Upload
gsudhanta1604
View
131
Download
4
Tags:
Embed Size (px)
DESCRIPTION
cim notes.pdf JJJJJJJJJJJJJJ VVVVVVVVVVVVVVVVVV VVVV VV B
Citation preview
17.12.2008
1
Computer integrated
manufacturing
(Lecture #13)
CIM (Computer Integrated CIM (Computer Integrated Manufacturing)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
17.12.2008
2
Computer Integrated Computer Integrated ManufacturingManufacturing
CIM allows the online and batch-related acquisition of process and quality data.
The flow of material within a multi-stage production process can be planned at any time and monitored from the central station.
Computer Integrated Computer Integrated ManufacturingManufacturing
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.
17.12.2008
3
CIM ConceptCIM Concept
l Acquisition of possible quality-relevant data of different process steps
l Serial interfacing of SPCs of a wide variety of manufacturers
l Assignment of data of each process step to individual silicon wafers (materials tracking)
l Acquisition of the wafer qualityl Visualisation of the possible quality-relevant data
on the wafer qualityl Evaluation of the datal Data storage for long-time CAQl Job and materials management
Historical Background (I)Historical Background (I)
1970s - 1980s…Flexible 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
17.12.2008
4
Historical Background (I)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)
1990s…Intelligent 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
17.12.2008
5
Historical Background (I)
1990s…Extended 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?What is CIM?
l a computer system?l a management philosophy?l a competitive strategy?l a data management and networking
problem?l a concept?l a technology?l a method for eliminating direct labor?l a deterministic technical system?l a socio-technical system?
17.12.2008
6
What is CIMWhat is CIM??
technology, tool or method used to improve entirely the design and manufacturing process and increase productivity
What is CIMWhat is CIM??l 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
l deliberate integration of automated systems logical organization of individual engineering, production and marketing/support functions into a computer integrated system
17.12.2008
7
What is CIM?What is CIM?
l 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?What is CIM?
l involves the use of computers to assist in
– the design,
– handling,
– processing,
– cataloging of materials as they flow through the manufacturing processes
l not computer controlled, but is the use of the computer assets to assist in difficult areas of manufacturing
17.12.2008
8
What is CIM?What is CIM?l 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?
l 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
17.12.2008
9
What is CIM?What is CIM?
l 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?What is CIM?
l 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
17.12.2008
10
What is CIM?What is CIM?
l 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?What is CIM?
l 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
17.12.2008
11
What is CIM?What is CIM?
l 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)
Computer Integrated Manufacturingis 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.
Definition of CIMDefinition of CIM
17.12.2008
12
Definition of CIMDefinition of CIM
DesignManufac-turing
Business
CIM
Major Subsystems in CIM
Marketing
CA- Storage &
Transportation(Logictics)
Information
System Quality
Product
CAD
Tool Machine
CAPP
PPS (MRP)
CAM
SFC CAPC TMS QC
Lower Level Controllers
17.12.2008
13
CIM Representative TopicsCIM Representative Topics
l Computer-aided concurrent engineering (CACE); Design for Manufacturability (DFM)
l PDES/STEP-based manufacturing applications l Computer numerical control (CNC); Direct/distributed
numerical control (DNC)l Computer process control, including adaptive process
controll Rapid prototyping principles & research
opportunitiesl Programmable controller/microcomputer applicationsl Computer aided process planning (CAPP), including expert
system applications l Industrial robot applications, including off-line
programmingl Group technology (GT) & GT manufacturing cells
CIM Representative TopicsCIM Representative Topics
l Flexible manufacturing systems (FMS's)l Local area networks, including MAP/TOP network
standards & ISO reference model l Production planning & control, including JIT andSAPl Product/process simulationl Automated material handlingl Data entry systemsl Automated inspection systems & quality engineeringl Productivity engineering, including manufacturing cost
analysisl MRP vs. JIT production systems; JIT vs. lean
manufacturing l AI applications in CIM l Other topics: Automation & human labor; green
manufacturing; AHP (decsion support tools)
17.12.2008
14
FLEXIBLE
MAUFACTURING
SYSTEM (FMS)
Conceptual idea is attributed to David Williamson in the 1960’s, but it took development of CNC and programmable controllers to make the concept truly viable.
Flexible ManufacturingFlexible Manufacturing SystemSystem
17.12.2008
15
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 ManufacturingFlexible Manufacturing SystemSystem
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)
Flexible ManufacturingFlexible Manufacturing SystemSystem
17.12.2008
16
A manufacturing system is a collection of integrated equipment and human resources, whose function is toperform one or more processing and/or assembly operations on a starting raw material, part, or set of parts.
Manufacturing System
=What are they?=How are they combined?=How are they organized?=Production machines=Material handling system=Computer control system=Human resources
Manufacturing System Components
17.12.2008
17
=Types of operations=Number of workstations & layout=Level of automation=Part or product variety (how to handle; types of flexibility)
Classification of Manufacturing System
=Mass production (transfer line)=Special systems=Flexible manufacturing system (FMS)=Flexible manufacturing cell (FMC)=Stand-alone CNC systems
Types of Manufacturing System
17.12.2008
18
FMS is a system dealing with ü high level distribution,ü data processingü and automated material flowUsing
computer controlled machines, assembly cells, industrial robots, inspection machines altogether with computer integrated material handling and storage systems.
( Mehdi Kaighobad)
Flexible ManufacturingFlexible Manufacturing SystemSystem
vFMS is a collection of
production equipment
logically organized under a host computer
and physically connected by a central transport system.
(David Perish)
Flexible ManufacturingFlexible Manufacturing SystemSystem
17.12.2008
19
FMS is a system consisting of 3 subsystems;fabricationmachiningassembly.
These subsystems are integrated with automatic storage; computer aided design, material handling devices and a computer.
(Kusiak)
Flexible ManufacturingFlexible Manufacturing SystemSystem
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
Flexible ManufacturingFlexible Manufacturing SystemSystem
17.12.2008
20
FMS: Impact on Manufacturing=Need for managing change=More complex products=Need for greater flexibility=Need for faster time-to-market
Flexible ManufacturingFlexible Manufacturing SystemSystem
Definition: FMSGroup of machines or processes, integrated with material handling equipment, and under the direction of a (central) control system, to produce avariety of parts, at non-uniform production rates, batch sizes & quantities.
Flexible ManufacturingFlexible Manufacturing SystemSystem
17.12.2008
21
Flexible ManufacturingFlexible Manufacturing SystemSystem
Operating Flexibility
Part
Desi
gn F
lexib
ilit
y
Types of FMS FlexibilityProduct design —Makes it possible toaccommodate 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.
Flexible ManufacturingFlexible Manufacturing SystemSystem
17.12.2008
22
Types of FMS FlexibilityOperating — Makes it possible to reducemanufacturing 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)
Flexible ManufacturingFlexible Manufacturing SystemSystem
=Microprocessor=Digital system simulation=Design optimization tools=Computer aided process planning=Process controlled quality=More software control=Advanced industrial controls=Industrial robots
FMS: Important Technologies
17.12.2008
23
=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
FMS: Other SignificantTechnologies
=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
Invest or Not Invest??
17.12.2008
24
=Production volumes=Product life & lead time requirements=Direct labor available=Dollars available to invest=Other investment alternatives for company
Invest or Not Invest??
Invest or Not Invest??
Product Flexibility (no. of part nos.Pro
ducti
on v
olu
me (
part
s/year)
Computer Integrated
Manufacturing Systems
(CIMS)CNC
Tra
nsf
er
line
17.12.2008
25
System Trade-offs
l 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
System Trade-offsl Stand-alone CNC
l Efficiently accommodates part design change
l Reprogram for design changeover/design change
l Low production quantities (~up to 800 parts/yr)
l CIMS
l Between high production rates & high flexibility (mid-volume)
l Fills in gap between transfer lines & low volume
l CNC machines
17.12.2008
26
FMS ConceptsFMS Concepts
l Single station routing part flow
l Sequential routing part flow
l Random routing part flow
FMS ConceptsFMS Concepts
l 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
17.12.2008
27
FMS ConceptsFMS Concepts
l 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
FMS ConceptsFMS Concepts
l 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
17.12.2008
28
FMS: Machine Tool TradeFMS: Machine Tool Trade--offsoffs
Tooling Flexibility Prod. Rate
Head changer
Multiple tool Moderate Moderate
Head indexer
Multiple tool Lowest Highest
Machining center
Single point (spindle)
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
17.12.2008
29
Personnel Requirementsfor 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 CellsManufacturing Cells
l Single station manned cells
l Single station automated cells
l Applications of single station cells
l Analysis of single station cells
17.12.2008
30
Single Station Manned CellsSingle Station Manned Cells
l 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
Single Station Automated CellsSingle Station Automated Cells
l 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
17.12.2008
31
Applications of Single Station Applications of Single Station CellsCells
l CNC machining center with parts carousel & automatic pallet changer
l CNC turning center with parts storage tray & robot (same or different parts)
l Cluster of CNC turning centers, each producing different part
l Plastic injection molding machine with mechanical arm to remove part
l Automated electronic assembly machinel Robotic assembly celll Stamping press that punches & forms small sheet
metal parts
Analysis of Single Station CellsAnalysis of Single Station Cells
l Determine number of required workstations
l Include setup timel Consider availability & machine
utilizationl Consider worker efficiencyl Consider defect ratel Determine number of machines for
single worker (cluster of machines)
17.12.2008
32
WHY NAME IT
FLEXIBLE MANUFACTURINGSYSTEM (FMS) ??
The Eleven Flexibilities
1 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
3 Operation Flexibility: ability to use different processing operations to produce part features
17.12.2008
33
4 Routing Flexibility: ability to use different machines to produce parts under the same set up to ensure against breakdowns and bottlenecks
5 Product Flexibility: ease of changing over the system to produce a new set of parts
6 Volume Flexibility: insensitivity of profit to production volume
7 Expansion Flexibility: ease of adding additional capacity
8 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
17.12.2008
34
Flexible ManufacturingFlexible Manufacturing SystemSystem
A general view of a flexible manufacturing system, showing several machine tools and an automated guided vehicle (Cincinnate Milacron Inc.)
Why FMSWhy FMS
Job Shops constitute 70% of the industrial systems
Its cheap
Its flexible
Its diverse
But highly inefficient production system
17.12.2008
35
Why FMSWhy FMS
=Increased Productivity=Cost-effective Investment=Flexibility
High Quality
Lower Cost
Shorter Lead Time
Resond to Change
Transfer Line
SpecialSystem
Flexible Manufacturing
Systems(FMS)
Manufacturing Cell
Standard and General Purpose
Machine
Low Product Variety High
High
Low
Flexible ManufacturingFlexible Manufacturing SystemSystem
Pro
ducti
on v
olu
me
17.12.2008
36
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
Flexible Manufacturing Cell
17.12.2008
37
Automated Storage and Retrieval Systems
AGV
AGV Machine
Center 2
M/CCELL
Load area/unload
Machine Center 3
CELLCONTROLLER
Flexible Manufacturing Cell
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
System Components
17.12.2008
38
Part Movement SystemØ ConveyorsØ tow cartsØ rail cartsØ AGVs
Parts are transported on palletized fixturesbetween stations
Docking areas are used for in process storage
Shuttles receive the loaded part and store indocks
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
17.12.2008
39
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
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
System Controller
17.12.2008
40
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
System Controller
17.12.2008
41
FMS DESIGN
Strategic issuesTactical 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
17.12.2008
42
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
17.12.2008
43
Computer Integrated ManufacturingComputer 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?