IML 425E:
425E: Introduction
IML 425E
425E
Elements of
COMPUTER INTEGRATED MANUFACTURING
by: H. Livatyalı
Fall 2009
2009 - 201
2010
ITU Dept. of ME
Gümüşsuyu, ISTANBUL
Gümüşsuyu,
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COURSE OUTLINE – IML 425E
425E
IML 425E:
425E: Introduction
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Introduction: major concepts
Network communications and enterprise integration
Review of part specification and CAD
Concurrent engineering
Computer-aided process planning
Computer numerical control (CNC) architecture and CNC programming
Programmable logic controllers
Automated materials handling and storage systems
MT
Industrial robotic systems
Manufacturing planning and control systems
Group technology and cellular manufacturing systems
Flexible manufacturing systems
Just-in-time manufacturing systems
Internet enabled manufacturing, virtual manufacturing, product data
management, management of emerging manufacturing technologies
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Basic Definitions for Manufacturing Systems
IML 425E:
425E: Introduction
Manufacturing is a set of correlated operations and activities
which includes product design, material selection, planning,
production inspection, management, and marketing of the
products, for the manufacturing industries.
Manufacturing Processes are the lower level activities (casting,
forming, machining, joining etc.) used to make products.
Manufacturing Engineering involves the design, operation and
control of manufacturing processes.
Manufacturing System is an organization that comprises several
interrelated manufacturing subsets. Its objective is to interface
with outside production functions in order to optimize the total
productivity performance of the system.
[Wang et al, 98] 3
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MANUFACTURING
IML 425E:
425E: Introduction
• The word “Manufacturing” is derived from the
Latin “ Manufactus”, meaning “Made by Hand”
• In a broad sense Manufacturing in the modern
world includes:
– product design
– prototype production
– manufacturing process and equipment
– quality control
– packaging & shipping
– marketing & sales
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Manufacturing
As A Technical Activity
IML 425E:
425E: Introduction
• The ultimate purpose of all engineering disciplines
is to produce something tangible and salable and
hopefully for the benefit of humanity.
• Manufacturing must be competitive in a global
economy; therefore, manufacturing productivity is a
major concern.
• Even if manufacturing employment declines,
contribution to GNP must be maintained to keep
the level of the standard of living.
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PRODUCTION
IML 425E:
425E: Introduction
• In Turkish: ÜRETİM; Doğada değişiklik yapma
• In a broad sense,
sense, production includes:
– Manufacturing
– Agriculture and food
– Chemical and metallurcigal industries
– Textiles
– Consumer electronics
– All sorts of supply items
– … Almost all the economic activities except
finance and commerce
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MANUFACTURIING
MANUFACTUR
IML 425E:
425E: Introduction
Manufactus”,
”,
• “Manufacturing
Manufacturing”” is derived from the Latin “ Manufactus
meaning “Made
“Made by Hand”
Hand”
• In Turkish: İMALÂT; Hammadde kullanılarak yapılan üretim
• In a broad sense,
sense, manufacturing in the modern world
includes:
– product design
– prototype production
– manufacturing process and equipment
– quality control
– packaging & shipping
– marketing & sales
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MANUFACTURING vs. PRODUCTION
IML 425E:
425E: Introduction
In broad meaning:
PRODUCTION
MANUFACTURING
In second meaning:
MANUFACTURING
PRODUCTION
… day to day production
… application of manufacturing in daily basis
Ex. Production planning and control (PPC)
In former British English: Production ~ Manufacturing
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The Manufacturing Enterprise
IML 425E:
425E: Introduction
[Singh, 98]
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Manufacturing Processes
IML 425E:
425E: Introduction
• In a process used for manufacturing “discrete
“discrete parts”,
parts”, a
given “material
“material”” (usually shapeless or of simple
geometry) is transformed into a “useful
“useful part”.
part”.
• This part usually has a complex geometry with well
defined
a) Shape,
b) Size,
c) Accuracy and Tolerances,
d) Properties, and
e) Appearance.
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Classification of
Manufacturing Processes
IML 425E:
425E: Introduction
A - Conventional Processes
• Primary Shaping (casting, injection molding, powder
metal compaction)
• Plastic Deformation (rolling, extrusion, forging, deep
drawing)
• Material Removal (turning, milling, broaching, EDM, ECM)
• Material Treatment & Finishing (heat treating, anodizing,
surface hardening)
• Joining and Assembly (welding, brazing, mechanical
assembly)
B - New Processes
• Additive Manufacturing (AM; Generative Technologies;
SLS, SLA, LOM, FDM, 3D printing)
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Computer Integrated Manufacturing
IML 425E:
425E: Introduction
CIM 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 personal
efficiency (SME).
The goal of CIM is the integration of all enterprise operations
and activities around a common corporate data
repository.
The term CIM was first coined by Harrington in 1973, by
introducing for an integrated approach to the enterprise
and against highly fragmented manufacturing operations
that lead to localized optimization.
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A Brief History
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The evolution of paradigms
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Automation and Control Technologies in the
Production System
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CIM
System
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[Groover, 01]
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The CIM Wheel
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Various Aspects of CIM
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425E: Introduction
• CIM is computerized integration of all aspects of design,
planning, manufacturing, distribution and management.
• CIM is more of a methodology and goal rather than
assemblage of equipment and computers.
• CIM depends on a large scale Integrated
Communications System involving computers, M/T’s and
controls.
Functions of Planning:
• Forecasting, Scheduling, Materials Requirement Planning
(MRP), Invoicing, and Accounting
Functions of Execution:
• Production, Process Control, Material Handling, Testing, and
Inspection
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Elements of CIM
IML 425E:
425E: Introduction
• Manufacturing Systems
• CADD
• CAE
• CAM
• CAPP
• Computer Simulation of Manufacturing Processes
• Concurrent Engineering
• Group Technology and Cellular Manufacturing
• Flexible Manufacturing Systems (FMS
(FMS))
• JIT Production (Lean Production and Agile Manufacturing)
• Communication Networks
• AI (Expert Systems, ANN and Fuzzy Systems)
• Automated inspection systems
E-manufacturing, EE-maintenance ...
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Benefits of CIM
IML 425E:
425E: Introduction
• Responsiveness to shorter product cycles, changing marker demand,
and global competition
• Emphasis on product quality and its uniformity through better process
control
• Better use of materials, machinery, and personnel, and reduction of
work--in
work
in--progress (WIP) inventory, thus improving productivity and
lowering product cost
• Better control of production, scheduling and management of the total
manufacturing operation, resulting in lower product cost
DATABASE:
• A single database shared by the entire manufacturing organization
• It consists of up
up--to
to--date, detailed and accurate data related to predicts,
designs, machines, processes, materials, production, finances,
purchasing, sales, marketing and inventory.
• Data Acquisition Systems (DAS)
• Databases must be timely, accurate, easily accessible, easily shared
and user friendly.
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IML 425E:
425E: Introduction
Cost vs. Time
[Singh, 98]
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Common Product Cost Structure
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[Groover, 01]
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Levels of
System Integration
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[Groover, 01]
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Computer Communications and LAN’s
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CADD
CAD
D: Computer Aided Design and Drafting
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425E: Introduction
CAD <=> Interactive Computer Graphics
Elements of CAD Systems:
• Geometric Modeling
• Design Analysis & Optimization
• Design Review & Evaluation
• Documentation & Drafting (or draughting)
IGES (Initial Graphics Exchange Specification)
PDES (Product Data Exchange Specification)
STEP (Standard for the Exchange Product Model data)
DXF (Data Exchange Format; AutoAuto-CAD)
Solid Models (Parasolids)
Proprietary Formats (PDGS; Ford)
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CAD: Mathematical Modeling
IML 425E:
425E: Introduction
Axisymmetric
Model
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Surface
Model
Solid
Model
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CAE
IML 425E:
425E: Introduction
Analysis Methods:
• Closed form (analytical) solutions
• Numerical Solutions (approximate numerical analysis)
• FDM (Finite Difference Method, e.g. CFD)
• FEM (Finite Element Method)
• FVM (Finite Volume Method)
• Computer Optimization systems
• Stochastic Systems
• Knowledge Based and Expert Systems
• Neural Networks
• Fuzzy Logic Systems
• Computerized experimentation and data acquisition
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CAM
IML 425E:
425E: Introduction
CAM is the use of computers and computer technology to assist in all phases
of manufacturing a product, including process and production planning,
machining, scheduling, management and quality control.
In the integrated
integrated CAD/CAM Systems:
Systems:
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CAD & CAM modules share common database
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No need for data exchange or recreation
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Automatic tool path generation
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Toll path verification and prevention of possible tool collisions with jigs,
fixtures or other interferences
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Coding and classification of parts using alphanumeric coding
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Standardized product development
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Reduced design effort, tryout and prototype work
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Reduced cost and increased productivity
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Evolution of
CAD and CAM
IML 425E:
425E: Introduction
[Singh, 98]
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CAPP: Computer Aided Process Planning
IML 425E:
425E: Introduction
Process planning is concerned with selecting methods of production,
tooling, fixtures, and machinery, sequence of operations and assembly.
> Variant (derivative) System:
System:
The computer file contains a standard process plan for the part to be
manufactured.
The standard process plan includes tools and M/T’s to be used, sequence
of manufacturing operations, operation data (speeds, feeds, time etc.)
An old plan for a similar part may easily be retrieved and modified, and the
routing sheet can be generated.
> Generative System:
System:
The process plan is automatically generated based on the same logical
procedures followed by a traditional process planner (Expert System).
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CE: Concurrent Engineering
IML 425E:
425E: Introduction
... 21st Century’s response to competive conditions of the world
market.
CE refers to the process of considering simultaneously the
requirements of assembly and manufacturing with design
requirements in order to reduce unit cost of production,
improve quality and reduce total lead time.
CE is managing mutual dependences of design, manufacturing,
distribution, support and service
CE’s
CE’s aim is to minimize lifelife-cycle cost, maximize customer
satisfaction, maximize flexibility, minimize lead time from
conception to delivery to the customer.
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Computer Numerical Control
IML 425E:
425E: Introduction
NC is a method of controlling the movements of machine tools
(M/T) by directly inserting coded instructions in the form of
numerical data (numbers and letters) into the system.
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PLC: Programmable Logic Controller
IML 425E:
425E: Introduction
Control of manufacturing processes in a proper sequence has been
performed by timers, switches, relays, counters etc. hardhard-wire devices
based on mechanical, electroelectro-mechanical, and pneumatic principles.
PLC’s
PLC
’s (Programmable Logic Controllers, since 1968) replace those.
PLC: A digitally operating apparatus which uses a programmable memory
PLC:
for internal storage of instructions for implementing specific functions such
as logic sequencing, timing, counting, and arithmetic to control through
digital or analog input/output modules, various types of machines or
processes.
PLC’s are heavy duty devices designed to operate in industrial environment.
Basic PLC functions:
On
On--off, motion, sequential operation and feedfeed-back control.
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Automated Materials Handling
and Storage Systems
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IML 425E:
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AGV’s, conveyors, cranes ...
Automatic Storage Systems
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Industrial Robotics
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Robot: Forced Labor
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Computerized Manufacturing Planning
and Control Systems
IML 425E:
425E: Introduction
The primary goal of MPCS (Manufacturing Planning and
Control Systems) in any organization is to ensure that the
desired products are manufactured:
manufactured:
• at the right time,
• in the right quantities,
• meeting the quality specifications and
• at minimum cost.
The integrated activities of MPCS are:
Determining the endend-item demand, translating demand into
production plans, establishing detailed plans of material flows
and tha capacity to support the overall manufacturing plans,
helping execute the plans etc...
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GT: Group Technology
IML 425E:
425E: Introduction
GT (Group Technology) provides a means of
identifying and exploiting similarities of parts and
processes.
Processing groups of similar parts together reduces
unnecessary duplication of effort by standardizing
and simplifying design features as well as related
manufacturing activities.
Includes coding and classification systems, cell design
methodologies and planning and control.
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Cellular Manufacturing
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425E: Introduction
Cellular manufacturing has some degree of automatic control
for:
• Loading and unloading raw materials and workpieces at WS
• Changing tools at WS
• Transferring workpieces and tools between WS
• Scheduling and Controlling the total operation in the cell
Central to this is a materials handling system.
• Attended (manned) Cells
• Untended (unmanned) Cells (indirect monitoring)
>>> Reduced workwork-inin-progress
>>> Multi functional operator and increased productivity.
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FMC: Flexible Manufacturing Cell
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FMS: Flexible Manufacturing System
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FMS consists of a number of manufacturing cells, each
containing an industrial robot serving several CNC
machines and an automated material handling system, all
interfaced with a central computer.
FMS represent the highest level of efficiency, sophistication
and productivity that has been achieved in manufacturing
plants.
FMS combines the benefits of:
• Highly productive but inflexible transfer lines
• Job
Job--shop production which can produce large product
variety on stand alone machines but is inefficient.
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JIT: JustJust-In
In--Time Production
IML 425E:
425E: Introduction
Goals of JIT:
• Receive supplies just in time to be used
• Produce parts just in time to be made into subassemblies
• Produce subassemblies just in time to be assembled into
finished products
• Produce and deliver finished products just in time to be sold
Traditional systems: Push systems
JIT systems:
Pull systems
KANBAN: (Visible record)
>> Production card and conveyance (move) card
>> Recently: bar coded plastic tags or other devices
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Factory of the Future
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?
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