computer Integrated manufacturing

1. computer Integrated manufacturing Larry Whitman whitman@imfge.twsu.edu (316) 691-5907 (316) 978-3742 Industrial & Manufacturing Enterprise Department The Wichita State University http://www.mrc.twsu.edu/whitman/classes/ie775

2. 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

3. 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.

4. Evaluation and participation read the chapters and contribute!!

5. Tentative Schedule

6. Grading Scale Not higher than!

7. 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

8. 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.

9. Tentative Course Outline DateTopic 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

10. Tentative Course Outline DateTopic 10/7 ERP and PDM for CIM 10/14 Presentation on paper (1 of the 3 above) 10/21 Wonderware software overview/Exam Review 10/28 Mid - Term Exam 11/4 Process Planning Project - Wonderware project (VB links) – Due on 12/16 11/11 Special Topics (agility, holonic manufacturing) 11/18 Project Work (no class) Paper # 4: - Special Topic (book report)–Due on 12/2 12/2 Various Applications 12/9 Presentations of book reports 12/15 Wonderware Project Report Due

11. Who are you? • Who -are you • Where - are you from? • Why -are you here? • What -do you want to get from this class?

12. Introduction • focus on the word ‘Integrated’ not on the word ‘computer’

13. 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.

14. Synonyms • CIE - computer integrated enterprise • CIME - computer integrated manufacturing enterprise • CIM means many different things to many different people.

15. CASA/SME CIM Wheel From CASA/SME

16. CASA/SME CIM wheel is a good overview of CIM • revised version (quality no longer separate) • no hierarchy • which are aided by CIM?

17. 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:

18. 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.

19. 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).

20. 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.

21. 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.

22. Wheel-Shared Knowledge and Systems

23. Wheel - Processes

24. 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

25. Wheel - Concurrent Engineering

26. Wheel - Virtual Enterprise

27. Wheel - Virtual Enterprise how well, not who performs each of the activities of the processes

28. Wheel - Resources

29. Wheel - Manufacturing Infrastructure Infrastructure separates top manufacturing regions and countries from others. • workforce • investment • transportation • communication • suppliers • schools • research • government support

30. Wheel

31. Mfg Buzzword Bingo From text

32. the CIM Jigsaw - what’s missing? Integration and Networks Computing Systems Activity Software (CAD, etc.) Info and Data Implementation Protocols and Standards Manufacturing CAM

33. 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!

34. Why CIM - to meet competitive pressures • to reduce lead times • to reduce costs • to reduce inventory (or need for)

35. Why CIM - to coordinate and organize data • functional - about organization (still important) • product - about parts • operational - plan or instructions • performance - reporting on performance

36. Why CIM - others • to eliminate paper • automate communication • simultaneous engineering (IPD) • because it is possible?

37. What is INTEGRATED? • parts indistinguishable? • no, seamlessly linked is what we mean From text

38. Integration - linked From text

39. EDI - electronic data interchange EDI : 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 Format A 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.

40. Islands of Automation Local optimization

41. 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

42. 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

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

44. 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

45. Summary Computer Integrated Manufacturing