Introduction to Computer-Integrated Manufacturing (Chapter 10) Dr.
Sami El ferik
Automation
Definition 1: automatically controlled operation of an apparatus, process, or system by mechanical or electronic devices that take the place of human organs of observation, effort and decision. Definition2: a process without direct human activity in the process
Human beings role in automated systems
Designing the system Monitoring of its operation Maintaining the system Presently, human involvement have been removed from many portions of the production system
Continuous flow processes
Example: oil refineries and chemical plants automation has reached a very high state of development.
Sensors measure critical process variables in real time and feed the measurement back to the control computer. The computer exercises an on-line optimization to determine any needed adjustments in the controlled process components.
Human interaction in continuous flow processes.
The process is fully automated with human monitoring the process in a control room containing readouts of the process variables and parameter settings.
Mass Production of discrete items
Ex: Automobile components. Usually called flow lines or transfer lines. Many special machines arranged sequentially. Work parts are transferred automatically from one machines to another. The machine performs their operations automatically. Ex: Robot welding, painting, parts handling and so on. Automated flow lines are flexible Through the use of computer and flexible manufacturing system
Batch production and job shop production
Introduction of CNC (Computer numerical controlled) machine. Use of flexible manufacturing concept.
Tools change automatically Machine can do several dozen operation 4 general type:
Flexible modules Stand alone FMS Classical FMS Robotized FMS.
Robotics
A programmable, multifunction manipulator designed to move material, parts, tools, or special devices through variable programmed motions for the performance of a variety of tasks. Type of robots.
Stationary robots Mobile robots
Aspects of robots
Four basic components:
Manipulators Actuator Control unit Variety of sensors:
Audio Visual Voice or speech recognition Tactile etc
Use of robots:
Machine loading Material transfer Painting/coating Welding Assembly Inspection Packaging Component insertion
OPEL
CIM
CIM is the integration of
Computer in Product design Computer in process design Computer in Electronic design
CAD
Computer aided process planning Numerical control Group technology Automated storage retrieval and handling Computer aided testing and inspection Computer aided factory management Flexible manufacturing system
CAM
CAD: is hardware and software
Computer in Product design: (3 components)
Design development: Geometric shape Design Analysis: weight volume, center of gravity, effect of temperature etc) Design simulation: system model, simulation and animation software Design review and evaluation Automated drafting Design retrieval and modification.
CAD
Computer in the process design
Model that express the system behavior (dynamic)
Differential equation (physically based) Statistically models Time series models: output is function of the output previous values as well as the input present and previous values. Parameters of the system are changed until the system gives the appropriate response.
CAM
Computer aided process planning Numerical control Group technology Automated storage retrieval and handling Computer aided testing and inspection Computer aided factory management Flexible manufacturing system
Computer aided factory management
Purpose: Coordinate review and control the activities of the entire plant. Integration of all the information and concepts together to manage and control available sources
Think of the big picture of CIM
The role of technology in the implementation and operation of CIM. Automation key elements of CIM The relationship between automation and the humans in the system How CIM can make an operation more effective
Continued.
Functional areas of the enterprise How will CIM impact these areas?
Marketing/Sales Engineering R&D Quality Assurance Warehousing & Distribution Shipping and Receiving Finance & Accounting Information Systems Human Resources Customer Service Manufacturing Material Management
Definitions of CIM
View 1:
technology, tool or method used to improve entirely the design and manufacturing process and increase productivity using computers to help people and machines to communicate
CIM cont.
View 2
series of integrated activities and operations involving the design, materials selection, planning, production, quality assurance, management and marketing of discrete consumer and durable goods (Bunce, 1985) deliberate integration of automated systems logical organization of individual engineering, production and marketing/support functions into a computer integrated system (Bunce, 1985)
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CIM cont
architecture for integration of multiple technologies through computers, linking each individual island of automation to a closed loop business system (Foong, 1991) integration of computer aided design, automatic material handling, robotics, process technologies, manufacturing planning & control, computer aided test, computer aided manufacturing
CIM Wheel 1985
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Percent of Respondents
10
20
30
40
50
60
70
lower mfg. cost
higher product quality
improved prod. control
better responsiveness
reduced inventory
Expected Benefits of CIM
increased flexibility
small lot capability
1993 SME Enterprise Wheel
other
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CIM More than just automation
CIM Can be found at several levels:
Shop floor automation / work cell
islands of automation
Low
Manufacturing Operations
islands are linked together
Information systems integration
Information shared across functional boundaries
Strategic or Supply Chain level
High Integration extends up to customers and down to the suppliers
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