View
39
Download
0
Category
Tags:
Preview:
DESCRIPTION
KR: Supplement B. Computer-Integrated Manufacturing (CIM). Definition of Automation. Automation is a technology with the application of mechanical, electronic, and computer-based systems to operate and control production, this technology includes: Automatic machine tools to process parts - PowerPoint PPT Presentation
Citation preview
KR: Supplement B
Computer-Integrated Manufacturing (CIM)
Definition of AutomationAutomation is a technology with the
application of mechanical, electronic, and computer-based systems to operate and control production, this technology includes:
Automatic machine tools to process partsAutomatic assembly machinesIndustrial robotsAutomatic material handling and storage systemsAutomatic inspection systems for quality controlFeedback control and computer process controlComputer systems for planning, data collection, and decision making to support manufacturing activities
Types of Automation
Fixed automationProgrammable automationFlexible automation
Fixed Automation Flexible Automation Programmable Automation
. Three types of production automation as a function of production volume and product variety.
Low Medium High
Production volume
Pro
duct
ion
vari
ety
Low
Medium
High
Number of different
parts
Parts per year
Flexible automation
Manual methods
Programmable automation
Fixed
Automation
Program
Machine control
unit Processing equipment
FIGURE Basic components of an NC system.Basic Components of an NC System.
General configuration of a direct numerical control (DNC)
Central computer
BulkMemory
NC programsTelecommunication lines
Machine tools
General configuration of a direct numerical control (CNC) system
TapeReader
for initial program
entry
NCProgramstorage
Microcomputer(softwarefunctions)
Computer-hardwareinterface
and servosystem
Robot and Its Standard Movements
Robot and Its Standard Movements
Where Robots Are Better
Hazardous work environment for human beingsRepetitive work cycleDifficult handling for human beingsMultishift operationInfrequent changeoversPart position and orientation are established
Possible Objectives for Installing an Automated Storage System in a Factory
or Warehouse
Increase storage capacityIncrease floor space utilizationRecover space for manufacturing facilitiesImprove security and reduce pilferageReduce labor cost in storage operationsIncrease labor productivity in storage
operationsImprove safety in storage functionImprove control over inventoriesIncrease stock rotationImprove customer service
Flexible Manufacturing SystemsWhat is an FMSA flexible manufacturing system consists of a group of processing stations (CNC), interconnected by means of an automated material handling and storage system, and controlled by an integrated computer system.
• Components of an FMS1. Processing stations2. Material handling and storage3. Computer control system
FMS
CIM Managerial Issues
Cost-benefit analysisAdvantagesCost justification
CIM and manufacturing strategyOrganizational and behavioral aspectsLessons learned
Synergistic Effects of a CIM System
CIM benefits
Benefits of each separate
technology
Benefits of data
integration
Advantage of CIM
Higher qualityShorter lead timeLess inventoryHigher flexibilityEconomy of scopeLess floor spaceLess material handling
CIM and Manufacturing Strategy
Cost leadership vs. differentiation Productivity vs. innovation Efficiency vs. flexibilityMarket segmentationFixed costs vs. variable costsBreak-even pointBarriers to entry
Flexible Manufacturing
Traditional Technology can be described by:Economy of scaleLearning curveTask specializationWork as a social activitySeparable variable costsStandardizationExpensive flexibility and variety
In contrast the CIM Factory is described by:Economy of scopeTruncated product life cycleMultimission facilitiesUnmanned systemsJoint costsVarietyProfitable flexibility and variety
Flexible Manufacturing
CentralizationLarge plantsBalanced linesSmooth flowsStandard product designLow rate of change and high stabilityInventory used as a buffer“Focused factory” as an organizing conceptJob enrichment and enlargementBatch systems
DecentralizationDisaggregated capacityFlexibilityInexpensive surge and turnaround abilityMany custom productsInnovation and responsivenessProduction tied to demandFunctional range for repeated reorganizationResponsibility tied to rewardFlow systems
Leading to factories that exhibit characteristics of:Traditional CIM
Taking Advantage of CIM Capabilities
Invest in flexibility of, not just equipment, but the organization as a whole.Deliberately truncate the product life cycle by introducing new versions frequently; and thus not giving the competitors a chance to catch up. Proliferate the range of products to the extent of customizing them one-by-one so that no customer has any reason to go to the competitors.Deliberately fragment the market into segments so small that they cannot support a conventional production system.Deliberately complicate the product so that it cannot be copied with the old manufacturing process and technology.
To effectively use the capabilities of CIM as a strategic weapon, a firm should:
Organizational and Behavioral Aspects of CIM
Integration of functionsFlattening the organization structureChanging role of supervisorsImpact on workers
Shift from direct to indirect workersIncreased skill requirementsDisplacement of workersRetraining and education
Lessons Learned
Focus on a flexible business enterprise.An automated mess is still a mess.People make flexible automation work.Provide an adequate funding.Focus on potentials of new technology.Understanding the emerging technologies.
CIM ExamplesToshibaToshiba’s computer factory in Ome is called an “intelligent
works” because a snazzy computer network links office, engineering and factory operations, providing just-in-time information as well as just-in-time parts. Ome workers assemble nine different word processors on the same line and, on an adjacent one, 20 varieties of laptop computers. Usually they make a batch of 20 before changing models, but Toshiba can afford lot sizes as small as ten.
Workers on the lines have been trained to make each model but don’t need to rely on memory. A laptop at every post displays a drawing and instructions, which change when the model does. Product life cycles for low-end computers are measured in months these days, so the flexible lines allow the company to guard against running short of a hot model or overproducing one whose sales have slowed, Toshiba’s next goal: to get managers thinking about how to ship small lots fast and cheaply, with quicker feedback from stores, so sales and distribution are as flexible as the factories
CIM ExamplesFujiFuji Electric’s investment in FMS and the like
soared starting in 1987. Fuji’s goal was to reduce lead time 30%, labor costs 70% , and work in-process inventory 50%.
When Fuji gets and order for an electric motor switch, 20% of the time the buyer wants-and gets 24 hour delivery. Another 40% must arrive within two days. Fuji didn’t narrow its product line: Those schedules are for customized work.
Variety Is FreeFlexibility Through Manufacturing
Technology
Ingersoll Milling Machine CompanyThe Ingersoll Co. uses an advanced CIM
system that links design with manufacturing and process control. Ingersoll’s state-of-the-art computer-controlled manufacturing system will machine over 25,000 different prismatic parts used for specialized motor controls. Seventy percent of the production will occur in lot sizes of one. Half of the 25,000 will never be used again. Production cost is approximately the same as for a long run of a single standard part.
Variety Is FreeFlexibility Through Manufacturing
Technology
Vought CorporationVought Corporation’s $10 million flexible
machining center began operations during the late 1980s. This advanced production technology allows the aerospace maker to produce some 600 different designs of specialized aircraft parts using the same equipment--even one design at a time in random sequence. It is expected to save Vought over $25 million annually in machine costs for these parts by performing 200,000 hours of work in less than 70,000 hours.
Recommended