From manufacturing

events to an integrated

process-

Integration as a

competitive advantage

David E. Suica, PE/ President / Fastems LLC

The basic premise is that every time someone needs to touch a part the cost

of that part increases.

Also each time there is human intervention an error can occur.

Wrong data entered

Poor measurements

A delay in part processing

This is true not only in manufacturing but in all industries. And cited in a

Cornell paper by Prof, Baker, Potter, Schroder and with lean principals as

sighted in LeanCor Supply chain Group.

The Challenge Setting and TrendsYour Customer

Competitiveness

Delivery

TimePrice

Delivery

Performance

Success Factors

You

Lead

Time Cost

Quality

Competition

Lack of talented

workforce

Smaller batch sizes

Shorter delivery times

Traceability demands

Safety

Globalization

Environment

Energy

Shorter product

life cycles

Market fluctuation

First time right

The Roots of Lean, Three M:s

External: market

demand fluctuations

Internal: missing

production resources,

machinery breakdowns,

sick leaves, etc.

Unevenness leads

to overburden of the

production machinery

and people.

Among the others unevenness and overburden leads to non-value-added work.

Which again leads to unevenness and overburden –

vicious circle aka. daily hassle at production is ready

UnevennessMura

OverburdenMuri

WasteMuda

From Challenge to Solution

UnevennessMura

OverburdenMuri

WasteMuda

How modern Manufacturing Management Software and Integrated

Automation can help you to create the flow:

1. managing unevenness

2. avoiding overburden

3. reducing non-value-adding work

Leading to:

1. shorter delivery times

2. reduced cost

3. improved delivery performance (quality)

Thus providing the ultimate goal of customer satisfaction

Why Creating Flow is Then so Hard?

Process, Machinery, Inspection Setups • Presetting • Measuring

Material • Cutting • Deburring

Washing

MES • PDM

CAM • QMS • TDM

ERP

KPI

Production system pyramid

Because team-play of many data system

and production assets are required,

but they are not connected!

ERP

MES

production simulation

Modern Manufacturing Environment

Modern Manufacturing

Environment creates

seamless production

team-play by integrating

production data systems and

production machinery to

work together Flow

Situational awareness

& transparency

Production Planning

and Simulation

Manufacturing Automation

(Production Execution)Setups • Presetting • Measuring

Material • Cutting • Deburring • Washing

QMS

TDM

ERP

PDM

CAM

KPI

MMSManufacturing

Management

Software

Manufacturing Automation

Setups • Presetting • Measuring

Material • Cutting • Deburring

Machine Pallets

Manufacturing Automation

(Production Execution)

Horizontal Machine Tools

Machine pallet

loading stationMMS operating panel

Total Integration

Page 8

ERP/MES-> Orders, part data

<- Production

feedback

TDM-> Tool base data

-> Tool offsets

<- Tool need

QUALITY

SYSTEMS<- Uptime data

<- Scrap data

<- Output data

PDM-> Production documents

TOOL PRESETTING-> Measured Tool offsets

CAD/CAM-> NC programs

MACHINE

TOOLS<-> NC programs, tool

data, program

selection/start/status,

hand shaking, machine

status

Trending – WIP eliminated from production chain

Page 9

• Conventional manufacturing routings have parts completed sequentially in different fixtures or work holding.

• This causes excess WIP and long lead times.

• In modern FMS technology it is possible to do all process steps with one setup.• One setup/clamping and part is ready for assembly!

MeasuringWashingDeburringMachiningPreparing

$ $$ $$$ $$$$

Manufacturing Automation

Setups • Presetting • Measuring

Material • Cutting • Deburring • Washing

Central tool storage (CTS) Automatic Storage for Machine

Pallets and Material Pallets

Horizontal Machine Tools

Machine pallet

station

Integrated material

management

Deburring Cell

Washing machine

CMM

Autoloading

Setups • Presetting • Measuring

Material • Cutting • Deburring • Washing

QMS

TDM

ERP

PDM

CAM

KPI

MMSManufacturing

Management

Software

Your Success Factors

Your Customer

CompetitivenessDelivery

TimePrice

Delivery

Performance

Thank you Fastems - 4000 systems worldwide

1982 24/7 8,200

First system

installed and

still in use

Teleservice support

world wide

Fastems record:

spindle hours

per year