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Fully Integrated System
Overview
• Manufacturing• Developments in Manufacturing
Technology• Advanced Manufacturing Technology• Computer Integrated Manufacturing (CIM)• Group Technology• Production Flow Analysis
What is Manufacturing?
• The transformation of raw materials to finished products
• Has evolved, is evolving, and will continue to evolve
• Backbone of industrialised and newly developing economies
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Manufacturing evolution?
• Craft• Standardisation• Industrial Revolution
– Concept of manufacturing– Automation– Computer Integrated Manufacturing
What is Manufacturing?
TransformationProcess
Technology
Departments
Organisation
Environment
MaterialsHandling
Machining Inspection
Assembly
Raw Material Inputs Product or Service Outputs
Internet
New/niche entrants
Traditional competitors
Partnerships and alliancesCustomers
Global economy
Costs
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External Challenges
• Niche market – new ideas• Traditional competition – must be monitored• Suppliers – finding the right suppliers• Partnerships and alliances – companies joining
force• Customers – meet their needs {The most
important thing?}• Global economy – investment, expenditure• Internet – direct access to customer, eg. Amazon
Mass Production
IdenticalProducts
Mass market
Production to Order
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Too much choice?
“Mass Customisation”
Requirements
Custom product
Shrinking Product Lifecycles
1970s 1980s 1990s 2000s
Time to Market
Product Life
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Developments in Manufacturing Technology
• Mechanisation• Programmable automation• Numerical control (NC) – programmable
automation, 1952• NC evolved into CNC and DNC• CAD – application of computers in design and
development• Combination of NC and CAD – CAM Technology• Advanced Manufacturing Technologies (AMTs)• Virtual CIM
19971990
1980
1970195519501930190017501600
Global manufacturing based on Virtual CIMConcept of Virtual CIM is introducedAdvanced systems in CAM, CAPP, CAQC, AS/RS, FMS
and CIMDevelopments in CAD, application of CAM based
systems and introduction of CIM conceptBeginning of CAD and development of NC, CNC, DNCEarly developments in NC for automationVery large mass production systemMass production systemMechanisation and early factory systemsCraftsmanshipManual and animal labour
Advanced Manufacturing Technologies (AMTs)
• AMTs are systems which provide flexibility as well as data driven computer integration for a manufacturing organisation
• AMTs illustrate a technological application where the manufacturing technology utilised is intelligent enough to process the activities with less human intervention
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CIM – a definition
• The dictionary of Advanced Manufacturing Technology defines CIM as a concept of a fully automated factory, where all manufacturing processes are integrated and controlled by computer(s)
Categorising AMTs
• AMTs can be categorised into 4 levels:
– Level 1 – stand-alone systems which include NC machines, CNC machines, robots, etc.
– Level 2 – computerised and non-computerised cellular groupings of equipment and materials for the production of families of parts: i.e. GT, FMS and CAE initiatives
– Level 3 – Linked islands of technology, which interconnects technologies in some functional units, but the islands are regarded as separate entities without interconnection
– Level 4 – fully integrated systems
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Another definition of CIM
The Computer and Automated Systems Association (CASA) of the Society of Manufacturing Engineers defines CIM as “An integrated system, which provides computer assistance to all business functions encompassing activities from accepting an order to delivery, within a manufacturing enterprise.”
Flexible Manufacturing Systems
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GeneralPurposeOr jobshop
CIMWork cells
FlexibleManufacturing
System FocusedAutomation
DedicatedAutomation
Num
ber
of p
rodu
cts
Annual volume
The prime purpose of CIM is to improve the overall profitability of
the firm
HOW?
QualityProductivityFlexibility
Achieving zero defects
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Motivation
• Enhancing efficiency and improving competitive position and profitability
• Enhancing production volume and achieving greater flexibility in production
• Obtaining increased flexibility in responding to requested changes and demands
• Enhancing productivity and boosting the unit’s image
• Optimal production flexibility and production scheduling
• Achieving more effective control of the manufacturing process
Advantages of CIM implementation
• Flexibility of product, volume and material• Improved productivity and quality• Improved interface between design and
manufacturing• Reduction in direct and indirect labour at various
levels and functional units including: middle management, engineering, administration, and operations support
• High quality designs which lead to good products
• High quality documentation and packages
Advantages of CIM implementation (cont.)
• Better standardisation and better material utilisation
• Time and floorspace savings• A common database eliminating duplicate
data storage on independent systems• Elimination of duplicate data entry• Reduction in inspection time and the
associated workforce• Competitive advantage
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CIM from customer order to delivery
Customer places anorder by computer.
Order is received by companybusiness information system,which relays it to the localfactory system.
At the factory the order isscheduled for production,and computer systemsends instructions to:
Factory machines tellingthem what to do.
The shipping department tellingit when to expect a product andwhere to ship it. When a productis shipped, the information isautomatically sent to accounts.
The procurement department whichis instructed to get the right parts.Orders or factory schedules aresent to outside suppliers.
Outside suppliers gear up their ownproduction and delivery to be able tosupply parts just-in-time.
All corporate departmentswatch each phase. Amongthem, accounting, whichprocesses billing once aproduct is shipped
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CIM from customer order to delivery
CIM integrates information flows in marketing, design, manufacturing, engineering, the resource requirements planning, purchasing, the production process, quality assurance, administration, etc. into a closed loop, controlled system.
Group Technology (GT)
• Group Technology is a philosophy that implies the notion of recognising and exploiting similarities in three different ways– By performing like activities together– By standardising similar tasks– By efficiently storing and retrieving information
about recurring problems
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http://www.strategosinc.com/group_technology.htm
Definition of Group Technology
• The logical arrangement and sequence of all facets of a company’s operations in order to bring the benefits of mass production to high variety, mixed quantity production
(Ranson 1972)
Key characteristics of a GT system
• Components classified into families
• Workloads are balanced between production groups
• Production groups are clearly identifiable on the shop floor
• Each group has a clearly identifiable degree of autonomy
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Cellular Manufacturing
• Application of GT in manufacturing in which all (or a portion) of a firm’s manufacturing system has been converted into cells
• A manufacturing cell is a cluster of machines or processes located in close proximity and dedicated to the manufacture of a family of parts or products
Cellular Manufacturing
Production Flow Analysis
• Developed by Professor John L. Burbidgeof the Cranfield Institute of Technology
• Method of identifying part families and associated groupings of machine tools
• PFA uses operations sequences and machine routings for parts produced in a manufacturing facility
• It groups together parts with identical or similar routing
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Traditional Layout
M
M
M
M
M
M L L
L L
D D
G
G
G
A A AReceiving andshipping
Milling Turning
Drilling
Grinding
HeatTreating
Assembly
GT Layout
MM
M L L
L
D
D
G
G
A
A A
Receiving
Shipping
HeatTreating