Kr supplement b
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KR: Supplement B. Computer-Integrated Manufacturing (CIM). Definition of Automation. Automation 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 parts

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Kr supplement b

KR: Supplement B

Computer-Integrated Manufacturing (CIM)


Definition of automation

Definition of Automation

Automation 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 parts

  • Automatic assembly machines

  • Industrial robots

  • Automatic material handling and storage systems

  • Automatic inspection systems for quality control

  • Feedback control and computer process control

  • Computer systems for planning, data collection, and decision making to support manufacturing activities


Types of automation

Types of Automation

  • Fixed automation

  • Programmable automation

  • Flexible automation

Fixed Automation

Flexible Automation

Programmable Automation


Three types of production automation as a function of production volume and product variety

Number of different parts

Programmable automation

. Three types of production automation as a function of production volume and product variety.

High

Production variety

Medium

Flexible automation

Fixed

Automation

Manual methods

Low

Parts per year

Low

Medium

High

Production volume


Basic components of an nc system

Basic Components of an NC System.

Program

Machine control unit

Processing equipment

FIGUREBasic components of an NC system.


General configuration of a direct numerical control dnc

Central

computer

Bulk

Memory

NC programs

Telecommunication lines

General configuration of a direct numerical control (DNC)

Machine tools


General configuration of a direct numerical control cnc system

General configuration of a direct numerical control (CNC) system

Tape

Reader

for

initial program

entry

NC

Program

storage

Microcomputer

(software

functions)

Computer-

hardware

interface

and

servosystem


Robot and its standard movements

Robot and Its Standard Movements

Robot and Its Standard Movements


Where robots are better

Where Robots Are Better

  • Hazardous work environment for human beings

  • Repetitive work cycle

  • Difficult handling for human beings

  • Multishift operation

  • Infrequent changeovers

  • Part position and orientation are established


Possible objectives for installing an automated storage system in a factory or warehouse

Possible Objectives for Installing an Automated Storage System in a Factory or Warehouse

Increase storage capacity

Increase floor space utilization

Recover space for manufacturing facilities

Improve security and reduce pilferage

Reduce labor cost in storage operations

Increase labor productivity in storage operations

Improve safety in storage function

Improve control over inventories

Increase stock rotation

Improve customer service


Flexible manufacturing systems

Flexible Manufacturing Systems

  • What is an FMS

    A 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 FMS

    • Processing stations

    • Material handling and storage

    • Computer control system


Kr supplement b

FMS


Cim managerial issues

CIM Managerial Issues

  • Cost-benefit analysis

    • Advantages

    • Cost justification

  • CIM and manufacturing strategy

  • Organizational and behavioral aspects

  • Lessons learned


Synergistic effects of a cim system

Synergistic Effects of a CIM System

Benefits of data integration

CIM benefits

Benefits of each separate technology


Advantage of cim

Advantage of CIM

  • Higher quality

  • Shorter lead time

  • Less inventory

  • Higher flexibility

  • Economy of scope

  • Less floor space

  • Less material handling


Cim and manufacturing strategy

CIM and Manufacturing Strategy

  • Cost leadership vs. differentiation

    Productivity vs. innovation

    Efficiency vs. flexibility

  • Market segmentation

  • Fixed costs vs. variable costs

  • Break-even point

  • Barriers to entry


Flexible manufacturing

Traditional Technology can be described by:

Economy of scale

Learning curve

Task specialization

Work as a social activity

Separable variable costs

Standardization

Expensive flexibility and variety

In contrast the CIM Factory is described by:

Economy of scope

Truncated product life cycle

Multimission facilities

Unmanned systems

Joint costs

Variety

Profitable flexibility and variety

Flexible Manufacturing


Flexible manufacturing1

Centralization

Large plants

Balanced lines

Smooth flows

Standard product design

Low rate of change and high stability

Inventory used as a buffer

“Focused factory” as an organizing concept

Job enrichment and enlargement

Batch systems

Decentralization

Disaggregated capacity

Flexibility

Inexpensive surge and turnaround ability

Many custom products

Innovation and responsiveness

Production tied to demand

Functional range for repeated reorganization

Responsibility tied to reward

Flow systems

Flexible Manufacturing

Leading to factories that exhibit characteristics of:

Traditional

CIM


Taking advantage of cim capabilities

Taking Advantage of CIM Capabilities

To effectively use the capabilities of CIM as a strategic weapon, a firm should:

  • 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.


Organizational and behavioral aspects of cim

Organizational and Behavioral Aspects of CIM

  • Integration of functions

  • Flattening the organization structure

  • Changing role of supervisors

  • Impact on workers

    • Shift from direct to indirect workers

    • Increased skill requirements

    • Displacement of workers

    • Retraining and education


Lessons learned

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 examples

CIM Examples

Toshiba

Toshiba’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 examples1

CIM Examples

Fuji

Fuji 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 free flexibility through manufacturing technology

Variety Is FreeFlexibility Through Manufacturing Technology

Ingersoll Milling Machine Company

The 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 free flexibility through manufacturing technology1

Variety Is FreeFlexibility Through Manufacturing Technology

Vought Corporation

Vought 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.


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