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dokumen.tips_me6703-computer-integrated-manufacturing-systems-2018-12-21-computer-integrated.pdf
1.
ME6703 - COMPUTER
INTEGRATED MANUFACTURING SYSTEMS © J.Jeevamalar, EGSPEC
2.
© J.Jeevamalar, EGSPEC
3.
UNIT I –
Introduction (10) Brief introduction to CAD and CAM Manufacturing Planning, Manufacturing control Introduction to CAD/CAM Concurrent Engineering-CIM concepts Computerized elements of CIM system Types of production Manufacturing models and Metrics Mathematical models of Production Performance – Simple Problems Manufacturing Control – Simple Problems Basic Elements of an Automated system Levels of Automation Lean Production Just-In-Time Production. © J.Jeevamalar, EGSPEC
4.
Product Development Cycle ©
J.Jeevamalar, EGSPEC
5.
Sequential Vs Concurrent Engineering Vs ©
J.Jeevamalar, EGSPEC
6.
Implementation of Concurrent Engineering ©
J.Jeevamalar, EGSPEC
7.
Computer-Aided Techniques CAD
(Computer-Aided Design) CAE (Computer-Aided Engineering) CAPP (Computer-Aided Process Planning) PPC (Production Planning and Control) ERP (Enterprise Resource Planning) CAM (Computer-Aided Manufacturing) CAQ (Computer-Aided Quality Assurance) © J.Jeevamalar, EGSPEC
8.
Interface between CAD/CAM ©
J.Jeevamalar, EGSPEC
9.
Computer Integrated Manufacturing
Computer Integrated Manufacturing (CIM) is the manufacturing approach of using computers to control the entire production process. In a CIM system functional areas such as Design, Analysis, Planning, Purchasing, Cost Accounting, Inventory Control and Distribution are linked through the Computer with factory floor functions such as Materials Handling and Management, providing Direct Control and Monitoring of all the operations. © J.Jeevamalar, EGSPEC
10.
CIM Wheel © J.Jeevamalar,
EGSPEC
11.
Computerized Elements of
CIM System © J.Jeevamalar, EGSPEC
12.
Elements of CIM ©
J.Jeevamalar, EGSPEC
13.
Activities of CIM ©
J.Jeevamalar, EGSPEC
14.
Benefits of CIM •
Manufacturing engineers are required to achieve the following objectives to be competitive in a global context, – Reduction in inventory – Lower the cost of the product – Reduce waste – Improve quality – Increase flexibility in manufacturing to achieve immediate and rapid response to: • Product & Production changes • Process & Equipment change • Change of personnel © J.Jeevamalar, EGSPEC
15.
Application of
Physical and Chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products. Overview of Manufacturing © J.Jeevamalar, EGSPEC
16.
Manufacturing Defined - Economic
Definition Transformation of materials into items of greater value by means of one or more Processing and/or Assembly operations Manufacturing adds value to the material Examples: Converting iron ore to steel adds value Transforming sand into glass adds value © J.Jeevamalar, EGSPEC
17.
Manufacturing Defined - Economic
Definition © J.Jeevamalar, EGSPEC
18.
Production Quantity Number of
units of a given part or product produced annually by the plant Three quantity ranges: 1. Low production – 1 to 100 units 2. Medium production – 100 to 10,000 units 3. High production – 10,000 to millions of units © J.Jeevamalar, EGSPEC
19.
Production Systems Batch Production Continuous Production Mass Production Flow Production Job Shop Production Production
Types © J.Jeevamalar, EGSPEC
20.
Types of Production
Facility © J.Jeevamalar, EGSPEC
21.
Variety of
metrics used by successful manufacturing to help managing company’s operations Quantitative metrics used to: Track performance in successive periods (i.e. months & years) Try out new technologies & new systems to determine company’s merits Identify problems with performance Compare alternative methods Make good decisions Manufacturing Models and Metrics © J.Jeevamalar, EGSPEC
22.
Manufacturing Models and
Metrics Manufacturing Metrics can be divided into 2 basic categories: 1) Production performance measure 2) Manufacturing Costs © J.Jeevamalar, EGSPEC
23.
Production concepts and Mathematical
Models Metrics that indicates Production Performance: Production Rate (Rp) Production Capacity (PC) Utilization (U) Availability (A) Manufacturing Lead Time (MLT) Work-In-Progress (WIP) © J.Jeevamalar, EGSPEC
24.
Metrics that indicates
Manufacturing Costs: Labor & material costs Costs of producing products Cost of operating a given piece of equipment Production concepts and Mathematical Models © J.Jeevamalar, EGSPEC
25.
Operation Cycle Time
Typical cycle time for a production operation: Tc = To + Th + Tth where Tc = Cycle Time, To = Processing Time for the Operation Th = Material Handling Time (e.g., loading and unloading the production machine) Tth = Tool Handling Time (e.g., time to change tools) © J.Jeevamalar, EGSPEC
26.
Production Rate (Rp)
In manufacturing, the number of goods that can be produced during a given period of time. Alternatively, the amount of time it takes to produce one unit of a good. For manufacturing and construction, a higher production rate can lead to a decrease in quality. Usually expressed in hourly rate Consider 3 types of production – Job Shop, Batch Prod & Mass Productions © J.Jeevamalar, EGSPEC
27.
In Batch Production,
time to process one batch of Q work units is Batch time, Tb = Tsu + QTc where; Tb = batch processing time (min) Tsu = setup time to prepare for the batch (min) Q = batch quantity (pc) Tc = operation cycle time per work unit (min/cycle) Assuming one work unit is completed each cycle, thus Tc also has units of min/pc Production Rate (Rp) – Batch Prod. © J.Jeevamalar, EGSPEC
28.
By dividing batch
time with batch qty: Average production time per work unit for the given machine, Tp = Tb /Q Production rate, Rp = 1/Tp The average production rate for the machine, Rp = 60/Tp Rp = hourly production rate (pc/hr) Tp = average production time per work unit (min/pc) 60 = constant to convert minutes to hours Production Rate (Rp) – Batch Prod. © J.Jeevamalar, EGSPEC
29.
In Job
Shop Production, when Q =1; The production time per work unit, Tp is: Tp = Tsu + Tc Tsu = Setup time to prepare for the batch (min) Tc = Operation cycle time per work unit (min/cycle) If Q > 1, revert to batch production case Production Rate (Rp) – Job Shop Prod. © J.Jeevamalar, EGSPEC
30.
The machine production
rate is determined by taking the reciprocal of Tc, Rc= 60 / Tc Where, Rc = theoretical or ideal production rate / cycle rate (cycles/hr) Tc = ideal cycle time (min/cycle) 60 = constant to convert minutes to hours Production Rate (Rp) – Mass Prod. © J.Jeevamalar, EGSPEC
31.
Production Capacity Production Capacity
defined as: the maximum rate of output that a production facility is able to produce under a given set of assumed operating conditions PC = n Sw Hs Rp Where, PC = weekly production capacity of the facility (output units/wk) n = no. of work centers working in parallel producing in the facility Sw = no. of shifts per period (shift/wk) Hs = hr/shift (hr) Rp = hourly production rate of each work center (output units/hr) Work center manufacturing system in the plant typically consisting of one worker & one machine © J.Jeevamalar, EGSPEC
32.
Utilization Utilization = amount
of output of a production facility relative to its capacity U = Q / PC U = utilization of the facility Q = actual qty produced by the facility during a given time period (i.e. pc/wk) PC = production capacity for the same period (i.e. pc/wk) Utilization can be assessed for the entire plant/any other productive resources (i.e. labor) It is often defined as the proportion of time that the facility is operating relative to the time available Usually expressed in % © J.Jeevamalar, EGSPEC
33.
Availability =
a common measure of reliability for equipment Especially appropriate for automated production equipment: A = MTBF / MTBF - MTTR A= availability (typically in %) MTBF = mean time between failures (hr) MTTR = mean time to repair (hr) MTBF indicates the average length of time between breakdowns of equipment MTTR indicates the average time required to service the equipment & put back into operation when breakdown occurs Availability © J.Jeevamalar, EGSPEC
34.
Manufacturing Lead time
(BATCH) Manufacturing Lead Time, MLT = total time required to process a given part or product through the plant Simplified form: MLT = average Manufacturing Lead Time for a part/product (min) no = no. of separate operations (machines) Tsu = setup time for operation Q = qty of part/product Tc = operation cycle time Tno = non-operation time © J.Jeevamalar, EGSPEC
35.
Work-In-Process WIP = work-in-process
in the facility (pc) A = availability U = utilization PC = production capacity of the facility (pc/wk) MLT = manufacturing lead time (hr) Sw = no. of shifts per week (shift/wk) Hsh = hours per shift (hr/shift) © J.Jeevamalar, EGSPEC
36.
Costs of Manufacturing
Operations Fixed costs - remain constant for any output level Variable costs - vary in proportion to production output level Adding fixed and variable costs TC = FC + VC(Q) where TC = total costs FC = fixed costs (e.g., building, equipment, taxes) VC = variable costs (e.g., labor, materials, utilities) Q = output level © J.Jeevamalar, EGSPEC
37.
Fixed and Variable
Costs © J.Jeevamalar, EGSPEC
38.
Manufacturing Costs © J.Jeevamalar,
EGSPEC
39.
Basic Elements of
an Automated System © J.Jeevamalar, EGSPEC
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