Manufacturing Processes for Engineering Materials (5 th Edition in SI Units)

1. Manufacturing Processes for Engineering Materials (5th Edition in SI Units) Chapter 15: Computer-Integrated Manufacturing Systems

2. Computer-Integrated Manufacturing • Computer-integrated manufacturing (CIM) describes the computerized integration of product design, planning, production, distribution and management. • CIM depends on usage of a large-scale integrated communications system. • Requires extensive database containing technical and business information.

3. Computer-Integrated Manufacturing • CIM systems consists of subsystems that are integrated as a whole, such as: • Business planning and support • Product design • Manufacturing process planning • Process automation and control • Factory-floor monitoring systems

4. Computer-Integrated Manufacturing Benefits • Shorter product life cycles • Product quality and uniformity • Better use of resources • Better control of the processes

5. Computer-Integrated Manufacturing Some examples: • Computer aided design and manufacturing (CAD/CAM) • Computer numerical control (CNC) • Adaptive control (AC) • Industrial robots for assembly • Automatic control • Computer-aided process planning (CAPP) • Group technology (GT) • Just-in-time production (JIT)

6. Computer-Aided Design and Engineering • Computer-aided design (CAD) uses the computers to create design drawings and geometric models of products and components.

7. Elements of computer-aided design systems • CAD system consists of four stages: 1. Geometric modeling • Constructs geometric mode with lines and dimensions.

8. Elements of computer-aided design systems 2. Design analysis and optimization • Design is subjected to an engineering analysis. 3. Design review and evaluation • Review and evaluation to check for any interference among various components.

9. Elements of computer-aided design systems 4. Documentation • Detailed, working drawings are developed and printed.

10. Computer-Aided Manufacturing • CAM involves the use of computer technology to assist in all phases of manufacturing. • CAD/CAM systems allows information transfer from design to planning stage. • Advantages of CAD/CAM are: • standardizing product development • reducing the effort of designing, evaluation and prototype work

11. Computer-Aided Process Planning • Process planning involves selecting methods of the sequence of operations, processing time and methods of assembly. • Computer-aided process planning (CAPP) view total operation as an integrated system, so that individual operations are coordinated with each other.

12. Elements of computer-aided process-planning systems • 2 types of CAPP systems: 1. Variant System • Computer files contain a standard process plan for a particular part to be manufactured. 2. Generative System • Process plan is automatically generated on the basis of the same logical procedures.

13. Elements of computer-aided process-planning systems Advantages of CAPP systems • Standardization of process plans improves the productivity. • Process plans can be prepared. • Process plans can be modified. • Routing sheets can be prepared. • Other functions can be incorporated.

14. Computer Simulation of Manufacturing Processes and Systems • Process simulation takes 2 forms: • Optimizes or improves performance. • Analyses multiple processes and their interactions. • Simulation helps engineers to organize and to identify critical machinery.

15. Computer Simulation of Manufacturing Processes and Systems • Process simulation takes 2 forms: • Optimize or improve performance. • Analyse multiple processes and their interactions. • Simulation helps engineers to organize and to identify critical machinery. • Able to conduct ergonomic analysis of various operations and machinery setups.

16. Group Technology • Group Technology (GT) is a concept to take advantage of design and processing similarities among the parts that are to be produced. • Attractive to consumer demand for variety of products which requires batch production.

17. Cellular Manufacturing • Group technology consists of one or more manufacturing cells. • Manufacturing cell is a small unit consisting of one or more workstations. • Cellular manufacturing used in material removal, sheet-metal forming operations and polymer processing.

18. Flexible Manufacturing Systems • In FMS all elements of manufacturing are integrated into an automated system. • Different computer instructions can be downloaded for each successive part that passes through a workstation. • Can handle a variety of part configurations and produce in any order.

19. Flexible Manufacturing Systems Elements of FMS • Workstations • Automated handling and transport of materials and parts • Control systems • System capable of transporting raw materials, blanks, and parts in various stages of completion anytime.

20. Just-in-Time Production • JIT concept has the following goals: • Receive supplies just in time to be used. • Produce parts just in time to be made into subassemblies. • Produce subassemblies just in time to be assembled into finished products. • Produce and deliver finished products just in time to be sold.

21. Just-in-Time Production • This approach emphasizes: • Worker pride and dedication • Elimination of idle resources • Teamwork • Advantages of JIT: • Low inventory-carrying costs • Rapid detection of defects • Reduced need for inspection and reworking of parts • Production of high-quality parts at lower cost

22. Lean Manufacturing • A systematic approach to identifying and eliminating waste in every area of manufacturing. • Helps identify whether the activity: • adds value • adds no value but cannot be avoided • adds no value but can be avoided

23. Artificial Intelligence • AI concerned with systems that exhibit some characteristics are usually associated with intelligence in human behaviour. • Has impact on the design, automation and overall economics of manufacturing operations. • AI encompasses the following: • Expert systems. • Natural language. • Machine (computer) vision. • Artificial neural networks. • Fuzzy logic.