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.