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Fully Integrated System

Overview

• Manufacturing• Developments in Manufacturing

Technology• Advanced Manufacturing Technology• Computer Integrated Manufacturing (CIM)• Group Technology• Production Flow Analysis

What is Manufacturing?

• The transformation of raw materials to finished products

• Has evolved, is evolving, and will continue to evolve

• Backbone of industrialised and newly developing economies

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Manufacturing evolution?

• Craft• Standardisation• Industrial Revolution

– Concept of manufacturing– Automation– Computer Integrated Manufacturing

What is Manufacturing?

TransformationProcess

Technology

Departments

Organisation

Environment

MaterialsHandling

Machining Inspection

Assembly

Raw Material Inputs Product or Service Outputs

Internet

New/niche entrants

Traditional competitors

Partnerships and alliancesCustomers

Global economy

Costs

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External Challenges

• Niche market – new ideas• Traditional competition – must be monitored• Suppliers – finding the right suppliers• Partnerships and alliances – companies joining

force• Customers – meet their needs {The most

important thing?}• Global economy – investment, expenditure• Internet – direct access to customer, eg. Amazon

Mass Production

IdenticalProducts

Mass market

Production to Order

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Too much choice?

“Mass Customisation”

Requirements

Custom product

Shrinking Product Lifecycles

1970s 1980s 1990s 2000s

Time to Market

Product Life

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Developments in Manufacturing Technology

• Mechanisation• Programmable automation• Numerical control (NC) – programmable

automation, 1952• NC evolved into CNC and DNC• CAD – application of computers in design and

development• Combination of NC and CAD – CAM Technology• Advanced Manufacturing Technologies (AMTs)• Virtual CIM

19971990

1980

1970195519501930190017501600

Global manufacturing based on Virtual CIMConcept of Virtual CIM is introducedAdvanced systems in CAM, CAPP, CAQC, AS/RS, FMS

and CIMDevelopments in CAD, application of CAM based

systems and introduction of CIM conceptBeginning of CAD and development of NC, CNC, DNCEarly developments in NC for automationVery large mass production systemMass production systemMechanisation and early factory systemsCraftsmanshipManual and animal labour

Advanced Manufacturing Technologies (AMTs)

• AMTs are systems which provide flexibility as well as data driven computer integration for a manufacturing organisation

• AMTs illustrate a technological application where the manufacturing technology utilised is intelligent enough to process the activities with less human intervention

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CIM – a definition

• The dictionary of Advanced Manufacturing Technology defines CIM as a concept of a fully automated factory, where all manufacturing processes are integrated and controlled by computer(s)

Categorising AMTs

• AMTs can be categorised into 4 levels:

– Level 1 – stand-alone systems which include NC machines, CNC machines, robots, etc.

– Level 2 – computerised and non-computerised cellular groupings of equipment and materials for the production of families of parts: i.e. GT, FMS and CAE initiatives

– Level 3 – Linked islands of technology, which interconnects technologies in some functional units, but the islands are regarded as separate entities without interconnection

– Level 4 – fully integrated systems

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Another definition of CIM

The Computer and Automated Systems Association (CASA) of the Society of Manufacturing Engineers defines CIM as “An integrated system, which provides computer assistance to all business functions encompassing activities from accepting an order to delivery, within a manufacturing enterprise.”

Flexible Manufacturing Systems

1000

100

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11 10 100 1000 10000 100000 1000000

GeneralPurposeOr jobshop

CIMWork cells

FlexibleManufacturing

System FocusedAutomation

DedicatedAutomation

Num

ber

of p

rodu

cts

Annual volume

The prime purpose of CIM is to improve the overall profitability of

the firm

HOW?

QualityProductivityFlexibility

Achieving zero defects

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Motivation

• Enhancing efficiency and improving competitive position and profitability

• Enhancing production volume and achieving greater flexibility in production

• Obtaining increased flexibility in responding to requested changes and demands

• Enhancing productivity and boosting the unit’s image

• Optimal production flexibility and production scheduling

• Achieving more effective control of the manufacturing process

Advantages of CIM implementation

• Flexibility of product, volume and material• Improved productivity and quality• Improved interface between design and

manufacturing• Reduction in direct and indirect labour at various

levels and functional units including: middle management, engineering, administration, and operations support

• High quality designs which lead to good products

• High quality documentation and packages

Advantages of CIM implementation (cont.)

• Better standardisation and better material utilisation

• Time and floorspace savings• A common database eliminating duplicate

data storage on independent systems• Elimination of duplicate data entry• Reduction in inspection time and the

associated workforce• Competitive advantage

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CIM from customer order to delivery

Customer places anorder by computer.

Order is received by companybusiness information system,which relays it to the localfactory system.

At the factory the order isscheduled for production,and computer systemsends instructions to:

Factory machines tellingthem what to do.

The shipping department tellingit when to expect a product andwhere to ship it. When a productis shipped, the information isautomatically sent to accounts.

The procurement department whichis instructed to get the right parts.Orders or factory schedules aresent to outside suppliers.

Outside suppliers gear up their ownproduction and delivery to be able tosupply parts just-in-time.

All corporate departmentswatch each phase. Amongthem, accounting, whichprocesses billing once aproduct is shipped

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4b

4c

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CIM from customer order to delivery

CIM integrates information flows in marketing, design, manufacturing, engineering, the resource requirements planning, purchasing, the production process, quality assurance, administration, etc. into a closed loop, controlled system.

Group Technology (GT)

• Group Technology is a philosophy that implies the notion of recognising and exploiting similarities in three different ways– By performing like activities together– By standardising similar tasks– By efficiently storing and retrieving information

about recurring problems

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http://www.strategosinc.com/group_technology.htm

Definition of Group Technology

• The logical arrangement and sequence of all facets of a company’s operations in order to bring the benefits of mass production to high variety, mixed quantity production

(Ranson 1972)

Key characteristics of a GT system

• Components classified into families

• Workloads are balanced between production groups

• Production groups are clearly identifiable on the shop floor

• Each group has a clearly identifiable degree of autonomy

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Cellular Manufacturing

• Application of GT in manufacturing in which all (or a portion) of a firm’s manufacturing system has been converted into cells

• A manufacturing cell is a cluster of machines or processes located in close proximity and dedicated to the manufacture of a family of parts or products

Cellular Manufacturing

Production Flow Analysis

• Developed by Professor John L. Burbidgeof the Cranfield Institute of Technology

• Method of identifying part families and associated groupings of machine tools

• PFA uses operations sequences and machine routings for parts produced in a manufacturing facility

• It groups together parts with identical or similar routing

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Traditional Layout

M

M

M

M

M

M L L

L L

D D

G

G

G

A A AReceiving andshipping

Milling Turning

Drilling

Grinding

HeatTreating

Assembly

GT Layout

MM

M L L

L

D

D

G

G

A

A A

Receiving

Shipping

HeatTreating