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Computer%20Integrated%20Manufacturing

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Title: Computer%20Integrated%20Manufacturing


1
Computer Integrated Manufacturing
  • Department of Industrial Systems Engineering

2
Production System
3
Four major production types
  • 1) ???? (job shop)
  • 2) ???? (flow shop)
  • 3) ???? ?? (project shop)
  • 4) ???? (continuous shop)

4
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5
Job Shop Layout
6
Manufacturing time in Job shop
7
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8
Robot Centered Cell
9
Production Types by Quantity
  • 1) Low production Less than 100 item
  • 2) Medium production 10010,000 item
  • 3) High production greater than 10,000 item

10
Production Quantity VS Variety
11
1) Low Quantity Production
  • job shop type, customized product, large variety
    of product type
  • ex) space capsules, airplane, special purpose
    machine
  • maximum flexibility

12
1) Low Quantity Production
  • fixed position layout type
  • (big product)
  • process layout type functional layout
  • lots of movement and WIP

13
2) Medium Quantity Production
  • product range 10010,000 item
  • Large product variety
  • batch production type

14
2) Medium Quantity Production
  • Facility changed after I production, order
  • repeatable
  • production rate higher than single product
  • type
  • Facility utilized commonly by lines
  • Batch changing time is required for setup
  • time (changeover time)

15
2) Medium Quantity Production
  • Product variety is not large
  • When setup time is small, various part groups are
    produced in a facility
  • Cellular layout type composed with various
    machines and work stations

16
3) High Quantity Production
  • mass production (greater than 10,000 items)
  • i) quantity production production with a single
    machine
  • Production with specialized purpose machine

17
3) High Quantity Production
  • ii) flow line production
  • Composed with several workstation
  • Each workstation composed of special machine
  • Conveyor belt used
  • ex) automobile, appliance assembly
  • Good for single model production

18
Production Types (discrete product)
19
CIM Background
  • Various tastes of customers
  • Reduction of cycle time
  • Requesting integrated systems for improving both
    technology and quality

20
Computer Integrated Manufacturing?
  • Integrated systems of functions in factories that
    are production, marketing, order, design,
    production control, inventory control, quality
    control, inspection, shipping, through
    communication and producing technology

21
CIM Model
22
CIM
  • Computer database
  • Integration Network
  • Manufacturing rapid development of new products
  • CIM conceptual rather than physical
  • Island of Automation partly automated but not
    integrated
  • Objectives of CIM managing enterprises

23
Elements of CIM
  • Information technology Computer, Communication,
    Control
  • Manufacturing technology Manufacturing, Market,
    Management
  • 3Cs support 3Ms

24
Elements of 3Cs
  • Computer IT, OS, programming language, database,
    artificial intelligence
  • Communication communication technology, MAP,
    TOP, LAN, VAN
  • Control control technology, algorithm, S/W for
    control

25
Targets of CIM
  • Developing high quality products with low cost
  • Integration and control of product design and
    manufacturing processes
  • Easy financial management
  • Increasing volume of sales

26
Benefits of CIM
  • Marketing
  • Engineering design
  • Research and Development
  • Manufacturing processes
  • Financial planning

27
Manufacturing system
  • Manufacturing system facility production
    technology management
  • Applying GT, CAPP, TMS to Production technology
  • Applying MRP, JIT to Management
  • Wide manufacturing system facility production
    technology management product design
    business plan

28
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29
Integrated Production System(ex)
30
Factory automation CIM
philosophy automation optimization
target unmanned factory rationalize
example FMC, FMS Linking CAD, CAM, MRP
element processing, material flow, measurement, inspection, assembly, CAD, CAM, CAPP, CAQ, MRP
target factory enterprise
focus hardware software
human replacing human reorganization
origin Japan USA, Europe
31
Function of CIM
  • 1) Order information and automatic scheduling
    through computer
  • - dealing individual orders of various
    products
  • - control of due dates
  • - preparing production planning
  • 2) Inventory control through JIT
  • - minimizing raw material, WIP, inventory
  • - utilizing bar code, RFID

32
  • 3) Statistical quality control
  • - quality improvement
  • 4) Monitoring facility, process
  • - data collection for facility operating
  • - report for producing defective goods
  • - records analysis of failing facility

33
  • 5) Data collection for MIS
  • - WIP data
  • - shipment data
  • - direct indirect labor data
  • - production control data defective rate,
    operation rate, failure rate, production rate
  • - supplier record quality, acomplishment
  • - defective production data

34
  • 6) Managing MIS Data
  • - reducing indirect cost
  • - rapid decision making using database
  • 7) Diagnosing failure
  • - minimizing down time
  • - details of failure (problems)

35
  • 8) Managing Technical Data, Document
  • - managing S/W program
  • - tool life data
  • - quality data
  • - product history
  • - document update
  • 9) Standard

36
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37
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38
CIM Hierarchy
  • 1st Level production facility
  • CNC, Robot, PLC
  • 2nd Level Work Cell
  • controlling 1st level activity
  • applying data from 1st to
  • process, production, quality control

39
  • 3rd Level Area level
  • managing several lines
  • production plan, facility maintenance
  • scheduling, assigning material, facility
  • 4th Level Factory level
  • controlling function of whole factory,
    inter-factory
  • sales control, wages, finance, long term
    production plan, marketing, customer services

40
Standardization for CIM
  • Capability of information transfer for different
    types of facilities

CIM Standard
ISO standard 6 levels Enterprise, factory,
area, cell, station, equipment
41
Manufacturing Automation Protocol - GM
  • Communication b/w different types of facility
  • Factory level network for machine device, robot,
    PLC, Computer
  • 7 levels

42
Technical Office Protocol Boeing, NBS
  • Data communication for different types of devices
    b/t office and design
  • Spread sheet, draft drawing, design, business
    document, e-mail

43
Initial Graphics Exchange Specification ANSI,
NBS
  • Data communication b/t CAD system
  • Neutral data file for data transformation b/t
    different CAD system

44
Product Data Exchange Specification NIST
  • Transformation of product information for
    different CAD system
  • Shape feature design element
  • Non-shape feature processing, inspection,
    assembly, material, heat treatment, strength

45
Standard for External Representation of Product
Data
  • ISO Workgroup TC 184/SC4
  • International standard for representing product
    model and data exchange format

46
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47
Function of CIM
  • Upper Level Planning, management, control
  • discrete time information
  • slow response time
  • Lower level action
  • - continuous time information
  • rapid response time

48
Upper Level Allocation
49
Enterprise System
  • Production planning control
  • Information technology management

Plant Control System
  • Scheduling
  • Material resource planning
  • Quality control

50
Optimization at Upper Level
  • Production plan
  • N production center m types of products
  • B1, b2, . bm
  • Linear programming
  • S.t.

51
Transportation Plan
  • From L warehouse to k warehouse,
  • e1, e2, e3, , ek transport
  • Linear programming

52
Elements of Upper Level of CIMat Enterprise,
Factory, Area
  • CAPP
  • MRP
  • Capacity Planning

53
Computer Aided Process Planning
  • Priority for process
  • Machine tool, process parameter
  • Not consistent for manual planning
  • Retrieval type GT code
  • Generative type

54
Generative Type
  • process plan for each part
  • Logic for process planning
  • 3D model for product information
  • Utilizing Group Technology
  • Logics for process planning and product
    information are integrated in database system

55
Material Requirement Planning
  • Inventory control for raw material, WIP, parts
  • MRP
  • - master production schedule file
  • - Bill of Material file
  • - MRP software for application

56
Capacity Planning
  • Evaluating manufacturing capacity
  • Allocating machine, facility, work personnel to
    MRP
  • Information for Capacity Planning
  • - production plan from MRP
  • - processing order
  • - work order specification
  • - facility
  • - man power

57
Function of CIM at Lower Level
  • Cell, Station, Device Level
  • Cell Controller
  • - production schedule from area level
  • - program selection for task
  • - down load the program

58
Function of CIM at Lower Level
  • Station Controller
  • - Managing PLC, Robot, CNC, sensors
  • - Controlling devices
  • - Controlling processes
  • - Monitoring processes

59
Function of CIM at Lower Level
  • Devices level
  • - CNCs, Robots, PLCs, Sensors,
  • Conveyors

60
Constructing Steps for CIM
  • Controlling production processes
  • - automation for order, supply,
    manufacturing, inspection, packing, shipping
  • - integration of manufacturing and office
    management
  • 2) Constructing communication network and database

61
Constructing Steps for CIM
  • 3) Automated processes, assembly, production
  • Reengineering for design
  • 4) Development and manufacture of automated
    processing facilities
  • Adopting automated recognizing system

62
Constructing Steps for CIM
  • 5) Enabling CIM for enterprises with business
    relationships
  • 6) Introducing Top down
  • Action Bottom up

63
Obstacles for CIM
  1. Communications b/t various companies of
    suppliers
  2. Automated facilities independently
  3. Weak solutions

64
Investment for CIM
  • Marketing managing customers report
  • Engineering Design using CAD
  • RD developing new products
  • Manufacturing process process planning,
    scheduling, reducing manufacturing lead time
  • Financing costing

65
Advantages of CIM
  1. Reducing developing time for new product
  2. Reducing transporting time
  3. Optimal inventory control
  4. Reducing planning time for production
  5. Reducing lead time for production
  6. Rapid response for customers claim
  7. Quality improvement
  8. Increasing competitive power

66
????? CIM ??? ??? ??
67
??? ?? ?? ??
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