Transcript Manufacturing Processes for Engineering Materials (5th Edition in SI

Manufacturing Processes
for Engineering Materials
(5th Edition in SI Units)
Chapter 15:
Computer-Integrated Manufacturing Systems
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Computer-Integrated Manufacturing
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Computer-integrated manufacturing (CIM) describes the
computerized integration of product design, planning,
production, distribution and management.
CIM depends on usage of a large-scale integrated
communications system.
Requires extensive database containing technical and
business information.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Computer-Integrated Manufacturing
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CIM systems consists of subsystems that are integrated
as a whole, such as:
Business planning and support
Product design
Manufacturing process planning
Process automation and control
Factory-floor monitoring systems
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Computer-Integrated Manufacturing
Benefits
1. Shorter product life cycles
2. Product quality and uniformity
3. Better use of resources
4. Better control of the processes
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Computer-Integrated Manufacturing
Some examples:
1. Computer aided design and manufacturing (CAD/CAM)
2. Computer numerical control (CNC)
3. Adaptive control (AC)
4. Industrial robots for assembly
5. Automatic control
6. Computer-aided process planning (CAPP)
7. Group technology (GT)
8. Just-in-time production (JIT)
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Computer-Aided Design and Engineering
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Computer-aided design (CAD) uses the computers to
create design drawings and geometric models of
products and components.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Elements of computer-aided design systems
• CAD system consists of four stages:
1. Geometric modeling
• Constructs geometric mode with lines and dimensions.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Elements of computer-aided design systems
2. Design analysis and optimization
• Design is subjected to an engineering analysis.
3. Design review and evaluation
• Review and evaluation to check for any interference
among various components.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Elements of computer-aided design systems
4. Documentation
• Detailed, working drawings are developed and printed.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Computer-Aided Manufacturing
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CAM involves the use of computer technology to assist
in all phases of manufacturing.
• CAD/CAM systems allows information transfer from
design to planning stage.
• Advantages of CAD/CAM are:
1. standardizing product development
2. reducing the effort of designing, evaluation and
prototype work
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Computer-Aided Process Planning
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Process planning involves selecting methods of the
sequence of operations, processing time and methods
of assembly.
Computer-aided
process planning (CAPP) view
total operation as an
integrated system,
so that individual operations
are coordinated with each other.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Elements of computer-aided process-planning systems
• 2 types of CAPP systems:
1. Variant System
• Computer files contain a standard process plan for a
particular part to be manufactured.
2. Generative System
• Process plan is automatically generated on the basis of
the same logical procedures.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Elements of computer-aided process-planning systems
Advantages of CAPP systems
1. Standardization of process plans improves the
productivity.
2. Process plans can be prepared.
3. Process plans can be modified.
4. Routing sheets can be prepared.
5. Other functions can be incorporated.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Computer Simulation of
Manufacturing Processes and Systems
• Process simulation takes 2 forms:
1. Optimizes or improves performance.
2. Analyses multiple processes and their interactions.
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Simulation helps engineers to organize and to identify
critical machinery.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Computer Simulation of
Manufacturing Processes and Systems
• Process simulation takes 2 forms:
1. Optimize or improve performance.
2. Analyse multiple processes and their interactions.
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Simulation helps engineers to organize and to identify
critical machinery.
Able to conduct ergonomic analysis of various
operations and machinery setups.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Group Technology
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Group Technology (GT) is a concept to take advantage of
design and processing similarities among the parts that
are to be produced.
Attractive to consumer demand for variety of products
which requires batch production.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Cellular Manufacturing
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Group technology consists of one or more
manufacturing cells.
Manufacturing cell is a small unit consisting of one or
more workstations.
Cellular manufacturing used in material removal, sheetmetal forming operations and polymer processing.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Flexible Manufacturing Systems
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In FMS all elements of manufacturing are integrated
into an automated system.
Different computer instructions can be downloaded for
each successive part that passes through a workstation.
Can handle a variety of part configurations and produce
in any order.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Flexible Manufacturing Systems
Elements of FMS
1. Workstations
2. Automated handling and transport of materials and
parts
3. Control systems
• System capable of transporting raw materials, blanks,
and parts in various stages of completion anytime.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Just-in-Time Production
• JIT concept has the following goals:
1. Receive supplies just in time to be used.
2. Produce parts just in time to be made into
subassemblies.
3. Produce subassemblies just in time to be assembled
into finished products.
4. Produce and deliver finished products just in time to be
sold.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Just-in-Time Production
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This approach emphasizes:
Worker pride and dedication
Elimination of idle resources
Teamwork
Advantages of JIT:
Low inventory-carrying costs
Rapid detection of defects
Reduced need for inspection and reworking of parts
Production of high-quality parts at lower cost
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Lean Manufacturing
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A systematic approach to identifying and eliminating
waste in every area of manufacturing.
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Helps identify whether the activity:
adds value
adds no value but cannot be avoided
adds no value but can be avoided
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd
Artificial Intelligence
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AI concerned with systems that exhibit some characteristics
are usually associated with intelligence in human behaviour.
Has impact on the design, automation and overall economics
of manufacturing operations.
AI encompasses the following:
Expert systems.
Natural language.
Machine (computer) vision.
Artificial neural networks.
Fuzzy logic.
Chapter 15: Computer-Integrated Manufacturing Systems
Manufacturing Processes for Engineering Materials
© 2008 Pearson Education South Asia Pte Ltd