isat 211 cim-1 1997-2000 m. zarrugh computer-integrated manufacturing (cim): what it is and key...

ISAT 211 CIM-1 1997-2000 M. Zarrugh

Computer-Integrated Manufacturing (CIM):What It Is and Key Issues*Definition:

The use of computer control and information technology to integrate and automate basic product development and production activities in a manufacturing enterprise.

Key Issues: Automation of product development activities Planning and control (low-level) of manufacturing

process Planning, scheduling and control (high-level) offactory

resources (materials, labor and machines) Communications and data management capabilities

* Read: (CAD/CAM Module by M. Zarrugh, pp. 1-14)


Computers in Manufacturing: Key Systems

Computer system(CommunicationsData Management

Control)

Design Automation

(CAD/CAE/Tech. Pubs.)

MFG Process Automation

(CAM/CAPP/CAT/Robotics)

MFG ResourcePlanning

(MRP/MRPII)

Engineering Manufacturing

Management

CAD Computer Aided DesignCAE Computer Aided EngineeringCAM Computer Aided ManufacturingCAPP Computer Aided Process PlanningCAT Computer Aided TestingMRP Manufacturing Resource Planning

CIM System: Basic Processes

Common Database,Management,

Control System

ComputerControl & Communications

PDM(manageproductdata andconfigurations)

MRPor

MRPII(manage

MFGresources)

Engineering

ManufacturingCAD

(design automation)Geometric modeling

Product structureAutomated draftingGroup technology

CAE(simulation)

StructuralThermal

Kinematic/DynamicLogic/Timing

Tech. Publishing(writing, multi-media)

Word-processingManuals

Documentation

CAM(process automation)

Process planningNC/CNC

Industrial robotsFMS

CAT(automated test)Prototype testingIn-process testing

InspectionCMM

MRP(factory MGMNT)Production control

PurchasingReceiving/warehouse

Materials tracking

1997-2000 M. Zarrugh ISAT 211 CIM-3


Design Automation: CADWhat is it?

CAD is an automated technology for electronic capture of geometry (form and fit) of parts and how the parts are arranged to form subassemblies and assemblies.

Its Benefits: Electronic form permits easy modification, distribution

and reuse of the data Removes drudgery from drawing process No need to re-enter data in downstream applications Electronic documents easier to track than paper Can be done by engineers so development is faster


CAD: Geometric Modeling Wireframes:

– 2D– 3D– 3D + surfaces

Solids: – B-rep (define boundary and fill it)– CSG (Boolean operations on conic primitives)– NURBS (analytical definition of surfaces and intersections)

Automated Drafting:– Generation of format detail and assembly drawings

through 2D projections and x-sections of 3D geometric models


Design Automation: Computer-Aided Engineering (CAE ) CAE is the application of scientific laws

to physical systems to predict their behavior under a variety of conditions without ever building actual hardware.

The geometry, captured in CAD as a solids model, can be used in many downstream simulations.

Structural analysis uses finite elements (FE) to predict small deformations and stresses for known geometry, boundary conditions, loads and elastic properties.


CAE: More Types of Engineering Simulations FE and finite difference models, used in

thermal simulations, determine temperature changes and distributions resulting from known heat loads and thermal properties.

Kinematic and dynamic simulations consider large displacements of interconnected rigid bodies (linkages or mechanisms) in response to specific motions and forces.

Electronic circuit designers use CAE tools to verify the logic and timing of ICs, VLSI devices and circuit boards.

Show Ideas video clip


Design Automation:Technical Publishing Product definition requires many documents created on

desktop publishing systems. The documents may specify applicable

standards, describe: – special materials or processing conditions– summarize test results and test and inspection methods– use and repair methods.

Standards needed to simplify the storage and archival of the documents.

Format translators and plug-ins required from transferring documents across systems.


Manufacturing Automation:Computer-Aided Manufacturing (CAM)What is it?

Originally CAM referred to numerical control of machine tools. Now CAM includes all automated processes in MFG.

Its benefits: Automation technology facilitates meeting customer's and

regulatory requirements. CAM increases productivity which reduces process

development and production cost. Automation reduces errors, rework and promotes use of

existing solutions which shortens time-to-market.


CAM Processes:Computer-Based Automation in Manufacturing Numerical Control (NC) and Computer Numerical

Control (CNC) of machine tools Automated (or Computer-Aided) Process Planning

(CAPP) and tooling and fixturing design Machine loading, machining, assembly and

inspection using industrial robots Automated materials handling, storage and retrieval Automated test and inspection Flexible Manufacturing Systems (FMS)


Computer Automation in Manufacturing:NC/CNC Numerical Control (NC) is the control of machine

tools by a series of numerical instructions encoded in an NC part program.

Computer Numerical Control (CNC) is direct control of machine tools using a dedicated computer on board. Part programs can be generated and edited at the machine tool.

CNC machine tools are often equipped with automatic tool changers and part loader to minimize waiting and setup times,


Computer Automation in Manufacturing: CNC Essential Features

CADSTATION

IdeasOld DesignsCreativityStandards

PartGeometry CAM

STATION

NC Programming

NCPrograms

NC or CNC Machine Tool

Speeds/FeedsMaterial & SizeTooling

Parts

Show video clip


Computer Automation in Manufacturing:Automated Process Planning (CAPP) Computer Aided Process Planning (CAPP) is a

computer assisted process of preparing instructions on how to fabricate a part or build an assembly.

CAPP begins with interpreting design data (geometry and materials) into manufacturing processes.

The output of CAPP is a part routing or a "process plan" detailing specific processing sequence, machines, tools, fixtures and cutting conditions (speeds and feeds).

The generation of process plans is not fully automated yet since it requires human input to provide detailed knowledge of current practices and capabilities.


Computer Automation in Manufacturing: Industrial Robots Industrial robots are articulated

machines that can move and process materials under computer control in the factory.

Robots give consistent performance in repetitive tasks: machine loading, inspection, monitoring, assembly, etc.

Robots can work in hazardous or unpleasant environments: spray painting, arc welding, grinding, sanding, cleaning, handling hazardous material


Computer Automation in Manufacturing: Industrial Robots Robots can reduce cost since they

work at about the same rate as people, but cost about 1/2 as much as labor to operate per hour.

Robots can increase productivity since they can work 24 hrs/day, do not need break or call in sick.

Robots can improve flexibility and since tasks can be changed by a mere change of program, but people need to be trained or retrained


Computers Automation in Manufacturing: Automated Testing and Inspection Testing and inspection close the loop around processes

to insure that they are producing the desired results. Prototype testing reduces the number of design

iterations and quickly checks conformance to design specifications.

Automated test equipment is used in electronic manufacturing to insure that devices and circuit boards are manufactured and assembled correctly.

Vision, Coordinate Measuring Machines (CMM) and robotic inspection systems are used in discrete and process manufacturing to inspect parts and products.


Computers Automation in Manufacturing: Flexible Manufacturing Systems (FMS) An FMS is a computer-based system in which machine tools and

workstations are arranged in groups or cells. Cells produce a limited variety of part types obtained from applying

group technology (GT). The cell layout minimizes waiting, part transfer and setup times.

An FMS can "randomly" produce a pre-determined variety of parts having similar processing requirements.

Computers control schedules and track materials. The major benefit of an FMS is flexibility:

– Producing a mix of different parts on-demand– Dynamic routing of parts to maintain work load balance– Accommodating changing production volumes


Computers in Manufacturing:Conclusions Because of intensifying competition and accelerating

rate of change, CIM emerges as a strategic weapon with which business can adapt and survive in an ever changing and increasingly competitive business climate.

CIM brings automation and integration which results in: – shorter product development cycle– lower product development cost– lower production costs– responsiveness to changing markets and technologies– increased process and product quality

isat 211 cim-1 1997-2000 m. zarrugh computer-integrated manufacturing (cim): what it is and key...

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