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2 August-Wilhelm Scheer C 1M ~:~fu~~~~n;:grated Towards the Factory of the Future Second, Revised and Enlarged Edition With 149 Figures Springer-Verlag Berlin Heidelberg New York London Paris Tokyo Hong Kong Barcelona

3 Prof. Dr. August-Wilhelm Scheer Institut fur Wirtschaftsinformatik an der Universitat des Saarlandes 1m Stadtwald D-6600 Saarbriicken 11, FRG ISBN-13: DOl: / e-isbn-13: This work is subject to copyright. All rights are reserved, whether the whole or part of the material is concerned, specifically the rights oftranslation, reprinting, reuse of illustrations, recitation, broadcasting, reproduction on microfilms or in other ways, and storage in data banks. Duplication of this publication or parts thereof is only permitted under the provisions of the German Copyright Law of September 9, 1965, in its version ofjune24, 1985, and a copyright fee must always be paid. Violations fall under the prosecution act of the German Copyright Law. Springer-Verlag Berlin Heidelberg 1988, 1991 Softcover reprint of the hardcover 2nd edition 1991 The use of registered names, trademarks, etc. in this publication does not imply, even in the absence of a specific statement, that such names are exempt from the relevant protective laws and regulations and therefore free for general use

4 Preface to the 2nd Edition The fears of the author. expressed in the preface to the 1st edition. that. although the CIM philosophy is correct. its implementation would be frustrated by the EDp-technical difficulties. have fortunately proved unfounded. Instead an increasing number of successful CIM implementations are appearing. The experience gained in the interim in implementing CIM is extensively incorporated in this edition. The "Y-CIM Information Management" model developed at the Institut fur Wirtschaftsinformatik (IWi) is presented as a tried and tested procedural approach to implementing CIM. The examples presented have also been brought up-to-date. Presentation of the CIM Center set up by manufacturers has been omitted. however. since examples of concrete applications have in the meantime replaced the interest in "laboratory versions". In addition to German examples. the experience of American CIM users is also presented. The primary aim is to allow comparative assessments. But. at the same time. this serves to demonstrate the way that American EDP manufacturers are thinking. which will have a decisive influence on the development of hardware and software products for CIM. The sections in the previous edition which provided surveys of further CIM developments: design stage cost estimation. the use of decision support systems (expert systems). and intercompany process chains. have in the meantime proved themselves to be effective CIM components and are therefore incorporated in the general text. I would like to thank all the named contributors for the punctual preparation and delivery of their manuscripts. I would also like to thank Ms. Irene Cameron for her careful translation of the German original. and my employees. particularly Mr. Carsten Simon. Ms. Rita Landry Schimmelpfennig. and Ms. Carmen Kachler. for their dedicated support in the technical preparation of the manuscript. Saarbrucken. West Germany December 1990 August-Wilhelm Scheer

5 From the preface to the 1st edition This book appeared in the Federal Republic of Germany in and within one year it had run to 3 editions. This indicates the strength of interest German industry is showing in CIM integration principles. CIM is. however. a concept of international relevance to the structuring of industrial enterprises. The author has made several research visits to CIM development centers of leading computer manufacturers and important industrial enterprises which have indicated that the stage of development of CIM in Germany in no way lies behind the international level. Rather. in the USA for example. considerable uncertainty exists regarding the status of manufacturing. For this reason. the CIM examples presented in this book are also of interest to US industry. The stance taken in this book of defining ClM as a total concept for industrial enterprises is increasingly shared internationally. CIM is more than CAD/CAM. Although ClM has been broadly accepted both in theory and in practice. its development is nevertheless subject to risks. A concept which is in itself correct can still come to grief if the implementation possibilities are not yet adequateley developed. So. in the 1960s. the MIS concept failed because the necessary database systems. user-friendly query languages. and comprehensive. operational base systems for providing data were not available. CIM must learn from this experience. Hence. it is important to convince the interested user as quickly as possible that the implementation of CIM is possible with currently available computer technology. But not only suitable computer tools are needed for the implementation of CIM. equally important is the new organizational know-how: a transition from specialized. subdivided operational processes to integrated. unified processes is needed. Given the economic interests of computer manufacturers. great efforts are currently being made to develop new hardware and software concepts for ClM. Here too. therefore. favourable prerequisites for the implementation of ClM are increasingly being met. A significant bottleneck. however. is training and retraining in integrated ClM concepts. This book. therefore. does not aim to put the functional details of the individual CIM components (PPC. CAD. CAP. and CAM) in the foreground. but rather to emphasize the integration principles and elaborate the implications of the integration principles for the functional demands of the individual components. Saarbriicken. West Germany January 1988 August-Wilhelm Scheer

6 Contents Preface v Introduction 1 A. The Meaning of the 'T' in CIM 2 I. Data and Operations Integration II. A Typical CIM Process Chain III. The CIM-Enterprise: The Computer Steered Industrial Firm IV. CIM Definitions B. The Components of CIM 19 I. Stage of Development of CIM Components a. Production Planning and Control 1. Primary Data Management 2. Planning Levels 3. Degree of Implementation 4. New Approaches to PPC Systems 4.1 Simultaneous Material and Capacity Management 4.2 Load-Oriented Order Release 4.3 Kanban 4.4 Running Total Concept 4.5 MRP II 4.6 Decentralization b. Computer Aided Design (CAD) 1. Tasks Geometric Models CAD Standard Interfaces Interactive Control c. Computer Aided Planning (CAP) 1. Work Scheduling for Conventional Processing 2. Work Scheduling for NC Machines

7 VIII II. d. Computer Aided Manufacturing (CAM) 1. Automated Production 1.1 Machine Tools 1.2 Robots 1.3 Storage Systems 1.4 Conveyance Systems 2. Computerized Organizational Forms for Flexible Production 2.1 Processing Centers 2.2 Flexible Production Cells 2.3 Flexible Production Systems 2.4 Production and Assembly Islands 2.5 Flexible Transfer Lines e. f. Computer Aided Quality Assurance (CAQ) Maintenance Interfaces Between CIM Components a. Data Relationships Between CAD and CAM b. Data Relationships Between PPC and CAD/CAM 1. Data Flow From CAD/CAM to PPC 1.1 Primary Data 1.2 Customer Order Data 1.3 Production Order Data 2. Data Flow From PPC to CAD/CAM 2.1 Primary Data 2.2 Customer Order Data 2.3 Production Order Data e. Implementation of elm: /1(- elm! Information Management 69 I. II. III. Procedures and Project Management for Developing a CIM Strategy Establishing Objectives Definition of CIM Process Chains a. Sub-Chain 1: Linking Planning and Control b. Sub-Chain 2: Linking CAD and CAM c. Sub-Chain 3: Linking Master Data Management (Product DeSCription Database) d. Sub-Chain 4: Linking Production Control and CAM

8 IX IV. v. VI. VII. e. Sub-Chain 5: Inter-Company Process Chains 99 l. PPC Integration Initial Position 102 l.2 Data Exchange Application Integration l.4 General Effects CAD/CAM Integration Initial Position Data Exchange Application Integration General Effects 115 f. Sub-Chain 6: Linking Operative Systems with Accounting and Controlling Systems 116 Critical Success Factors CIM Function Levels a. Levels Concept 127 b. Tasks of a CIM Level 131 Data Structures 134 Applications Software 140 a. Standard Software 140 b. In-House Development Using Pre-Fabricated Components and 141 Standards c. Expert Systems in CIM Structure and Areas of Application 143 (Dipl.-Wirtsch.-Ing. Dieter Steinmal111. Institutjii.r Wirtschaftsiriformatik awo, University of Saarbriicken) 2. Expert System for Design Stage Cost Estimation 151 (Dip!.-Inform. Martina Bock, Dip!. -Inform. Richard Bock. Instltutfzlr Wirtschaftsinfonnatik awo, University of SaarbriickenJ 2.1 Introduction Structure and Mode of Operation of Expert Systems Design Stage Cost Estimation in the Planning 152 Phase Design Stage Cost Estimation in Phase 2 of the 155 Design Process Design Stage Cost Estimation in Phase 3 of the 157 Design Process 2.3 System Architecture 157

9 x VIII. Computer-Technical Model a. b. Hardware Architecture Integration Instruments 1. Organizational Solution 2. Use of Tools 2.1 Microcomputers/Workstations 2.2 Database Query 2.3 Networking of Computer Systems Types of Network The Aims of MAP MAP Functions Embedding of MAP in General Network Architectures 3. Data Exchange 4. Common Database 5. Inter-Application Communication c. CIM Data Handlers as Integration Bridges IX. Implementation Paths D. elm Implementations 191 I. CIM Solutions in the German Industry a. CIM Implementation at ABS Pumpen AG, Lohmar (Dip!. -lng. (TU) Klaus Blum. ABS Pumpen AG, Lofunar; Dipl. -Kjrn. Wilftied Emmerich, IDS Prof &heer GmbH, Saarbrilcken) b. Information and Control System in the Production Area as a Central Agency for the Dataflow of a CIM concept at BMW AG. Dingolfing (Dip!.-lng. (FH) Richard Baumgartner. BMW AG. Dingolfing) c. Computerized Flexible Production Chains for Pressed Sheet Metal Parts at MBB, Bremen (Dr.-lng. Ulrich Grupe)

10 XI d. CIM Implementation at Metabowerken, Niirtingen 203 (Dipl-Ing. Manfred Heubach, Metabowerke, Nilrtingen; Dipl.-Kjm. Helmut Kruppke, IDS Prof. Scheer GmbH, Saarbrilcken) 1. Developing a CIM Strategy Focal Areas of the Metabo CIM Strategy Levels Approach in the Production Planning and 206 Control Area 2.2 Applications Integration in the Technical Areas Hardware and Database Model Status and Development of the CIM Implementation 209 at Metabo e. Fully Automated Material Flow and Information Systems in 210 a Siemens AG Factory (Dipl. rer. pol Erich Berner, Siemens AG, Pofng; Dr. Gilnter Friedrich, Siemens AG, Munich) 1. New Directions in CIM Integration Structure of the Production and Material Flow in the 212 Factory 2.1 Automated Transport System Receipt of Goods Parts Production and Flat Assembly Unit Production Material Supply System for Assembly Integration of the Automated Logistic System and 216 Production Planning and Control (PPC) 4. Integration Axis: Databases and Programs Complete CIM System 218 f. Implementation of a CIM model by J. M. Voith (Heidenheim) 220 (Dr. lng., Dipl.-Kjm. Heinz Weible, J. M. Voith GmbH, Heidenheim; Dipl.-Math. DetlejSchOlfng, J. M. VoithGmbH, HeidenheimJ 1. Starting Point and Objectives Information Processing Systems to Support Order 221 Handling 2.1 Overall Concept and Step-by Step Approach System Environment Applications Systems Project Organization and Project Introduction Strategy" Open Issues and Future Plans Cost/Benefit Considerations 231

11 XII II. CIM-Solutions in the USA a. IBM Works, Lexington (Kentucky) b. HP Works in Lake Stevens (Washington) and Cupertino ( CalifoITlia) c. L1V Aircraft Products Group, Dallas (Texas) d. Westinghouse Electrical Corporation, College Station (Texas) e. DEC Works, Sprtngfield (Massachusetts) f. Summary E. elm Promotion Measures 247 I. II. The CIM-Technology-Transfer-Centers' Program Using the Example of the Saarbrucken Site (Dipl.-Wirtsch.-Ing. Peter KarL Dtpl.-Ing. TIwmas Geib, Institutjilr Wtrtschajtstnjormattk (IWO, University oj Saarbrilcken) a. Tasks of the CIM-Technology-Transfer-Centers b. Seminar on the Cross-Section Topic "CIM Strategy" c. Demonstration Possibilities CIM Promotion in the European Community (EC) (Dipl.-Kjm. Alexander Hars, Dipl. -Kjm. Joachim Klein. Dipl.-Kjm. Jutta Michely, Institutjilr Wirtschajtstnjormattk (IWO, University oj Saarbrilcken) a. The ESPRIT Program b. The elm Field in ESPRIT 1. CIM Architecture and Communications 2. Manufacturing Systems Design and Implementation 3. Product Design and Analysis Systems 4. Management and Control of ManufactUring Processes 5. Robotics and Shop Floor Systems F. References 263 G. Index 279