Introduction to Computer Integrated Manufacturing (CIM) Learning Objectives

Transcription

1 Introduction to Computer Integrated Manufacturing (CIM) 1 Learning Objectives Modern manufacturing process and its various components, highlighting the different systems (e.g., CAD, CAE, MRP/ERP, CAM, CNC, CMM and PDM), showing: different types of information what happens in each system integration challenges 2 1

2 Basic Flow of Information Customer Requirements Requirements Engineering Product Characteristics Manufacturing / Supplier Processes 3 Production Quality Controls 4 Manufacturing Systems Computer Aided (CAD) Computer Aided Engineering (CAE) Finite Element Analysis (FEA) Computational Fluid Dynamics (CFD) Manufacturing Resource Planning (MRP) Enterprise Resource Planning (ERP) Computer Aided Manufacturing (CAM) Product Data Management (PDM) Co-ordinate Measuring Machine (CMM) Computer Numerical Control (CNC) 2

3 Manufacturing Data Request for Quote (RFQ) Process Plan Bill of Material (BOM) Customer order Supplier and component data Product design Analysis & simulation data NC program Tooling and fixture design Engineering Change data Purchase Order (PO) Assembly instructions Operating, maintenance and user manual specification Inspection & verification data Test plan, test instruction, test cases and test results QC & QA data 5 Typical to Production Flow CAD Systems Concept Preliminary Detailed CAE Systems Engineering Analysis Engineering Manufacturing Prelim Production Planning Production Planning ERP or MRP Systems CAM Systems 7 Prelim Tool Final Tool NC Programming 3

4 Typical to Production Flow CAD Systems Concept Preliminary Detailed Engineering Manufacturing 9 What is CAD? Computer-Aided I-DEAS, CATIA, Unigraphics, ProE Use of computers in the product design process; can be used for sketching, schematics, analysis, and prototyping CAD systems can be used for Geometric Modeling (parametric, features); and Automatic Drafting (sectional views, projections, etc.) 10 4

5 I-DEAS CAD Systems 11 Unigraphics CAD System 12 5

6 Typical to Production Flow CAD Systems Concept Preliminary Detailed CAE Systems Engineering Analysis Engineering Manufacturing 14 What is CAE? Computer-Aided Engineering StarCD, Ansys, and Abaqus Use of computer simulation as a tool for Engineering Analysis : Minimize part weight, increase part robustness, etc. Integrate with CAD and CAM 15 6

7 Types Of CAE Dynamic Analysis Stress Analysis FEA (Finite Element Analysis) 16 Thermal Analysis Flow Analysis CFD (Computational Fluid Dynamics) Typical to Production Flow CAD Systems Concept Preliminary Detailed CAE Systems Engineering Analysis Engineering Manufacturing Prelim Production Planning Production Planning ERP or MRP Systems CAM Systems 17 Prelim Tool Final Tool NC Programming 7

8 What is CAM? Computer-Aided Manufacturing Determine the accuracy of designs prior to manufacture Uses CAD drawings to produce the machine code needed to make the actual part Eliminates unnecessary production cost as well as reducing time needed to produce part 19 CAM Systems Automatic Lathe CNC 21 8

9 CAM Systems CMM coordinate measuring machine 22 Typical to Production Flow CAD Systems Concept Preliminary Detailed CAE Systems Engineering Analysis Engineering Manufacturing Prelim Production Planning Production Planning MRP or ERP Systems 27 9

10 PDM Systems (Product Data Management) What is PDM? Product Data Management Giving people the right information to do their job at the right time On average people spend 40% of time looking finding right data only 20% of the time Used mainly for concurrent engineering 37 10

11 Detailed Example of the Engineering Process at Wescast Industries 38 Wescast Industries World s largest supplier of exhaust manifolds for passenger cars and light trucks Work with customers globally Manufacturing facilities in Ontario (5), as well as the USA and Hungary Sales and design locations in Canada, Germany, the USA and the UK Use I-DEAS, CATIA, Unigraphics and ProE 39 11

12 Engineering Process Stress Simulation Flow Simulation 3-D CAD Process Simulation Production Rapid Prototyping Part Approval Verification Rapid Tooling Validation 40 Wescast Engineering Process Flow Concept Flow Simulation Stress Simulation Process Simulation Rapid Prototyping Verification Rapid Tooling Validation Part Approval 41 Production 12

13 Wescast Engineering Process Flow Concept 42 Concept 3-D CAD Stage This is where the customer & manufacturing requirements are captured and modeled into a 3-D Computer Aided Virtual. This data is used in all subsequent stages D CAD model ready for translation to other formats 13

14 Concept 44 Workarounds chair initial design review meetings. use outside resources to create or improve geometry. work shifts or take advantage of Global time difference. 3-D CAD Stage This is where the customer & manufacturing requirements are captured and modeled into a 3-D Computer Aided Virtual. This data is used in all subsequent stages. Potential Errors miscommunication incomplete design incorrect data Challenges lack of information incompatible geometry tight time-line lack of resources 3-D CAD model ready for translation to other formats Wescast Engineering Process Flow Concept Flow Simulation 45 14

15 Flow Simulation Flow Simulation Flow Simulation Stage Computational Fluid Dynamics is used to virtually simulate the exhaust gas flow thru the manifold. Gas elements are checked such as; velocity, temperature, pressure and dispersement across the exit opening. This information is used to optimize the manifolds flow rate and improve emissions. 46 Analysis data report Interactive 3-D visual flow image Flow Simulation Workarounds use outside resources to create or improve geometry. work shifts or take advantage of Global time difference. make assumptions Flow Simulation Flow Simulation Stage Computational Fluid Dynamics is used to virtually simulate the exhaust gas flow thru the manifold. Gas elements are checked such as; velocity, temperature, pressure and dispersement across the exit opening. This information is used to optimize the manifolds flow rate and improve emissions. Challenges lack of information incompatible geometry tight time-line lack of resources 47 Potential Errors miscommunication incorrect assumption incorrect data Analysis data report Interactive 3-D visual flow image 15

16 Wescast Engineering Process Flow Concept Flow Simulation Stress Simulation 48 Stress Simulation Stress Simulation 49 Stress Simulation Stage Finite Element Analysis is used to virtually apply stress forces to the manifolds exterior design. In a virtual environment the manifold is mounted onto the cylinder head of the engine. Next, virtual forces are applied bringing the weak areas to the surface, which are highlighted in a colour map. This information is used to increase robustness and eliminate redundancy. Analysis data report Multiple colour images 16

17 Stress Simulation Workarounds use outside resources to create or improve geometry. work shifts or take advantage of Global time difference. make assumptions 50 Stress Simulation Potential Errors miscommunication incorrect assumption incorrect data Stress Simulation Stage Finite Element Analysis is used to virtually apply stress forces to the manifolds exterior design. In a virtual environment the manifold is mounted onto the cylinder head of the engine. Next, virtual forces are applied bringing the weak areas to the surface, which are highlighted in a colour map. This information is used to increase robustness and eliminate redundancy. Challenges lack of information incompatible geometry tight time-line lack of resources Analysis data report Multiple colour images Wescast Engineering Process Flow Concept Flow Simulation Stress Simulation Process Simulation 51 17

18 Process Simulation Process Simulation Stage This is where the manufacturing process is simulated using computer aided technologies. During this stage process related defects are projected. This virtual information is used to help refine the process design in order to reduce scrap rates and improve yield. 52 Interactive 3-D visual images showing solidification results. Process Simulation Interactive 3-D visual images showing solidification results. Process Simulation Stage This is where the manufacturing process is simulated using computer aided technologies. During this stage process related defects are projected. This virtual information is used to help refine the process design in order to reduce scrap rates and improve yield. Potential Errors incorrect data incorrect material parameters. Workarounds use outside resources for computing power, or to create or improve geometry. Challenges incompatible geometry tight time-line lack of resources slow computer process speeds obtaining material parameters

19 Wescast Engineering Process Flow Concept Flow Simulation Stress Simulation Process Simulation Rapid Prototyping 54 Rapid Prototyping Rapid Prototyping Stage In this stage the 3-D Computer Aided Virtual is transformed into a physical replication. This hand held replica is used by all team members to better visualize the design intent. It can be mounted to an engine to check for interference issues, and it can also be used to perform physical testing. 55 Full size physical representation of the final product. 19

20 Rapid Prototyping Rapid Prototyping Stage In this stage the 3-D Computer Aided Virtual is transformed into a physical replication. This hand held replica is used by all team members to better visualize the design intent. It can be mounted to an engine to check for interference issues, and it can also be used to perform physical testing. Workarounds use outside resources to create or improve geometry, or to create the physical prototype. Challenges incompatible geometry tight time-line lack of resources 56 Potential Errors incorrect data poor assembly and build. Full size physical representation of the final product. Wescast Engineering Process Flow Concept Flow Simulation Stress Simulation Process Simulation Rapid Prototyping Verification 57 20

21 Verification Verification Stage Using a Rapid Prototype, air is pressurized thru the manifold design. Elements that are checked range from: air velocity, volumetric flow, and dispersment across the exit opening. The resulting information here is used to substantiate data that is derived from the CFD results. This test is also used when computational resources are limited. 58 Analysis data report with volumetric flow results. Results compare inlet ports for balance. Verification Potential Errors incorrect set-up machine out of calibration 59 Workarounds use outside resources to create or improve geometry. work shifts or take advantage of Global time difference. make assumptions Verification Stage Using a Rapid Prototype, air is pressurized thru the manifold design. Elements that are checked range from: air velocity, volumetric flow, and dispersment across the exit opening. The resulting information here is used to substantiate data that is derived from the CFD results. This test is also used when computational resources are limited. Challenges lack of information tight timeline lack of resources Analysis data report with volumetric flow results. Results compare inlet ports for balance. 21

22 Wescast Engineering Process Flow Concept Flow Simulation Stress Simulation Process Simulation Rapid Prototyping Verification Rapid Tooling 60 Rapid Tooling Rapid Tooling Stage This stage is where rapid tooling is created using the 3-D Computer Aided Virtual CAD data. 61 Rapid tooling designed to support low volume production runs. 22

23 Rapid Tooling Potential Errors incorrect CAD data incorrect tool design Workarounds use outside resources to create or improve geometry. use outside resources to create tooling. use outside resource overseas. Rapid Tooling Stage This stage is where rapid tooling is created using the 3-D Computer Aided Virtual CAD data. Challenges incompatible geometry tight time-line lack of resources Overseas deliveries 62 Rapid tooling designed to support low volume production runs. Wescast Engineering Process Flow Concept Flow Simulation Stress Simulation Process Simulation Rapid Prototyping Verification Rapid Tooling Validation 63 23

24 Validation 64 Analysis report on durability, failures, warping, cracking, breakage & melt down. Validation Stage The Engine Exhaust Simulator is used to validate the manifold design. It replicates the engine testing that is used by the customer (better known as the Dynamometer test). The information gathered here will be used to help validate the manifold design. Inferred Images Validation Potential Errors incorrect manifold incorrect set-up Workarounds make assumptions to customers dyno set-up. Analysis report on durability, failures, warping, cracking, breakage & meld down. 65 Validation Stage The Engine Exhaust Simulator is used to validate the manifold design. It replicates the engine testing that is used by the customer (better known as the Dynamometer test). The information gathered here will be used to help validate the manifold design. Inferred Images Challenges tight time-line lack of resources matching the customers Dyno set-up 24

25 Wescast Engineering Process Flow Concept Flow Simulation Stress Simulation Process Simulation Rapid Prototyping Verification Rapid Tooling Validation Part Approval 66 Part Approval Part Approval Stage The Dyno test is performed by the customer on a prototype engine. The engine cycles hot (900C) & cold (200C) for 200 hours. 67 Observation comments pertaining to crack, warp, breakage, leak and melt down 25

26 Part Approval Potential Errors incorrect manifold design late delivery Workarounds use a mock-up of a similar production part Part Approval Stage The Dyno test is performed by the customer on a prototype engine. The engine cycles hot (900C) & cold (200C) for 200 hours. Challenges tight time-line capturing all design changes 68 Observation comments pertaining to crack, warp, breakage, leak and melt down Wescast Engineering Process Flow Concept Flow Simulation Stress Simulation Process Simulation Rapid Prototyping Verification Rapid Tooling Validation Part Approval Production 69 26

27 Production Production Stage Once the manifold design has been validated by the Dyno test, the customer will give the approval to begin the production tooling. 70 A production part that meets and/or exceeds the customer expectations. Production Potential Errors manifold design is not production intent 71 Workarounds NONE Production Stage Once the manifold design has been validated by the Dyno test, the customer will give the approval to begin the production tooling. A production part that meets and/or exceeds the customer expectations. Challenges tight time-line capturing design intent from prototype designs to production designs meeting quoted target rates 27

28 72 Summary CAD systems generate the product design Can be expensive and some designers struggle to make the 2-D to 3-D paradigm shift CAE systems support design improvements through virtual simulations Not widely accepted yet and expensive to operate CAM systems used to manufacture tooling from CAD designs Compatibility with CAD systems is still a problem ERP/MRP systems used to monitor and manage entire business PDM systems used to tie design management with manufacturing management Need company-wide buy-in, may be a high cost 73 Islands of Automation Systems evolution CAM CAD CAPP CAE PDM Robotics DNC CIM FMC VM B2C GUI B2B NC FMS CNC ERP AM OPT OO SCM GT CAPM MRP TPM MRPII WCM PDM JIT TQM LM QC QA 2D drafting WWW 6σ 1960 s 1970 s 1980 s 1990 s 2000 s Deming s 14 rules IBM vs SAP: Evolution of complex system: open / data driven 28