COMPUTER INTEGRATED MANUFACTURING

Transcription

1 COMPUTER INTEGRATED MANUFACTURING A. ALAVUDEEN N. VENKATESHWARAN

2 COMPUTER INTEGRATED MANUFACTURING

3 COMPUTER INTEGRATED MANUFACTURING A. Alavudeen Assistant Professor Department of Mechanical Engineering Kalasalingam University, Krishnankoil Tamil Nadu N. Venkateshwaran Assistant Professor Department of Mechanical Engineering Rajalakshmi Engineering College Chennai PHI Learning Private Limited New Delhi

4 COMPUTER INTEGRATED MANUFACTURING A. Alavudeen and N. Venkateshwaran 2008 by PHI Learning Private Limited, New Delhi. All rights reserved. No part of this book may be reproduced in any form, by mimeograph or any other means, without permission in writing from the publisher. ISBN The export rights of this book are vested solely with the publisher. Second Printing January, 2010 Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, Connaught Circus, New Delhi and Printed by Jay Print Pack Private Limited, New Delhi

5 CONTENTS Preface...xv Acknowledgements... xix 1. Introduction Definitions Basic Concepts Nature and Role of the Elements of CIM System CIM Wheel Concept or Technology? Evolution of CIM Development of Numerical Control Emergence of Computers Computer-Aided Design Computer-Aided Manufacturing (CAM) From CAD and CAM to CAD/CAM CASA/SME CIM Wheel (Background) Manufacturing Automation Protocol Overview Problems Definition Physical Alternatives (Layer 1 OSI Model) Data Link Layer (Layer 2 OSI Model) Application Layer Details for TOP Application Layer MAP and TOP MAP and Other Standards Islands of Automation 18 v

6 vi Contents 1.10 Challenges and Trends Manufacturing in Transition Profit and Performance Productivity and Automation 19 Review Questions Group Technology Introduction Basic GT Layouts Process (Functional) Layouts Product Layouts (Sequential-flow; Assembly Line) Comparison of Product and Process Layouts Designing Process Layouts Block Diagramming Relationship Diagramming Service Layouts Designing Product Layouts Line Balancing Coding System Opitz Classification System The MICLASS System 38 Review Questions Flexible Manufacturing Systems Introduction Dedicated Manufacturing Systems Flexible Manufacturing Systems Cellular Manufacturing Systems Major Elements of FMS Production Equipment Materials Handling System Problems with FMS Enterprise Resource Planning (ERP) Mixed-Model Assembly Lines Cell Technology and Flexible Manufacturing Systems Process/Production Flows and Cell Technology Teams and Cells Automatic Guided Vehicles (AGVs) Advantages of Using AGV Systems in FMS Automated Storage (AS) and Retrieval Systems (RS) Buffer Storing of Parts Chip Removal and Washing Stations Computer Control System Optimization of FMS Operational Elements of a Typical Flexible Manufacturing Cell 56

7 Contents vii Types of Data Associated with the Flexible Manufacturing Cell Job Scheduling Tool Requirements Setting up Workplace Carrier Clamping or Palletising Material Flow Control Machine Tool Program Synchronization CNC Program Supply Tool Flow Control Tool Changing Cell Magazine Management System Visualization System Configuration 64 Review Questions Shop Floor Control Introduction Shop Floor Control Features Major Displays Major Reports Phases of SFC Order Release Order Scheduling Order Progress Manufacturing Control Methodology Application Simplified Manufacturing Planning and Control System Inputs Manufacturing Planning and Control System Manufacturing Planning Software Manufacturing Control Software Cost of Inadequate MPC MPC System Activities Shop Floor Data Collection Types of Data Collection Systems On-line Data Collection Systems Off-line (batch) Data Collection Systems Data Input Techniques Centralized Terminal Satellite Terminals Work Centre Terminals Automatic Data Collection System Bar Code Technology 79

8 viii Contents Fixed Beam Reader Moving Beam Reader 80 Review Questions Production Planning and Control Operation Management The Conversion Process Where Do New Products and Services Come From? Planning for Production Design Planning Facilities Planning and Site Selection Operational Planning Operations Control Purchasing Inventory Control Scheduling Quality Control 88 Review Questions Computer Aided Process Planning Automated Process Planning Computer-Aided Process Planning Methods of Computer-Aided Process Planning Variant Process Planning Generative Process Planning Artificial Intelligence Implementation Considerations Process Planning Systems MRP (Material Requirements Planning) Manufacturing Resource Planning (MRP II) 107 Review Questions JIT-Lean Production History of MRP, JIT and Lean Production Automobile Manufacturing Production Methods Toyota Production System Just-in-Time Production Kanban System Automation Lean Manufacturing What is Lean Manufacturing? Principle of Lean Some Basic Characteristics of Lean Manufacturing 123

9 Contents ix Value of Product Continuous Improvement Perfection Focus on Waste The Relationship of Waste to Profit Four Functions of Lean Production Production Flow Planning Performance Measures Organization The True Costs of Inventory Production Operations Operations Support The Supply Chain The Lean Enterprise Leaning Your Customers Keys to Lean Success Characteristics of Lean Manufacturing Benefits of Lean Production Applications Agile Manufacturing Introduction 139 Review Questions Open System/CIM Data Model Introduction Open Manufacturing Systems Modelling a Manufacturing System Open Manufacturing Systems Development of Manufacturing Execution System for Machining Future of Open Manufacturing System Use Networks, Protocols and Standards The Intelligent Manufacturing Systems (IMS) Center Manufacturing Automation Protocol (MAP) Activities Research and Development in Manufacturing Computer Integrated Manufacturing/MAP Production Engineering Capabilities Equipment Development Capabilities Database in CIM Relational Databases and Object Orientation The Relatiol Data Model The Object Model Persistence Frameworks Essential Characteristics of an Object-relational Framework 155

10 x Contents 8.12 Common Object-Relational Services Persistence Query Transactions Concurrency 158 Review Questions 159 References NC and CNC Machines Introduction Historical Background Basic Components of an NC Program of Instruction Machine Control Unit Steps in NC Process Plan Part Programming Preparation of Punched Tape Verification of Punched Tape Production Verification of Numerical Control Machine Tool Programs Classifications of NC Machine Tools Based on Motion Type Based on Control Loops Based on Power Supply Based on Positioning System Basics of Motin Control and Feedback for NC Machines Control of NC Machines What Does CNC Mean NC Part Programming Introduction Punched Tape Part Programming Methods Manual Part Programming Computer Assisted Part Programming Punched Tape Programming Format NC Part Programming Modern Machining Systems: Interpolation and DNC Automatically Programmed Tools Direct Numerical Control (DNC) Actual Arrangement of DNC Function of DNC Adaptive Control Types of Adaptive Control System 204 Review Questions 207

11 Computer Integrated Manufacturing 25% OFF Publisher : PHI Learning ISBN : Author : ALAVUDEEN, A., VENKATESHWARAN, N. Type the URL : Get this ebook