Part VI MANUFACTURING SUPPORT SYSTEMS Chapters: 23. Product Design and CAD/CAM in the Production System 24. Process Planning and Concurrent Engineering 25. Production Planning and Control Systems 26. Just-In-Time and Lean Production Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 1/29 Manufacturing Support Systems in the Production System Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 2/29 1
Ch 23 Product Design and CAD/CAM in the Production System Sections: 1. Product Design and CAD 2. CAD System Hardware 3. CAM, CAD/CAM, and CIM 4. Quality Function Deployment Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 3/29 Manufacturing Support Systems The procedures and systems used by a firm to manage its production operations and solve the technical and logistics problems associated with: Designing the products, Planning the processes, Ordering materials, Controlling work-in-process as it moves through the plant, and Delivering quality products to customers Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 4/29 2
The Design Process The general process of design is characterized as an iterative process consisting of six phases: 1. Recognition of need - someone recognizes the need that can be satisfied by a new design 2. Problem definition - specification of the item 3. Synthesis - creation and conceptualization 4. Analysis and optimization - the concept is analyzed and redesigned 5. Evaluation - compare design against original specification 6. Presentation - documenting the design (e.g., drawings) Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 5/29 The Design Process Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 6/29 3
Computer-Aided Design (CAD) Any design activity that involves the effective use of the computer to create, modify, analyze, or document an engineering design Commonly associated with the use of an interactive computer graphics system, referred to as a CAD system The term CAD/CAM is also used if the computer system supports manufacturing applications as well as design applications Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 7/29 Reasons for Using a CAD System To increase the productivity of the designer To expand the available geometric forms in design - wider range of mathematically defined shapes possible To improve the quality of the design - more engineering analysis possible, consideration of more alternatives To improve design documentation - better drawings than with manual drafting To create a manufacturing database - creation of the design documentation also creates manufacturing data To promote design standardization - use of design rules to limit the number of hole sizes, fasteners, etc. Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 8/29 4
The Design Process Using CAD Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 9/29 How a CAD System is Used in Product Design (Steps 3-6) 3. Geometric modeling CAD system develops a mathematical description of the geometry of an object, called a geometric model 4. Engineering analysis Mass properties, interference checking for assemblies, finite element modeling, kinematic analysis for mechanisms 5. Design evaluation and review Automatic dimensioning, error checking, animation 6. Automated drafting Preparation of engineering drawings quickly Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 10/29 5
Geometric Models in CAD Wire-frame model Solid model Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 11/29 CAD System Hardware The hardware for a typical CAD system consists of the following components: 1. One of more design workstations 2. Digital computer 3. Plotters, printers, and other output devices 4. Storage devices Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 12/29 6
Typical CAD System Configuration Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 13/29 Design Workstations The interface between the computer and the user in the CAD system Functions: 1. Communicate with the CPU 2. Continuously generate a graphical image 3. Provide digital descriptions of the image 4. Translate user commands into operating functions 5. Facilitate interaction between the user and the system Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 14/29 7
CAD System Configurations 1. Host and terminal Mainframe serves as host for graphics terminals The original configuration in the 1970s and 1980s when CAD technology was first developing 2. Engineering workstation Stand-alone computer system dedicated to one user Often networked for sharing data and plotters 3. CAD system based on a personal computer PC with high-performance CPU and high resolution graphics display monitor Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 15/29 Host and Terminal Configuration Original CAD system configuration in 1970s and 1980s Host computer is a mainframe or large mini computer Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 16/29 8
Engineering Workstation Configuration An engineering workstation is a stand-alone computer system dedicated to one user and capable of executing graphics software and other programs requiring highspeed computational power Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 17/29 CAD System based on a PC This is a personal computer with a high-performance CPU and high resolution graphics display screen PC-based CAD systems can be networked (as shown) to share files, output devices, and for other purposes Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 18/29 9
Computer-Aided Manufacturing The effective use of computer technology in manufacturing planning and control Most closely associated with functions in manufacturing engineering, such as process planning and NC part programming CAM applications can be divided into two broad categories: 1. Manufacturing planning 2. Manufacturing control Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 19/29 CAM Applications in Manufacturing Planning Computer-aided process planning (CAPP) Computer-assisted NC part programming CAD/CAM assisted NC part programming Computerized machinability data systems Computerized work standards Cost estimating Production and inventory planning Computer-aided assembly line balancing Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 20/29 10
CAM Applications in Manufacturing Control Process monitoring and control Quality control Shop floor control Inventory control Just-in-time production systems Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 21/29 CAD/CAM Concerned with the engineering functions in both design and manufacturing Denotes an integration of design and manufacturing activities by means of computer systems Goal is to not only automate certain phases of design and certain phases of manufacturing, but to also automate the transition from design to manufacturing In the ideal CAD/CAM system, the product design specification residing in the CAD data base would be automatically converted into the process plan for making the product Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 22/29 11
Computer Integrated Manufacturing Includes all of the engineering functions of CAD/CAM Also includes the firm's business functions that are related to manufacturing Ideal CIM system applies computer and communications technology to all of the operational functions and information processing functions in manufacturing From order receipt, Through design and production, To product shipment Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 23/29 The Scope of CAD/CAM and CIM Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 24/29 12
Computerized Elements of a CIM System Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 25/29 Quality Function Deployment A systematic procedure for defining customer desires and requirements and interpreting them in terms of product features and process characteristics A series of interconnected matrices are established between customer requirements and the technical features of a proposed new product The matrices are a progression of phases in which customer requirements are first translated into product features, then into manufacturing requirements, and finally into quality procedures for controlling the manufacturing operations Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 26/29 13
Quality Function Deployment Shown as a series of matrices that relate customer requirements to successive technical requirements in a typical progression Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 27/29 The Starting Matrix: The House of Quality Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 28/29 14
Steps in QFD: The House of Quality 1. Identify customer requirements 2. Identify product features needed to meet customer requirements 3. Determine technical correlations among product features 4. Develop relationship matrix between customer requirements and product features 5. Comparative evaluation of input customer requirements 6. Comparative evaluation of output technical requirements Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover. 29/29 15