CIM Part 2

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CIM Computer-integrated manufacturing (CIM) uses computers to monitor and control most aspects of manufacturing. Computers link design and production operations with purchasing, inventory, shipping, sales, accounting, and payroll. Computer Integrated Manufacturing

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Why use CIM? Computer Integrated Manufacturing Responsiveness to rapid changes in market demand and product changes. Better use of materials, machinery, personnel, reduction in inventory. Better control of the total manufacturing operation. Manufacturing High-Quality Products at Low Cost.

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CAD Computer-aided design (CAD) uses a computer and software to make accurate drawings of parts and products. CAD can show what the product will look like, how it should be made, how it will work, and what materials it will be made of. Computer Integrated Manufacturing

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CAD History Computer Integrated Manufacturing CAD research began in the 1960.s in the automotive and aerospace industries (General Motors, McDonnell Douglas)‏ In 1963, Ivan Sutherland developed the first sketch pad for manipulating computer graphics. As computers have become faster and more powerful, CAD software packages have become commonplace in the modern industrial workplace.

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CAD History Computer Integrated Manufacturing Boeing’s 777 airplane was designed entirely on computer, without the construction of an initial prototype

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CAD Packages Computer Integrated Manufacturing AutoCAD ProEngineer Ideas SolidWorks Unigraphics Others

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CAM Computers are also used to operate and control many machines and processes used in manufacturing. CAD drawings may sometimes be directly input into a CAM system. Computer Integrated Manufacturing

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CAM History Computer Integrated Manufacturing In the 1950.s MIT demonstrated the numerical control of a machine using a computer language called Automatically Programmed Tool (APT). Numerically Controlled (NC) machinery has been developed to perform a diverse array of operations, such as milling and turning.

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CAM History Computer Integrated Manufacturing Other techniques for prototyping include stereo-lithography, lamination methods, and selective laser sintering . More advanced machining cells have been developed that integrated many of these machining functions

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CNC Computer numerical control (CNC) uses computer-controlled machines to perform a series of operations over and over. Drilling, milling, and lathes are often controlled by CNC programming. CNC machines are reprogrammed to make different parts. Computer Integrated Manufacturing

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Advantages of CNC Computer Integrated Manufacturing Increased Flexibility Greater Accuracy More Versatility

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Rapid Prototyping Rapid prototyping utilizes a CAD system and a 3D printer to produce a 3-D model of a product layer-by-layer. Computer Integrated Manufacturing

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Motivation for Rapid Prototyping Computer Integrated Manufacturing Shorter lead times from design to prototype Ability to incorporate designs from multiple locations Potential for one-of-a-kind customization Can increase precision and detail of prototype

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Motivation for Rapid Prototyping Computer Integrated Manufacturing Provides initial testing of form and function Can be used to create molds for mass-production

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Rapid Prototype Process Computer Integrated Manufacturing

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Rapid Manufacturing The techniques are the same ones used for rapid prototypes, except that the process is repeated to make tens or hundreds of actual products for sale. Computer Integrated Manufacturing

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Characteristics of a Line Layout Volume operation; continuous production Capital intensive resources (equipment)‏ Faster processing rates Lower inventories Less time lost to changeovers Less flexibility Low resources used; low volume products Computer Integrated Manufacturing

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Computer Integrated Manufacturing

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Production Cells A group of functionally dissimilar production capabilities (different equipment) located in physical proximity which are dedicated to the complete processing of given product. Computer Integrated Manufacturing

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Computer Integrated Manufacturing

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Characteristics of Manufacturing Cells Short Lead-Times Small Backlogs (In-process Inventory)‏ Reduced Material Handling Improved Quality More Flexible Workforce Computer Integrated Manufacturing

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ADVANTAGES OF CELLS Improved workflow Increased operational flexibility Reduced material handling Improved quality Computer Integrated Manufacturing

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ADVANTAGES OF CELLS Improved equipment utilization Facilitates reduced setup times and tooling costs (Identifies families of parts)‏ Flexible staffing and improved operator utilization Computer Integrated Manufacturing

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ADVANTAGES OF CELLS Computer Integrated Manufacturing Improved human relations Workers respond positively when goals are apparent and attainable Workers have a greater sense of importance Labor productivity increases Problems are continually revealed and solved by the “Cell Teams!”

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ADVANTAGES OF CELLS Computer Integrated Manufacturing Improved/Simplified Shop Floor Control Simplified paperwork Less supervision?? Accurate equipment and manpower requirement analysis

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ADVANTAGES OF CELLS Computer Integrated Manufacturing Improved/Simplified Shop Floor Control Facilitates Better Quality and “Quicker Adjustments” Improved information flow

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DISADVANTAGES OF CELLS Computer Integrated Manufacturing Reduced Flexibility Imbalance of machine utilization Equipment Cost (Duplication)‏ Higher Skill/Training Relocation Costs Tooling/Support Cost of Downtime

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DISADVANTAGES OF CELLS Computer Integrated Manufacturing Traditional Methods of Cost Justification Don’t Work Obsolescence of Technology Potential of crippling delays due to machine breakdowns, operator absenteeism,etc.

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Lean Manufacturing A systematic approach to reducing how long it takes to complete a defined set of tasks out of the conviction that “Time = Cost”. Computer Integrated Manufacturing

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Lean Manufacturing Continuous improvement Just-in-time inventory management (JIT)‏ Teamwork Work cells Computer Integrated Manufacturing

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Computer Integrated Manufacturing

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8 Wastes in Manufacturing Wait time includes setup, handling, order processing, storage/retrieval, rework, inspection, breakdowns, and unscheduled maintenance. In most of manufacturing, value-added time is a small % of total time, and is scattered throughout the process. Computer Integrated Manufacturing

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Just-in-Time Inventory & Production Designed to keep only the immediately needed parts on hand. Saves costs because less storage space is needed and there are fewer unused parts. New parts are delivered to the factory “Just-In-Time” to be used. Computer Integrated Manufacturing

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Computer Integrated Manufacturing Just-in-Time Inventory & Production First implemented in Japan Eliminate sources of waste Receive supplies Just-In-Time Produce parts Just-In-Time Produce subassemblies Just-In-Time Produce and deliver finished products Just-In-Time to be sold

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Low Inventory Carrying Costs Fast Detection of Defects Reduced Inspection and Rework of Parts High-Quality Parts Produced at Low Cost Computer Integrated Manufacturing Advantages of JIT