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World Class Technologies for Manufacturing. World Class Technologies for Manufacturing. Patrick J. Delaney, CFPIM, CIRM, CPM. National Manufacturing Week. Chicago McCormick Place February 23-26, 2004 Manufacturing Enterprise Automation Manufacturing Process Automation

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World Class Technologies for Manufacturing

World Class Technologies for Manufacturing

Patrick J. Delaney, CFPIM, CIRM, CPM


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National Manufacturing Week

Chicago

McCormick Place

February 23-26, 2004

  • Manufacturing Enterprise Automation

  • Manufacturing Process Automation

  • Product Design Automation

  • Facility Security & Automation

  • Data Capture and Data Tracking Automation


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Computer-Integrated Manufacturing

Rehg & Kraebber, Prentice Hall, 3rd Ed. 2004

  • Purdue University

  • 30 Engineering Schools

  • Manufacturing Technology Program




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World Class Technologiesfor Manufacturing

  • Electronic Commerce [www.com+EDI]

  • Internet Supply Chain Systems Suite

  • Enterprise Resource Planning Systems

  • Advanced Planning & Scheduling Systems

  • Integrated ERP/CRM/SRM

  • Wireless WANs [over 30 miles]

  • RFID Tracking Technology

  • Global Tracking Systems

  • Internet B2B Server Applications

  • Sales & Field Force Automation [SFA]

  • Mobile Connectivity [MC]

  • Computer Aided Design CAD/PLM

  • Computer Aided Manufacturing [CAM]

  • Manufacturing Automation Controllers

  • Device and cell controllers


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DuPont Innovation

  • Automotive Coatings Technology

  • Wet on Wet Paint Systems

    • Rust coating

    • Primer coat

    • Color coat

    • Clear coat

  • Final stage oven dry


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Robotic Evolution

  • Hydraulic in early 1980s

  • Electric/electronic today

  • Newer vision systems

  • Higher accuracy & repeatability

  • Proprietary controllers [Motorola]

  • Advanced CAD/CAM

  • Simulation

  • Greater path accuracy [0.05mm]

  • Dual robotic cells

  • Jig-less manufacturing

Betty Boop


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Manufacturing Software Development Path

MES

APS

SFC

ERP/ERO

MRP II

Inventory

control

MRP

CRM

Order Entry

SFA

DRP

Forecasting

SCM


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Supply Chain Event Managers [SCEM]

i2 Global Logistics Monitor

  • Monitor all E-commerce transactions

  • Business rule based

  • Create action messages and flags

  • Check each event for validity and accuracy

  • Accommodates all trading partners

  • Order status, shipping, inventory, billing, etc.

Computer Associates BizWorks


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Ford Case

Internet CAD

  • E-commerce graphics application

  • Internet transfer of engineering documents & graphics

  • Utilizing a translation software to interface with incompatible supplier applications


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Daimler-Chrysler Case

  • Laser based 100% inspection

  • Automatic collection of SPC data

  • Line stopping feedback

  • Machine analysis and preventive maintenance warnings

  • Bi-lingual inspection instructions

  • Automated display of ISO 9000 procedures

  • Intranet sharing of QA data across plant sites


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Honda Supplier

  • Inbound items are bar-coded

  • Outbound items are bar-coded

  • WIP isn’t bar-coded

  • Warehouse isn’t bar-coded

  • Cycle counts daily

  • Physical inventory every 30 days


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Old Rand-McNally Publishing Co. Case

Cycle Counting Approach

  • Largest printing plant in the U. S.

  • Very large warehouses

  • F.G. Four racks high

  • Lose signatures

  • Cycle counters

    • Flashlights

    • Binoculars

    • Computer print out


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Data Capture Devices

  • Hand held devices

  • Pen based devices

  • Scanner/data input devices

  • RFID tracking

  • ERP integrated

  • Windows CE - OS

  • Finger size point & scan

  • Micro-chip theft control

  • Electronic asset tracking [EAT]

  • Rackrunners

  • MicroStamp RFID Technology


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Voice Recognition Technology

InfoWorld 100

Technology Winner 2003

  • Warehouse picking application

  • Headset communications

  • Belt clip display system

  • Two-way communications

  • Improved pick accuracy to one error in 3,000 picks


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Technology Assessment Team

  • Technology Assessment

  • Investment priorities

  • Integration issues

  • Benchmarking study

  • New employee profiles

  • Technology training

  • Payback measurements

  • University relationships

  • Technology Vision


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Today’s Typical Systems Environment

  • Most technologies are only partially implemented or interfaced

  • Budget constraints constantly cut back deployments

  • Acquisitions & divestments force major steps backward

  • E-commerce skill sets are weak

  • Short term needs interfere with obtaining quality deliverables

  • End to end supply chain initiatives have overwhelmed the development queue

  • Outsourcing has built more islands of automation


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World Class Technologies Assessment

A

C

SOPHISTICATION

B

D

INTEGRATION


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Today’s Purdue Graduates

  • Database structuring and administration [Quick BASIC, C+]

  • Design techniques of Expert Systems [PC Easy & EXSYS]

  • PC based ERP

  • Distributed system design & networking

  • Hands-on PLC programming [programmable controllers]

  • Apply CAD and CAE software tools

  • Work in a $10 million CIM laboratory

    • CIM software

    • CNC workstations

    • automated materials handling with robots

    • automated data capture [RFID]

    • vision systems


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PPR Hub

Process Planning

Robotics

Production System

Ergonomics

Product

Process

Resource

Efficiency

HUB

Cost Analysis

QA

Scheduling & Control

Factory Flow Simulation

System Integrators: Rockwell/ IBM/ Dassault/ ABB/ EDS/ MIT


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National Manufacturing Week

Chicago McCormick Place

February 23-26, 2004

www.manufacturingweek.com

  • What industries are using your product?

  • What new features have been added to your product since last year?

  • What are the integration features of your product?


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Speaker Contact Data

  • Patrick J. Delaney

    NWU Research Park

  • E:mail: [email protected]

  • Phone:

    1-800-806-5177


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