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computer Integrated manufacturing

Industrial & Manufacturing Enterprise DepartmentThe Wichita State Universityhttp://www.mrc.twsu.edu/whitman/classes/ie775

Larry Whitman whitman@imfge.twsu.edu(316) 691-5907

(316) 978-3742

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IE775

Text Computer Integrated Manufacturing: from

concepts to realisation, Roger Hannam; 1996,

Addison-Wesley, New York, NY

Also, other books will be needed (don’t have to buy)

Rajan Suri, Quick Response Manufacturing; A Companywide Approach To Reducing Lead Times, Productivity Press Inc., 1998.

H. T. Goranson, The Agile Virtual Enterprise : Cases, Metrics, Tools, 1999. Shigeo Shingo, A Study of the Toyota Production System from an Industrial Engineering

Viewpoint James P. Womack, Daniel T. Jones, Lean Thinking : Banish Waste and Create Wealth in Your

Corporation

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Course Goals

Goals: Concepts and techniques for developing computer integrated manufacturing systems. CIM components, CAD/CAM Interfaces, Computer Aided Process Planning and its role in the development of CIM systems, Enterprise Resources Planning (ERP) for CIM, Product Data Management (PDM) in a CIM environment, databases, and networking will be addressed with an emphasis on design guidelines.

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Evaluation

Evaluation:

Mid-Term 25%

Project 30%

Papers (4 papers)

40%

Instructor Points

5% (note this includes attendance)

and participationand participationread the chapters and contribute!!

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Tentative Schedule

IMPORTANT DATES AND TENTATIVE EXAM SCHEDULE

Mid-Term

Last date to withdraw with a "W" October 29, 1999

Paper1 - The Manufacturing Enterprise September 16, 1999

Paper2 - CIM Case Study September 23, 1999

Paper3 - CIM Models October 14, 1999

Paper4 - Special Topic (book report) December 2, 1999

Project December 16, 1999 by 5PM.

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Grading Scale

Grading:

Letter Grade

A 93 - 100%

B 84 - 92%

C 70 - 83%

D 60 - 69%

F <60%

Not higher than!Not higher than!

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Papers

Papers: The papers will be of the 3-5 page variety. The papers will be 2-3 pages and the book report will be 5 pages. The paper should be 75% summary of the paper/book and 25% critique/commentary

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Project

The project will be accomplished with ONE or TWO other students. The project will utilize the Wonderware "In-Touch" man-machine interface software (and possibly use the "In-Control" and "IndustrialSQL Server") products if you desire)).

The project will likely be the difference between an ‘A’ and a ‘B’. The project grade will be mostly determined on the creativity and skill level shown.

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Tentative Course Outline

Date Topic

8/26 Course Introduction/ Chapter 1 in text

9/2 Overview of the Manufacturing Enterprise

Paper #1: The Manufacturing Enterprise – Due on 9/16

9/9 CIM and CAD/CAM

9/16 CIM Models (Architecture and Models)

Paper # 2: CIM Case Study – Due on 9/23

9/23 Networks

9/30 CIM Databases

Paper # 3 - CIM Models – Due on 10/14

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Tentative Course Outline

Date Topic

10/7 ERP and PDM for CIM10/14 Presentation on paper (1 of the 3 above)10/21 Wonderware software overview/Exam Review10/28 Mid - Term Exam11/4 Process PlanningProject - Wonderware project (VB links) – Due on 12/1611/11 Special Topics (agility, holonic manufacturing)11/18 Project Work (no class)Paper # 4: - Special Topic (book report)–Due on 12/212/2 Various Applications12/9 Presentations of book reports12/15 Wonderware Project Report Due

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Who are you?

Who -are you Where - are you from? Why -are you here? What -do you want to get from this

class?

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Introduction

focus on the word ‘Integrated’ not on the word ‘computer’

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Formal Definition

“the integration of business, engineering, manufacturing and management information that spans company functions from marketing to product distribution.” Harrington

originally, to integrate what had already been computerized.

shop floor processes manufacturing engineering planning of those

processes production planning and control of both the

shop floor and the materials used.

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Synonyms

CIE - computer integrated enterprise CIME - computer integrated

manufacturing enterprise

CIM means many different things to many different people.

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CASA/SME CIM Wheel

From CASA/SME

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CASA/SME CIM wheel is a good overview of CIM

revised version (quality no longer separate)

no hierarchy

which are aided by CIM?

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CASA/SME CIM Wheel (background) 1985 - The Computer and Automated Systems Association

of the Society of Manufacturing Engineers (CASA/SME) published its vision of enterprise-wide teaming--the CIM Enterprise Wheel

1992 - New Manufacturing Enterprise Wheel. This updated vision preserves the understanding gained from the previous CIM Enterprise Wheel. The old Wheel looked primarily at automation and integration inside the enterprise. The new Wheel looks outside as well. It adds understanding in these six areas:

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CASA/SME CIM Wheel (background) The central role of a customer-oriented mission and vision to strive

for continuous improvement.

The importance of teams and human networking in the new manufacturing environment.

The continuing importance of computer tools, now increasingly distributed and networked. This includes tools to support networking and concurrent engineering.

A focus on key processes and best practices throughout the enterprise, from marketing through design, manufacturing, and customer support.

Recognition of the move away from bureaucratic structures, to leaner and more agile organizations.

The need to integrate an understanding of the external environment, including customers, competitors, suppliers, and the global manufacturing infrastructure.

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Wheel - Six Elements

The new Manufacturing Enterprise Wheel describes six fundamental elements for competitive manufacturing: The central role of the customer and evolving customer

needs. The role of people and teamwork in the

organization. The revolutionary impact of shared knowledge and

systems to support people and processes. Key processes from product definition through

manufacturing and customer support. Enterprise resources (inputs) and responsibilities

(outputs).

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Wheel - customer centered

A customer-centered mission provides a clear direction to align activities and empowers the work of teams in the new manufacturing enterprise.

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Wheel - people

The central role of people in the organization forms the inner circle of the Wheel. The enterprise is only as strong as its people, organization, and culture.

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Wheel-Shared Knowledge and Systems

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Wheel - Processes

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Wheel - 15 Processes

PRODUCT/PROCESS DEFINITION

1) Business Definition

2) System Design

3) Component Design

4) Continuous Improvement

5) Documentation and Release

MANUFACTURING (/Service)

6) Resource Planning

7) Operations Planning

8) Component Fabrication

9) Assembly and Test

10) Material Management

CUSTOMER SUPPORT

11) Global Organization

12) Distribution

13) Sales and Promotion

14) Customer Services

15) Life-Cycle Transitions

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Wheel - Concurrent Engineering

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Wheel - Virtual Enterprise

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Wheel - Virtual Enterprise

Product/Process Definition Manufacturing Customer Support

1 Business Definition 6 Resource Planning 11 Global Organization

2 System Design 7 Operations Planning 12 Distribution

3 Component Design 8 Component Fabrication 13 Sales and Promotion

4 Continuous Improvement 9 Assembly and Test 14 Customer Services

5 Documentation and Release 10 Material Management 15 Life-Cycle Transitions

how well, not who

performs each of the activities of the processes

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Wheel - Resources

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Wheel - Manufacturing Infrastructure

•workforce

•investment

•transportation

•communication

•suppliers

•schools

•research

•government support

Infrastructure separates top manufacturing regions and countries from others.

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Wheel

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Mfg Buzzword Bingo

From text

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the CIM Jigsaw - what’s missing?

Computing SystemsComputing Systems

Software (CAD, etc.)Software (CAD, etc.)

ManufacturingCAMManufacturingCAM

Info and DataInfo and Data

ActivityActivity

Integrationand

Networks

Integrationand

Networks

Protocolsand

Standards

Protocolsand

Standards

ImplementationImplementation

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Why CIM?

because it is cool - NO! because everyone else is -NO!

CIM is not an end, it is the means to an end

must be linked to strategy!

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Why CIM - to meet competitive pressures

to reduce lead times

to reduce costs

to reduce inventory (or need for)

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Why CIM - to coordinate and organize data

functional - about organization (still important)

product - about parts

operational - plan or instructions

performance - reporting on performance

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Why CIM - others

to eliminate paper

automate communication

simultaneous engineering (IPD)

because it is possible?

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What is INTEGRATED?

parts indistinguishable? no, seamlessly linked is what we mean

From text

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Integration - linked

From text

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EDI - electronic data interchangeEDI : Electronic Data Interchange - (1) The subject of electronic data exchange and sharing generally, or (2) Electronic data and/or document interchange format (X12), particularly in a purchasing context.

EDIF : Electronic Data Interchange FormatA neutral file specification for the transfer of electronic CAD/CAM data.

EDIFACT : Electronic Data Interchange for Administration, Commerce & Trade

A standard for commercial transactions between (differing) computer systems

of different commercial organizations. Although we often talk of EDI applied to exchange of technical information it is properly used to describe commercial transactions such as the passing of invoices. Standards for EDI exist and are widely used. UN EDIFACT is becoming the accepted standard for this type of transaction. When technical information is exchanged between computer systems (see the item on datasheets), this is really a sub-set of technical data sharing. In these circumstances we should use the term technical EDI, or TEDI.

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Islands of Automation

Local optimizationLocal optimization

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MAP/TOP/STEP

only 15% of over 40,000 systems can communicate

cost of communication is 50% of total

wiring costs occur when new systems are installed or retooled

custom software is needed to interface two processes

programmable equipment increasing rapidly

single largest roadblock to future automation of plants

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MAP

• based on Open Systems Interconnection (OSI) • seven layer broadband token-bus communication spec • MAP and TOP always connected, differ in applications • GM has 8 plants running MAP with 25 (1990 )• GM installing MAP as they overhaul plant • tests on ethernet • Lotus 1-2-3 "Factory" has MAP protocols

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TOP

• exchange of info in electronic mail, • word processing, • file transfer, • graphics, • database management, • business analysis tools

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TOP objectives

• allow the interconnection of multiple office local-area networks (LANs), which could be connected to wide-area networks (WANs) and digital private-branch exchanges (PBXs) for long-distance communications

• specify existing or emerging international and industry standards • make possible an office communications network in which equipment

from multiple suppliers can be used • facilitate free and easy data access and the interchange of data by

equipment from different suppliers • lower office systems costs by reducing the need for multiple cables and

customized networking software • improve the flexibility and adaptability of production systems to meet

changing demands • shorten the lead time for designing and implementing integrated office

systems

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Summary

Computer Integrated Manufacturing