COMPUTER INTEGRATED MANUFACTURING

COMPUTER INTEGRATED MANUFACTURING A. ALAVUDEEN N. VENKATESHWARAN

COMPUTER INTEGRATED MANUFACTURING

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-110001 2010

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-978-81-203-3345-1 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-110001 and Printed by Jay Print Pack Private Limited, New Delhi-110015.

CONTENTS Preface...xv Acknowledgements... xix 1. Introduction... 1 20 1.1 Definitions 1 1.2 Basic Concepts 3 1.2.1 Nature and Role of the Elements of CIM System 5 1.2.2 CIM Wheel 7 1.2.3 Concept or Technology? 8 1.3 Evolution of CIM 8 1.3.1 Development of Numerical Control 9 1.3.2 Emergence of Computers 9 1.3.3 Computer-Aided Design 9 1.3.4 Computer-Aided Manufacturing (CAM) 10 1.3.5 From CAD and CAM to CAD/CAM 10 1.3.6 CASA/SME CIM Wheel (Background) 10 1.4 Manufacturing Automation Protocol 12 1.4.1 Overview 12 1.4.2 Problems 12 1.4.3 Definition 12 1.4.4 Physical Alternatives (Layer 1 OSI Model) 12 1.4.5 Data Link Layer (Layer 2 OSI Model) 13 1.4.6 Application Layer 13 1.5 Details for TOP 13 1.6 Application Layer 14 1.7 MAP and TOP 15 1.8 MAP and Other Standards 16 1.9 Islands of Automation 18 v

vi Contents 1.10 Challenges and Trends 18 1.10.1 Manufacturing in Transition 18 1.10.2 Profit and Performance 19 1.10.3 Productivity and Automation 19 Review Questions 20 2. Group Technology... 21 42 2.1 Introduction 21 2.2 Basic GT Layouts 23 2.3 Process (Functional) Layouts 24 2.4 Product Layouts (Sequential-flow; Assembly Line) 25 2.5 Comparison of Product and Process Layouts 26 2.6 Designing Process Layouts 26 2.6.1 Block Diagramming 27 2.7 Relationship Diagramming 29 2.8 Service Layouts 31 2.9 Designing Product Layouts 31 2.9.1 Line Balancing 31 2.10 Coding System 37 2.10.1 Opitz Classification System 38 2.10.2 The MICLASS System 38 Review Questions 41 3. Flexible Manufacturing Systems... 43 67 3.1 Introduction 43 3.2 Dedicated Manufacturing Systems 43 3.3 Flexible Manufacturing Systems 43 3.3.1 Cellular Manufacturing Systems 44 3.4 Major Elements of FMS 47 3.4.1 Production Equipment 47 3.5 Materials Handling System 48 3.6 Problems with FMS 49 3.7 Enterprise Resource Planning (ERP) 49 3.8 Mixed-Model Assembly Lines 49 3.9 Cell Technology and Flexible Manufacturing Systems 51 3.9.1 Process/Production Flows and Cell Technology 51 3.9.2 Teams and Cells 51 3.10 Automatic Guided Vehicles (AGVs) 51 3.10.1 Advantages of Using AGV Systems in FMS 52 3.11 Automated Storage (AS) and Retrieval Systems (RS) 53 3.11.1 Buffer Storing of Parts 53 3.11.2 Chip Removal and Washing Stations 54 3.11.3 Computer Control System 55 3.12 Optimization of FMS 55 3.12.1 Operational Elements of a Typical Flexible Manufacturing Cell 56

Contents vii 3.12.2 Types of Data Associated with the Flexible Manufacturing Cell 57 3.12.3 Job Scheduling 57 3.12.4 Tool Requirements 58 3.12.5 Setting up Workplace Carrier 59 3.12.6 Clamping or Palletising 60 3.12.7 Material Flow Control 60 3.12.8 Machine Tool Program 61 3.12.9 Synchronization 61 3.12.10 CNC Program Supply 61 3.12.11 Tool Flow Control 62 3.12.12 Tool Changing 63 3.12.13 Cell Magazine Management 63 3.12.14 System Visualization 64 3.12.15 System Configuration 64 Review Questions 65 4. Shop Floor Control... 68 81 4.1 Introduction 68 4.2 Shop Floor Control Features 69 4.3 Major Displays 69 4.4 Major Reports 69 4.5 Phases of SFC 70 4.5.1 Order Release 70 4.5.2 Order Scheduling 71 4.5.3 Order Progress 72 4.6 Manufacturing Control 72 4.7 Methodology 74 4.8 Application 75 4.8.1 Simplified Manufacturing Planning and Control System 75 4.8.2 Inputs Manufacturing Planning and Control System 76 4.8.3 Manufacturing Planning Software 76 4.8.4 Manufacturing Control Software 76 4.8.5 Cost of Inadequate MPC 77 4.8.6 MPC System Activities 77 4.9 Shop Floor Data Collection 77 4.10 Types of Data Collection Systems 77 4.10.1 On-line Data Collection Systems 78 4.10.2 Off-line (batch) Data Collection Systems 78 4.11 Data Input Techniques 78 4.11.1 Centralized Terminal 78 4.11.2 Satellite Terminals 79 4.11.3 Work Centre Terminals 79 4.12 Automatic Data Collection System 79 4.12.1 Bar Code Technology 79

viii Contents 4.12.2 Fixed Beam Reader 80 4.12.3 Moving Beam Reader 80 Review Questions 80 5. Production Planning and Control... 82 89 5.1 Operation Management 82 5.2 The Conversion Process 82 5.3 Where Do New Products and Services Come From? 83 5.4 Planning for Production 84 5.4.1 Design Planning 84 5.4.2 Facilities Planning and Site Selection 84 5.4.3 Operational Planning 85 5.5 Operations Control 86 5.5.1 Purchasing 86 5.5.2 Inventory Control 86 5.6 Scheduling 87 5.7 Quality Control 88 Review Questions 89 6. Computer Aided Process Planning... 90 114 6.1 Automated Process Planning 90 6.2 Computer-Aided Process Planning 91 6.3 Methods of Computer-Aided Process Planning 94 6.3.1 Variant Process Planning 94 6.3.2 Generative Process Planning 97 6.4 Artificial Intelligence 100 6.5 Implementation Considerations 101 6.6 Process Planning Systems 102 6.7 MRP (Material Requirements Planning) 105 6.7.1 Manufacturing Resource Planning (MRP II) 107 Review Questions 114 7. JIT-Lean Production... 115 142 7.1 History of MRP, JIT and Lean Production 115 7.1.1 Automobile Manufacturing 116 7.1.2 Production Methods 116 7.2 Toyota Production System 117 7.3 Just-in-Time Production 119 7.3.1 Kanban System 119 7.3.2 Automation 120 7.4 Lean Manufacturing 121 7.4.1 What is Lean Manufacturing? 121 7.4.2 Principle of Lean 122 7.4.3 Some Basic Characteristics of Lean Manufacturing 123

Contents ix 7.4.4 Value of Product 124 7.4.5 Continuous Improvement 124 7.4.6 Perfection 124 7.4.7 Focus on Waste 124 7.4.8 The Relationship of Waste to Profit 126 7.4.9 Four Functions of Lean Production 127 7.4.10 Production Flow 127 7.4.11 Planning 128 7.4.12 Performance Measures 131 7.4.13 Organization 131 7.4.14 The True Costs of Inventory 131 7.4.15 Production Operations 132 7.4.16 Operations Support 134 7.4.17 The Supply Chain 135 7.4.18 The Lean Enterprise 135 7.4.19 Leaning Your Customers 136 7.4.20 Keys to Lean Success 137 7.4.21 Characteristics of Lean Manufacturing 137 7.4.22 Benefits of Lean Production 138 7.4.23 Applications 139 7.5 Agile Manufacturing 139 7.5.1 Introduction 139 Review Questions 142 8. Open System/CIM Data Model... 143 160 8.1 Introduction 143 8.2 Open Manufacturing Systems 143 8.3 Modelling a Manufacturing System 145 8.3.1 Open Manufacturing Systems 145 8.4 Development of Manufacturing Execution System for Machining 146 8.5 Future of Open Manufacturing System Use 146 8.6 Networks, Protocols and Standards 148 8.7 The Intelligent Manufacturing Systems (IMS) Center 148 8.8 Manufacturing Automation Protocol (MAP) Activities 149 8.9 Research and Development in Manufacturing 149 8.10 Computer Integrated Manufacturing/MAP 150 8.10.1 Production Engineering Capabilities 151 8.10.2 Equipment Development Capabilities 151 8.11 Database in CIM 152 8.11.1 Relational Databases and Object Orientation 152 8.11.2 The Relatiol Data Model 153 8.11.3 The Object Model 154 8.11.4 Persistence Frameworks 154 8.11.5 Essential Characteristics of an Object-relational Framework 155

x Contents 8.12 Common Object-Relational Services 156 8.12.1 Persistence 157 8.12.2 Query 157 8.12.3 Transactions 158 8.12.4 Concurrency 158 Review Questions 159 References 159 9. NC and CNC Machines... 161 208 9.1 Introduction 161 9.2 Historical Background 162 9.3 Basic Components of an NC 163 9.3.1 Program of Instruction 163 9.3.2 Machine Control Unit 163 9.4 Steps in NC 165 9.4.1 Process Plan 165 9.4.2 Part Programming 165 9.4.3 Preparation of Punched Tape 166 9.4.4 Verification of Punched Tape 166 9.4.5 Production 166 9.5 Verification of Numerical Control Machine Tool Programs 116 9.6 Classifications of NC Machine Tools 168 9.6.1 Based on Motion Type 169 9.6.2 Based on Control Loops 169 9.6.3 Based on Power Supply 170 9.6.4 Based on Positioning System 171 9.7 Basics of Motin Control and Feedback for NC Machines 171 9.7.1 Control of NC Machines 172 9.7.2 What Does CNC Mean 173 9.8 NC Part Programming 177 9.8.1 Introduction 177 9.8.2 Punched Tape 178 9.9 Part Programming Methods 185 9.9.1 Manual Part Programming 185 9.9.2 Computer Assisted Part Programming 188 9.9.3 Punched Tape Programming Format 188 9.9.4 NC Part Programming 190 9.10 Modern Machining Systems: Interpolation and DNC 197 9.11 Automatically Programmed Tools 198 9.12 Direct Numerical Control (DNC) 201 9.12.1 Actual Arrangement of DNC 202 9.12.2 Function of DNC 203 9.13 Adaptive Control 204 9.13.1 Types of Adaptive Control System 204 Review Questions 207

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