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INTEGRATION BY GROUP

TECHNOLOGY
CAD-CAM
UNIT III
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The fact of organizing information can be a great
advantage for CAD-CAM integration.

Without data classification we would loose time
and resources for the information organization.
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Group technology is a way to organize
information to make this integration more
efficient.
It can be compared to the animal kingdom
classification.
Kingdom
Phylum
Class
Order
Family
Genus
Species
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Suppose the case of a plant where thousands of
part numbers are handled and where the batch
sizes decrease each time, as the variety of the
products increases.
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However, if we look closely, certain products are
very similar.

This information is very useful for a design
engineer that looks for similar products to the one
that is about to be designed.
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In the same way, a manufacturing engineer
would like to know if there is already a product
similar to the one that is about to be produced in
order to take some references out of its
production process.
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From this we obtain the group technology, as a
way to group families of products with similar
characteristics.
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The original concept of group technologies is the
following:
to understand that many problems are
similar, and that grouping similar problems, you
can find a single solution for a set of problems
saving that way time and effort.
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An essential aspect of CAD and CAM integration
is the integration of information used by
Engineering, Manufacturing and all other
departments in the company.
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G.T. provides a medium to structure and save
information about parts like:
Design and manufacturing attributes
Characteristics of processes
Manufacturing capacities
All of these can be compatible to computarizing
and analysis.
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G.T. provides a common language for users.
The integration of several types of related parts
information would be virtually impossible without
G.T.
As a consequence, G.T. is an important part of
CAD/CAM integration.
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G.T. starts grouping parts into families based
on their attributes.

Normally these attributes are based on:
1. The geometry of the part
2. The characteristics of the production process
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The geometric classification of the families is
normally based on:
Size
Shapes
The classification of the production processes is
based on:
The type of process
Sequence
Number of operations
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The type of operation is determined by:
The process method
The method of holding the part
The tool
The conditions of processing
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There are at least three methods that can be
utilized to make parts families:
Visual-manual search
Production flow analysis
Classification and codification
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The visual manual search is not greatly utilized
in the formal applications of group technology
due that it can lead to inconsistent results.

This is due to different reasons like the
perceptions of each person regarding the
manufacturing capacity, machines and tools,
and the recognition of the significant attributes
of the parts.
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The flow production analysis (FPA) is a
structured technique to analyze the sequence of
operations (routines) through which parts pass
by during their fabrication.

Parts that pass through common operations are
grouped together in families of parts.

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In the FPA, machines that are utilized to make
these common operations can be grouped
together in production cells.

As a consequence, this technique can be utilized
in a plant layout.
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FPA Matrix

M = Number of machines

N = Number of parts

X = 1 if the part j has an operation on machine i;
0 if this condition is not met.
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
A 1 1
B 1 1 1
C 1 1 1 1 1 1
D 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
E 1 1
F 1 1 1 1
G 1 1 1 1 1
H 1 1 1 1 1
I 1 1 1 1
J 1 1
K 1 1
M
a
c
h
i
n
e

N
u
m
b
e
r

Part Number
2 11 1 10 16 18 12 6 3 4 7 8 9 14 15 19 5 13 17
H 1 1 1 1
D 1 1 1 1 1
F 1 1 1 1
A 1 1
B 1 1 1
E 1 1
D 1 1 1 1 1 1 1 1 1 1
C 1 1 1 1 1 1
I 1 1 1 1 1
G 1 1 1 1
J 1 1
K 1 1
GRUPO 1
GRUPO 2
GRUPO 3
M
a
c
h
i
n
e

N
u
m
b
e
r

Part Number
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If the machine-components chart is small, you
can manually group together parts with similar
operations by moving rows and columns.

However, a more correct method is to utilize a
computer procedure to make this job.
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In order for this FPA technique to be successful,
precise and efficient routines are required for
each part.

These routines do not exist in many companies.
If they exist, frequently they are inaccurate
because of the lack of maintenance or that they
can be inconsistent.
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These inaccurate classifications normally occurr
due to the lack of a system of parts codification.

Furthermore, FPA is based on criteria, since it
could happen that some of the parts may not
appear to belong to a certain family.

It must also be determined when certain
machines must be duplicated in more than one
family.
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The FPA does not consider the characteristics of
the parts or their functions, therefore it must
not be used for Design Engineering.

However, compared to codification technique, it
is much simpler and easy to carry on.
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Parts Classification is the process of
categorizing parts into groups, which are also
called families, according to a set of rules or
principles.
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Codification is the process of assigning symbols
to the part.

The objectives are to group together similar
parts and to separate parts that are different to
each other.
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The symbols inside the Codification must have
meanings that reflect the attributes of the part,
making it easier the analysis or information
processing.
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Many classification and codification systems
have been developed, and many people have
tried to improve them.

But no system has ever had a universal
acceptance.
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This is mainly due to two things:

1. The information that is represented in the
classification and codification varies from one
company to another.

2. The two biggest usages of G.T. are the
recovery of the design and the cell production,
hence each company has its own needs for
these functions.
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A reason for a design engineer to classify and
codificate parts is to reduce the design effort by
identifying similar parts that already exist.

Some of the most significant attributes in which
it can be identified are the shape, material and
the size.
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If the parts classification and codification is
successful, it must be able to identify some
additional attributes:

1. Tolerances
2. Materials manufacturability
3. Process requirements
4. Machine tools requirements
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The classification and codification helps the
companies to improve the communication
between design and manufacturing.

This way, CIM will also be facilitated.
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Even though exist more than 100 classification
and codification systems, all of them can be
grouped together in three different basic types:

1. Hierarchical or monocode
2. By attributes or polycode
3. Hybrid or mixed
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On the Hierarchical Code the meaning of each
character depends on the previous character.

This means that each character amplifies the
information according to the previous
character.
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The Hierarchical Code delivers a lot of
information in a relatively small number of
digits.

To find the meaning of each digit in this type of
system can be complicated, even though the
application of the defined system is relatively
simple.
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Attributes code: is also called polycode, chain
code, discrete code or fixed digit code.

The meaning of each character in an attributes
code, in contrast with a hierarchical code, is
that they are independent to each other.
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Therefore, each attribute of a part can be
assigned a specific position in an attribute code.
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POSSIBLE DIGIT VALUE
DIGIT CHARACTERISTIC TYPE 1 2 3 4
1 External Shape
Cylindrical or
without
deviations
Cylindrical with
deviation
s
Box type ___
2 Internal Shape None Center hole Other hole ___
3 Number of Holes 0 1-2 3-5 ___
4 Type of Holes Axial Crossed Axial crossed ___
5 Gear Teeth Worm Internal spur External spur ___
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On this example, this type of gear would have
the code 22213, where digit 3 of the fifth
position means that the part has an external
spur, regardless of the values of the digits on
the previous positions of the code.
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If this attribute code had been used for several
parts and we would want to retrieve
information about all the parts with external
spurs, we would just have to identify all the
parts with a 3 on the 5th position of the code.
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Consequently, an attributes code is popular
among the manufacturing organizations due
that it makes easier the identification of parts
that have similar characteristics and that
require similar processes.
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A disadvantage of an attributes code is that any
position in the code must be reserved for each
different attribute; therefore, the resulting code
can be too long.
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Hybrid code: is the combination of the two
types of codes previously reviewed.
(hierarchical and by attributes).

With this type of code, the advantages of each
system are taken into account.
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Hybrid code: In this case, the code for a part is a mixture of
polycodes and monocodes. Such coding methods use
monocodes where they can, and use polycodes for the other
digits -- in such a way as to obtain a code structure that
captures the essential information about a part shape. This is
the most commonly used method of coding and classification.
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In this system, the first digit, for instance, can
be used to identify the type of the part, like a
gear.
The following 5 positions can be reserved for a
short attributes code that describes the
attributes of the gear.

B 3 2 6 4 1
1st position to
indicate the type
of part
The following 5 positions to
indicate the attributes (color,
size, type of teeth, etc.)
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The following digit, in the 7th position, can be
used to designate another subgroup, like the
type of material, followed by another attributes
code that describes its attributes.

B 3 2 6 4 1 D 3 9
7th position to indicate
another subgroup, like
the type of material.
The following positions to
indicate other attributes.
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With this system, a hybrid code can be created,
and is able to be relatively more compact than
just only an attributes code, without loosing the
ability to easily identify the parts with specific
characteristics.

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