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Computer Integrated Design and Manufacture

Integrated Data Models in Design and Manufacture


C.S.Kumar CAD-CAM and Robotics Lab. Department of Mechanical Engineering, IIT Kharagpur Kumar@mech.iitkgp.ernet.in
C.S.Kumar, Mechanical Engineering, IIT Kharagpur

Nature of Manufacturing Operations


Globalisation
Rapid Product Cycles Widespread proliferation of Information and Communication Technologies (ICT)

The Realities of Modern Manufacturing


Globalization - Once underdeveloped countries (e.g., China, India, Mexico, Brazil) are becoming major players in manufacturing International outsourcing - Parts and products once made locally are now being made offshore (in China or India) or near-shore (in Eastern Europe) Local outsourcing - Use of suppliers locally to provide parts and services

More Realities of Modern Manufacturing


Contract manufacturing - Companies that specialize in manufacturing entire products, not just parts, under contract to other companies Trend toward the service sector Quality expectations - Customers, both consumer and corporate, demand products of the highest quality Need for operational efficiency - manufacturers must be efficient in in their operations to overcome the labor cost advantage of international competitors

Globalization
Design Product Manufacturing

Costs Transport Labour Local standards / cultures / law Demand supply and supply chain management (SCM)

Production strategies Assemblies


Fully knocked down Semi knocked down Parts / design replacements Quality and functionality

Breaking Down Barriers

Traditional Product Development


Customer requirements (sales and marketing) Conceptual design (Industrial designers)
Detailed design and analysis (engineering)

Manufacturing

Distribution and Sales

Support and Service

(Now is increasingly relevant)

Disposal ?

Concurrent Product Development


Design Support Customer Engineering

Sales

Manufacturing

Concurrent Engineering
Simultaneous decision making by design teams Integrates product design & process planning Details of design more decentralized Needs careful scheduling - tasks done in parallel

Concurrent Engineering Teams


Interdisciplinary, cross-functional Includes customer, marketing, design, engineering, manufacturing, sales, support Concurrent engineering teams are physically colocated to promote collaboration

Sequential Vs. Concurrent Product Development


Activity A Sequential

Activity B
Activity C Time to market

Concurrent Competitive Advantage!

Conventional Collaboration
Communication

face-to-face discussion, memos, telephone, whiteboard, bulletin board, wall charts, etc.

Collaboration

meetings, colocated workgroup


notebooks, binders, printed reports, photocopies, drawings, forms, data files

Knowledge management

Geographically Distributed Teams

Enterprise data and information

Transparent global network

Company A

Company B

Virtual Collaboration
Communication

fax, telephone, mail email, discussion groups, shared whiteboard, videoconferencing application sharing, shared network workspace (files in shared directories)

Collaboration

Knowledge management

Product data management system, document management system, distributed databases

Enterprise Functions in Manufacturing

Source: Principles of Comp Intgd Manuf : Jean-Baptiste Waldner / Wikipedia

Source: JTEC Report on Japanese Electronics Industry (1995) : A Typical Implementation

CAD Processes
Computer Aided Drafting 3D modelling and representation

Layers Assemblies

Visualisation -> Drafting Process Planning: 3D Models -> Machining plan : CAM Planners 3D Models -> Products (Rapid Prototyping)

New requirements
CAD Models to be shared Shared visualisations Modifications easily reflected -> Consistency and safe data propagation Parametric Design Feature based Design Constraints modelling

Product Life Cycle Constraints


Rapid development cycles Thin lead margins Fast turn-around in new feature introduction Fast turn-around in bugs recovery Global and local constraints

Software and Tools


Parametric Technologies (PTC)

Dassault Systems (3DS)


Pro/Engineer Windchill PDMLink Windchill ProjectLink

Autodesk (AutoCAD, Inventor) Unigraphics (UGS SolidEDGE) now under Siemens Delcam (IDEAS)

CATIA, Solid Works : Design DELMIA : Manufacture ENOVIA, SMARTEAM : Product Life Cycle Mgmt Solidworks

Manufacturing
Automation Computer Controlled Machines Robotics Automated work handling systems Precision and repeated operations High quality in output

Sales, support and market


Global Markets ERP and Web based operations Mass Customization Tracking and support Life time support GM - Onstar

Industrial Automation Machines


Storage Systems Handling Systems Assembly Lines Assembly Cells Machines Actuators Sensors Production Lines Production Cells Machines Actuators Sensors

Industrial Automation Computing


Computers Controllers Actuators Sensors Software

Industrial Automation - why?


1. Production Systems 2. Automation in Production Systems 3. Manual Labor in Production Systems 4. Automation Principles and Strategies 5. Organization of the Course

Manufacturing Approaches
Automation Flexible manufacturing Quality programs Integration Lean production

Facilities Factory and Equipment


Factory, production machines and tooling, material handling equipment, inspection equipment, and computer systems that control the manufacturing operations

Manufacturing Support Systems


Business functions - sales and marketing, order entry, cost accounting, customer billing Product design - research and development, design engineering, prototype shop Manufacturing planning - process planning, production planning, MRP, capacity planning Manufacturing control shop floor control,

inventory control, quality control

Computer Integrated Manufacturing

Automated System
Periodic Automated Examples: Worker System Automated machine tools Transfer lines Automated assembly systems Transformation Process Industrial robots Automated material handling and storage systems Automatic inspection systems for quality control

Three Automation Types


Programmable Automation

Variety

Flexible Automation

Fixed Automation

Quantity

Fixed Automation
Sequence of processing (or assembly) operations is fixed by the equipment configuration Typical features: Suited to high production quantities High initial investment for custom-engineered equipment High production rates Relatively inflexible in accommodating product variety

Programmable Automation
Capability to change the sequence of operations through reprogramming to accommodate different product configurations Typical features: High investment in programmable equipment Lower production rates than fixed automation Flexibility to deal with variations and changes in product configuration Most suitable for batch production Physical setup and part program must be changed between jobs (batches)

Flexible Automation
System is capable of changing over from one job to the next with little lost time between jobs Typical features: High investment for custom-engineered system Continuous production of variable mixes of products Medium production rates Flexibility to deal with soft product variety

Reasons for Automating


1. 2. 3. 4.
To increase labor productivity To reduce labor cost To mitigate the effects of labor shortages To reduce or remove routine manual and clerical tasks To improve worker safety To improve product quality To reduce manufacturing lead time To accomplish what cannot be done manually To avoid the high cost of not automating

5. 6. 7. 8. 9.

Automation Principles
1. Understand the existing process

Input/output analysis Value chain analysis Charting techniques and mathematical modeling Reduce unnecessary steps and moves
Ten strategies for automation and production systems Automation migration strategy

2. Simplify the process

3. Automate the process

Automation Strategies
1. Specialization of operations 2. Combined operations 3. Simultaneous operations 4. Integration of operations 5. Increased flexibility 6. Improved material handling and storage 7. On-line inspection 8. Process control and optimization 9. Plant operations control 10.Computer-integrated manufacturing

Automation Migration Strategy

Various areas being covered


Definition of Industrial Automation Mathematical Models for Manufacturing Industrial Systems

Control Systems Sensors and Actuators Automated Machine Tools Industrial Robotics Logic Controllers Handling Systems Storage Systems Identification Systems Manufacturing Cells Assembly Lines Flexible Manufacturing Systems

Thank you
End of Introductions.

C.S.Kumar, Mechanical Engineering, IIT Kharagpur

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