© 2008 pearson education south asia pte ltd chapter 15: computer-integrated manufacturing systems...
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© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Manufacturing Processes Manufacturing Processes for Engineering Materials for Engineering Materials
(5(5thth Edition in SI Units) Edition in SI Units)Chapter 15: Chapter 15:
Computer-Integrated Manufacturing SystemsComputer-Integrated Manufacturing Systems
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Computer-Integrated Manufacturing
• 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.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Computer-Integrated Manufacturing
• CIM systems consists of subsystems that are integrated as a whole, such as:
1. Business planning and support2. Product design3. Manufacturing process planning4. Process automation and control5. Factory-floor monitoring systems
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Computer-Integrated Manufacturing
Benefits1. Shorter product life cycles2. Product quality and uniformity3. Better use of resources4. Better control of the processes
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
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 assembly5. Automatic control6. Computer-aided process planning (CAPP)7. Group technology (GT)8. Just-in-time production (JIT)
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Computer-Aided Design and Engineering
• Computer-aided design (CAD) uses the computers to create design drawings and geometric models of products and components.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Elements of computer-aided design systems
• CAD system consists of four stages:1. Geometric modeling• Constructs geometric mode with lines and dimensions.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
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.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Elements of computer-aided design systems
4. Documentation• Detailed, working drawings are developed and printed.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Computer-Aided Manufacturing
• 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 development2. reducing the effort of designing, evaluation and
prototype work
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Computer-Aided Process Planning
• 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.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
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.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Elements of computer-aided process-planning systems
Advantages of CAPP systems1. 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.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Computer Simulation of Manufacturing Processes and Systems
• Process simulation takes 2 forms:1. Optimizes or improves performance.2. Analyses multiple processes and their interactions.
• Simulation helps engineers to organize and to identify critical machinery.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Computer Simulation of Manufacturing Processes and Systems
• Process simulation takes 2 forms:1. Optimize or improve performance.2. Analyse multiple processes and their interactions.
• Simulation helps engineers to organize and to identify critical machinery.
• Able to conduct ergonomic analysis of various operations and machinery setups.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Group Technology
• 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.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Cellular Manufacturing
• 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, sheet-metal forming operations and polymer processing.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Flexible Manufacturing Systems
• 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.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Flexible Manufacturing Systems
Elements of FMS1. Workstations2. Automated handling and transport of materials and
parts3. Control systems• System capable of transporting raw materials, blanks,
and parts in various stages of completion anytime.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
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.
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Just-in-Time Production• This approach emphasizes: 1. Worker pride and dedication 2. Elimination of idle resources3. Teamwork• Advantages of JIT:1. Low inventory-carrying costs2. Rapid detection of defects3. Reduced need for inspection and reworking of parts4. Production of high-quality parts at lower cost
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Lean Manufacturing
• A systematic approach to identifying and eliminating waste in every area of manufacturing.
• Helps identify whether the activity:1. adds value2. adds no value but cannot be avoided 3. adds no value but can be avoided
© 2008 Pearson Education South Asia Pte Ltd© 2008 Pearson Education South Asia Pte Ltd
Chapter 15: Computer-Integrated Manufacturing SystemsChapter 15: Computer-Integrated Manufacturing SystemsManufacturing Processes for Engineering Materials Manufacturing Processes for Engineering Materials
Artificial Intelligence• 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:1. Expert systems.2. Natural language.3. Machine (computer) vision.4. Artificial neural networks.5. Fuzzy logic.