ROC) algorithm Direct Clustering algorithm Bond Energy Algorithm

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Composite Component in GT

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G T Cell
A cells contains all necessary facilities to complete the processing of a family or families of parts A family of parts can only be defined by
relating it to a particular group of machines, and a group by relating it to a family.

Groups vary greatly in type and size, widely in the number of machines and different machines types

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Jumbled flows in a job shop without GT

Lathing Milling Drilling D D

M Grinding

Assembly A A A

Receiving and shipping

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Line flows in a job shop with GT cells

Assembly area A A

Cell 1

Cell 2

Receiving

Cell 3

Shipping

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Group Layout
Advantages
1. Increased machine utilization

2. Compromise between product layout and process layout, with associated advantages 4. Supports the use of general purpose equipment 5. Shorter travel distances and smoother flow lines than for process layout

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Group Layout
Limitations 1. General supervision required 2. Higher skill levels required of employees than for product layout 3. Compromise between product layout and process layout, with associated limitations 4. Depends on balanced material flow through the cell; otherwise, buffers and work-in-process storage are required 5. Lower machine utilization than for process layout

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