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2008

Computer integrated manufacturing (Lecture #13)

CIM (Computer Integrated Manufacturing)

= Historical background = What is CIM? = Definition of CIM = Implementation and operation of CIM = Hierarchical and Distributed Control = (Virtual) Enterprises & ERP Systems = Data mining = Lean Production & Agile Manufacturing = Flexible Manufacturing System = Flexible Manufacturing Cell = Concurrent engineering = Design for X = Reverse engineering

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Computer Integrated Manufacturing

CIM allows the online and batchrelated acquisition of process and quality data. The flow of material within a multistage production process can be planned at any time and monitored from the central station.

Computer Integrated Manufacturing

Job and materials management permits job-controlled production. Even if complaints are received years after delivery of the components produced, both production and quality data and the materials used can be easily determined.

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CIM Concept
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Acquisition of possible quality-relevant data of different process steps Serial interfacing of SPCs of a wide variety of manufacturers Assignment of data of each process step to individual silicon wafers (materials tracking) Acquisition of the wafer quality Visualisation of the possible quality-relevant data on the wafer quality Evaluation of the data Data storage for long-time CAQ Job and materials management

Historical Background (I)

1970s - 1980sFlexible Manufacturing Systems/Cells a group of CNC machinery/equipment linked by an automated materials handling system, whose operation is integrated by supervisory computer control Provided efficient mid-volume, mid-variety production Increased machine utilization Reduced work-in-process inventory, labor and tooling costs, setup costs, lead time, lot size Ability to react quickly to engineering changes

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Historical Background (I)

1980s...Computer Integrated Manufacturing computer assisted control and integration at all levels of a manufacturing enterprise Strict hierarchical information flow Totally automated, unmanned, paperless factory Integration problems in heterogeneousm environments

Historical Background (I)

1990sIntelligent Manufacturing architecture for highly decentralized manufacturing systems, built from a modular mix of autonomous, cooperative, and intelligent elements (agents) Re-emergence of the human factor seeking to maximize the use of human intellectual skills and flexibility Migrating from hierarchy to Vertically Capability of rapid self-reconfiguration by incorporating human and machine intelligence

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Historical Background (I)

1990sExtended Enterprises global integration throughout the complete supply chain in manufacturing: Virtual Enterprise a community of factories each focused on what it does best, all linked by a network that would enable them to operate as one flexibly and inexpensively regardless of their location l An enterprise mostly made of functions provided by other enterprises l Extensive use of standards and information technology tool l Organizations and teams operate autonomously but cooperatively l Pushing toward true integration of design and manufacturing

What is CIM?
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a computer system? a management philosophy? a competitive strategy? a data management and networking problem? a concept? a technology? a method for eliminating direct labor? a deterministic technical system? a socio-technical system?

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What is CIM? CIM?

technology, tool or method used to improve entirely the design and manufacturing process and increase productivity

What is CIM? CIM?

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using computers to help people and machines to communicate series of integrated activities and operations involving
the design, materials selection, planning, production, quality assurance, management marketing of discrete consumer and durable goods

deliberate integration of automated systems logical organization of individual engineering, production and marketing/support functions into a computer integrated system

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What is CIM?
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focuses on the computer as the center of control of the entire factory, starting from the computerization of the fabrication and assembly processes to the information flow for
production control, quality, maintenance, material handling,

What is CIM?
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involves the use of computers to assist in

the design, handling, processing, cataloging of materials as they flow through the manufacturing processes

not computer controlled, but is the use of the computer assets to assist in difficult areas of manufacturing

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use of electronic technology to streamline traditionally separate phases,

including concept, design, manufacture, analysis, maintenance, into a single process in order to reduce lead time and improve quality of the product

What is CIM?

What is CIM?
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an approach to the organization and management of a firm, in which the functions of

design, manufacturing, production management are mutually rationalized completely coordinated, through the use of appropriate levels of computer and information/communication technologies

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What is CIM?
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use of computer hardware, software, and communications networks in all aspects of a manufacturing company including inventory control, quality control, planning, cost accounting, design, and manufacturing (machine control)

What is CIM?
utilizes the computer, not only to automate the design, control, assembly, and planning, but to link these processes into an organizational entity l control of information flow and material or product flow to best serve the customer
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What is CIM?
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including information, to best serve the customer; typically incorporating together the following technologies: computer aided manufacturing, computer aided design, computer aided process planning, computer aided quality control, computer aided design

What is CIM?
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concept of a completely automated factory in which all the functions of a company (design methods, production, administration, accounting, marketing, etc.) are integrated and controlled in the company and use common data shared through the same database

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What is CIM?
consists of three dimensions: l the engineering dimension involves CAD/CAM and CAPP activities; l the networking and systems dimension; l the continuous improvement dimension that encompasses areas such as MRP II, TQM, JIT and theory of constraints (TOC)
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Definition of CIM
Computer Integrated Manufacturing
is the integration of the total manufacturing enterprise through the use of integrated systems and data communications coupled with new managerial philosophies that improve organizational and personnel efficiency.

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Definition of CIM

Design CIM

Manufacturing

Business

Major Subsystems in CIM

Marketing
Product

Information CA- Storage & Transportation (Logictics) System Quality

Tool

CAD Machine CAPP PPS (MRP) CAM SFC CAPC TMS QC Lower Level Controllers

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CIM Representative Topics

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Computer-aided concurrent engineering (CACE); Design for Manufacturability (DFM) PDES/STEP-based manufacturing applications Computer numerical control (CNC); Direct/distributed numerical control (DNC) Computer process control, including adaptive process control Rapid prototyping principles & research opportunities Programmable controller/microcomputer applications Computer aided process planning (CAPP), including expert system applications Industrial robot applications, including off-line programming Group technology (GT) & GT manufacturing cells

CIM Representative Topics

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Flexible manufacturing systems (FMS's) Local area networks, including MAP/TOP network standards & ISO reference model Production planning & control, including JIT andSAP Product/process simulation Automated material handling Data entry systems Automated inspection systems & quality engineering Productivity engineering, including manufacturing cost analysis MRP vs. JIT production systems; JIT vs. lean manufacturing AI applications in CIM Other topics: Automation & human labor; green manufacturing; AHP (decsion support tools)

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FLEXIBLE MAUFACTURING SYSTEM (FMS)

Flexible Manufacturing System

Conceptual idea is attributed to David Williamson in the 1960s, but it took development of CNC and programmable controllers to make the concept truly viable.

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Flexible Manufacturing System

A series of automatic machine tools or items of fabrication equipment linked together with an automatic material handling provision for random fabrication of parts or assemblies that fall within predetermined families

Flexible Manufacturing System

FMS is a group of NC machine tools that can randomly process group of parts, having automated material handling and central computer control to dynamically balance resource utilization so that the system can adapt automatically to changes in parts production mixes, and levels of output. (Kearney and Treaker)

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Manufacturing System
A manufacturing system is a collection of integrated equipment and human resources, whose function is to perform one or more processing and/or assembly operations on a starting raw material, part, or set of parts.

Manufacturing System Components

=What are they? =How are they combined? =How are they organized? =Production machines =Material handling system =Computer control system =Human resources

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Classification of Manufacturing System

=Types of operations =Number of workstations & layout =Level of automation =Part or product variety (how to handle; types of flexibility)

Types of Manufacturing System

=Mass production (transfer line) =Special systems =Flexible manufacturing system (FMS) =Flexible manufacturing cell (FMC) =Stand-alone CNC systems

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Flexible Manufacturing System

FMS is a system dealing with high level distribution, data processing and automated material flow Using computer controlled machines, assembly cells, industrial robots, inspection machines altogether with computer integrated material handling and storage systems. ( Mehdi Kaighobad)

Flexible Manufacturing System

vFMS is a collection of production equipment logically organized under a host computer and physically connected by a central transport system. (David Perish)

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Flexible Manufacturing System

FMS is a system consisting of 3 subsystems; fabrication machining assembly. These subsystems are integrated with automatic storage; computer aided design, material handling devices and a computer. (Kusiak)

Flexible Manufacturing System

FMS is Business Driven =Improved profitability =Reduced lead times =Reduced inventory levels =Rapid response to market changes =Lower staffing levels =Improved manufacturing effectiveness =Increased operational flexibility =Increased predictability =Increased control

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Flexible Manufacturing System

FMS: Impact on Manufacturing =Need for managing change =More complex products =Need for greater flexibility =Need for faster time-to-market

Flexible Manufacturing System

Definition: FMS Group of machines or processes, integrated with material handling equipment, and under the direction of a (central) control system, to produce a variety of parts, at non-uniform production rates, batch sizes & quantities.

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Flexible Manufacturing System

Part Design Flexibility

Operating Flexibility

Flexible Manufacturing System

Types of FMS Flexibility Product design Makes it possible to accommodate a variety of product designs, including new products and modified designs; stems from recent advances in manufacturing controls that allow design details to reside in a machine software rather than the mechanics of its physical structure.

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Flexible Manufacturing System

Types of FMS Flexibility Operating Makes it possible to reduce manufacturing costs while responding to changes in manufacturing conditions, such as production schedules and model mix; characterized by capability to make up lost production (achieved in past

through large WIP inventory)

FMS: Important Technologies

=Microprocessor =Digital system simulation =Design optimization tools =Computer aided process planning =Process controlled quality =More software control =Advanced industrial controls =Industrial robots

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FMS: Other Significant Technologies

=Advanced sensors =Improved diagnosis =Higher speed =On-line/in-process inspection =Quick-change tooling =Tool wear monitor =Development with other processes,
e.g., forming; heat treat; assembly

Invest or Not Invest??

=Type of equipment available vs. operations needed =Types of parts & number of part #'s =Part tolerances & material requirements =Design change expected =Operational/schedule change expected

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Invest or Not Invest??

=Production volumes =Product life & lead time requirements =Direct labor available =Dollars available to invest =Other investment alternatives for company

Invest or Not Invest??

Production volume (parts/year) Transfer line

Computer Integrated Manufacturing Systems (CIMS) CNC

Product Flexibility (no. of part nos.

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System Trade-offs
Transfer lines l Large volume production/high output rate (~15,000+ parts/yr) l Parts are virtually identical; sometimes only one part l Changeover difficult/requires shutdown of line & machine retooling l Need to replace machines for major design changes
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System Trade-offs
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Stand-alone CNC Efficiently accommodates part design change Reprogram for design changeover/design change Low production quantities (~up to 800 parts/yr) CIMS Between high production rates & high flexibility (midvolume) Fills in gap between transfer lines & low volume CNC machines

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FMS Concepts
Single station routing part flow l Sequential routing part flow l Random routing part flow
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FMS Concepts
Single station l Tailor to design or operational change need l Attributes of both random & sequential flow l Problem areas: overall accuracy & required head investment
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FMS Concepts
Sequential flow l Accommodates operational part mix change; higher throughput capacity l Similar operation sequences l Simpler material handling l Potential problems: over & under utilization; machines repeated for repeated operations
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FMS Concepts
Random flow l High degree of design flexibility & limited operating flexibility l Complex material handling system l Potential problems: availability of machine tools; reduced capacity with over & under utilized machine tools
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FMS: Machine Tool Trade-offs TradeTooling Head changer Head indexer Machining center Multiple tool Multiple tool Single point (spindle) Flexibility Prod. Rate Moderate Lowest Highest Moderate Highest Lowest

Computer Functions for FMS

=Control of each workstation =Distribution of control instructions to workstations =Production control =Traffic control =Shuttle control =Workhandling system monitoring =Tool control =System performance monitoring & reporting

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Personnel Requirements for FMS

=System manager =Electrical technician =Mechanical/hydraulic technician =Tool setter =Fixture setup & lead man =Load/unload man =Rover operator =Other: NC programmer; computer programmers; other support staff

Manufacturing Cells
Single station manned cells l Single station automated cells l Applications of single station cells l Analysis of single station cells
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Single Station Manned Cells

Requires shortest amount of time to implement l Requires least capital investment l Technologically, easiest to install & operate l Often results in lowest cost per unit produced l Most flexible manufacturing system
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Single Station Automated Cells

Reduced labor requirement/cost l Easiest & least expensive among automated systems to implement l Higher production rates possible l First step in implementing integrated multistation automated system
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Applications of Single Station Cells

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CNC machining center with parts carousel & automatic pallet changer CNC turning center with parts storage tray & robot (same or different parts) Cluster of CNC turning centers, each producing different part Plastic injection molding machine with mechanical arm to remove part Automated electronic assembly machine Robotic assembly cell Stamping press that punches & forms small sheet metal parts

Analysis of Single Station Cells

Determine number of required workstations l Include setup time l Consider availability & machine utilization l Consider worker efficiency l Consider defect rate l Determine number of machines for single worker (cluster of machines)
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WHY NAME IT FLEXIBLE MANUFACTURING SYSTEM (FMS) ??

The Eleven Flexibilities

Machine Flexibility: wide range of operations, minor set ups, generic fixtures, large tool magazines, automatic tool changers 2
Material Handling Flexibility: move various parts between machines and storage areas and, maintain proper oritentation

Operation Flexibility: ability to use different processing operations to produce part features

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Routing Flexibility: ability to use different machines to produce parts under the same set up to ensure against breakdowns and bottlenecks

Product Flexibility: ease of changing over the system to produce a new set of parts

Volume Flexibility: insensitivity of profit to production volume 7 Expansion Flexibility: ease of adding additional capacity

Control Flexibility : ability to run unattended for a long period 9 Production Flexibility : range of part types that could be produced without major capital expense Insensitivity of profit to production volume 10 Process Flexibity : Ability to Produce variety of Parts with the same set up time 11 Market Flexibility : sum of product, Process and Volume Expansion

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Flexible Manufacturing System

A general view of a flexible manufacturing system, showing several machine tools and an automated guided vehicle (Cincinnate Milacron Inc.)

Why FMS
Job Shops constitute 70% of the industrial systems Its cheap Its flexible Its diverse But highly inefficient production system

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Why FMS
=Increased Productivity =Cost-effective Investment =Flexibility

High Quality Lower Cost Shorter Lead Time Resond to Change

Flexible Manufacturing System

High Production volume
Transfer Line Special System Flexible Manufacturing Systems (FMS) Manufacturing Cell Standard and General Purpose Machine

Low Low

Product Variety

High

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Flexible Manufacturing Cell

A flexible manufacturing cell is a set of numerically controlled machines linked by a flexible material handling system ( e.g., robot, automated guided vehicle AGV) all controlled by a computer system.

Flexible Manufacturing Cell

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Flexible Manufacturing Cell

Automated Storage and Retrieval Systems
CELL CONTROLLER
M/C
CELL

A G V

Machine Center 2

AGV

Load area /unload

Machine Center 3

System Components
Machines Backbone of system used for producing prismatic shapes (including engine blocks, pumps casting having no shapes as well as rotational parts) robots grip rotational parts fixtures grip prismatic parts tool changers /tool magazines to minimize setup times

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Part Movement System

Conveyors tow carts rail carts AGVs

Parts are transported on palletized fixtures between stations Docking areas are used for in process storage Shuttles receive the loaded part and store in docks

Supporting Workstations
Provision of load/unload station Automatic washers for parts cleaning Centralized storage area containing pallets Coordinate measuring machines (CMM) for accurate measurements and locations of features

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System Controller
= = Brain of the cell It is a computer with an attendant worker to keep track of performance and intervene to change priorities = = Keeps track of system status The status includes location of all parts, tools, carts including those in waiting

System Controller
Watches operational status of each machine Controller downloads commands to individual machines and system components In more advanced systems, the controller is intelligent and thinks ahead

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System Controller
Sends AGVs to pick parts in advance The controller makes sure the parts are automatically routed to alternate machines in case of machine breakdowns

System Controller
Either the controller or the CNC machine itself can keep track of cutting time for each tool and know when it is time to change the tool to prevent quality problem Travel times of AGVs are monitored to change the batteries Controller software development is the most complex task

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FMS DESIGN
Strategic issues Tactical issues

Why FMS be installed ?

Strategic Issues
Message to customers as well as competitors progressiveness high tech processes responsiveness rapidness meet customized market demand quickly eagerness for embracing engineering changes

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Tactical issues
Select type of parts to be made on FMS Decide operation sequence to be used for making these parts Select experienced vendors and have consultations with them on FMS desirable features and costs

Hardware Decisions
It includes machining centers, tool changers, pallet loaders, cutting tools, pallets, fixtures, system storage, machine buffers, material handling carts and system controllers Auxiliary components tool wear sensors, on line inspection devices, data acquisition devices

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Computer Integrated Manufacturing

Questions : 1. Define computer integrated manufacturing (CIM). 2. What role does the computer (or computer technologies) play in CIM? 2. How is CIM different from conventional manufacturing concepts? 3. What is meant by the term concurrent engineering? 4. What is distributed control ? 5. Why is distributed control easier to maintain than a centralized computer planning and control system?

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