Manufacturing Engineering Technology in SI Units, 6th Edition

Chapter 39: Computer-Integrated Manufacturing Systems

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Chapter Outline
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Introduction Cellular Manufacturing Flexible Manufacturing Systems Holonic Manufacturing Just-in-time Production Lean Manufacturing Communications Networks in Manufacturing Artificial Intelligence Economic Considerations
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Introduction

Integration means that manufacturing processes, operations and management are treated as a system Flexible manufacturing is capable of responding to product changes, fluctuating demands and ensuring on-time delivery of products to the customer Holonic manufacturing is a new concept on how manufacturing units can be organized to achieve higher efficiency in operations
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Cellular Manufacturing

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A manufacturing cell is a small unit consisting of one or more workstations. A workstation contains one machine (single-machine cell) or several machines (group-machine cell) Capabilities of cellular manufacturing: Loading and unloading raw materials Changing tools at workstations Transferring workpieces and tooling between workstations Scheduling and controlling the total operation in the cell
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Cellular Manufacturing
Flexible Manufacturing Cells (FMCs) Manufacturing cells can be made flexible by 1. CNC machines 2. Machining centers 3. Industrial robots 4. Mechanized systems for handling materials and parts FMCs can be unattended or unmanned Cost of FMCs is very high, have increased productivity, flexibility and controllability
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Cellular Manufacturing
Cell Design Design and placement require efficient layout and organization of the plant and the consideration of product flow lines Cost of flexible cells is high, but outweighed by increased productivity, flexibility and controllability

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Cellular Manufacturing
EXAMPLE 39.1 Manufacturing Cells in a Small Machine Shop In a small shop, the machines in the cells are arranged to allow an operator to machine a part in the most efficient and precise manner Each cell allows the operator to monitor the performance of the machines in the cell

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Flexible Manufacturing Systems

A flexible manufacturing system (FMS) integrates all of the major elements of production into a highly automated system

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Flexible Manufacturing Systems

The system can handle a variety of part configurations and produce them in any order

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Flexible Manufacturing Systems

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FMS have the following major benefits: Parts can be produced in any order Direct labor and inventories are reduced or eliminated Lead times required for product changes are shorter System is self-correcting, production is more reliable and product quality is uniform

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Flexible Manufacturing Systems

Elements of FMS Basic elements are: 1. Workstations and cells 2. Automated handling and transport of materials and parts 3. Control systems May incorporate furnaces, various machines, trimming presses, heat-treating facilities, and cleaning equipment
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Flexible Manufacturing Systems

Scheduling Machines must not stand idle and proper scheduling and process planning are crucial Scheduling for FMS is dynamic, no setup time is wasted in switching between manufacturing operations

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Flexible Manufacturing Systems

Economic Justification of FMS FMS installations are capital intensive Thorough costbenefit analysis must be conducted before any final decision is made Analysis include the costs of capital, energy, materials and labour

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Flexible Manufacturing Systems

EXAMPLE 39.2
Flexible Manufacturing Systems in Large and Small Companies

Large FMS requires the extensive training of personnel An FMS leads to a manufacturing enterprise that is less lean

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Holonic Manufacturing

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Holonic manufacturing is a new concept describing a unique organization of manufacturing units Each component is an independent entity and a subservient part of a hierarchical organization 3 fundamental observations: Complex systems will evolve Holons are simultaneously self-contained A holarchy consists of (a) autonomous wholes and (b) dependent parts
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Holonic Manufacturing

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A manufacturing holon is an autonomous and cooperative building block of a manufacturing system Maximum flexibility can be achieved by providing intelligence to: Support all production and control functions Manage the underlying equipment and systems

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Just-in-time Production

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The just-in-time (JIT) production has the following goals: Receive supplies just in time to be used Produce parts just in time to be made into subassemblies Produce subassemblies just in time to be assembled into finished products Produce and deliver finished products just in time to be sold
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Just-in-time Production

JIT is also called zero inventory, stockless production, and demand scheduling This approach emphasizes Pride and dedication Elimination of idle resources Teamwork

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Just-in-time Production
Advantages of JIT Advantages of just-in-time: 1. Low inventory carrying costs 2. Fast detection of defects 3. Reduced inspection and reworking of parts 4. High-quality products made at low cost

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Just-in-time Production
Kanban Kanban means visible record Record consisted of two types of cards: 1. Production card 2. Conveyance card or move card

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Lean Manufacturing

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Lean manufacturing involves: Identify value Identify value streams Make the value stream flow Establish pull

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Communications Networks in Manufacturing

Local area network (LAN) is a hardware-andsoftware system where logically related groups of machines and equipment communicate with each other Wide area networks (WANs) is used for longer distances Different types of networks can be linked with file transfer protocols (FTPs)

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Communications Networks in Manufacturing

Wireless local area networks (WLANs) allow equipment data-collection devices to maintain a network connection Wireless networks are slower than hardwired; their flexibility makes them desirable

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Communications Networks in Manufacturing

Communications Standards Each cells computers have their own specifications and proprietary standards Manufacturing automation protocol (MAP) was standardised The International Organization for Standardization (ISO)/Open System Interconnect (OSI) reference model is accepted worldwide
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Artificial Intelligence

Artificial intelligence (AI) is that part of computer science which is concerned with systems that exhibit some characteristics The goal of AI is to simulate such human behaviours on the computer AI has a major effect on the design, automation, and overall economics of the manufacturing operation

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Artificial Intelligence
Expert Systems An expert system (ES) is defined as an intelligent computer program that solve difficult real-life problems by the use of knowledge-based and inferential procedures

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Artificial Intelligence
Expert Systems The field of knowledge required to perform the task is called the domain of the expert system To construct expert systems one needs: 1. A great deal of knowledge 2. A mechanism for manipulating that knowledge to create solutions

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Artificial Intelligence
Natural-language Processing Natural-language interfaces allow a user to obtain information commands or typed questions Computer software will have speech synthesis and recognition (voice recognition) capabilities

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Artificial Intelligence
Machine Vision Computers and software can be combined with cameras and other optical sensors Can perform inspecting, identifying, sorting parts and guiding robots

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Artificial Intelligence
Artificial Neural Networks Humans are much better at pattern-based tasks Artificial neural networks (ANN) gain capabilities through computer imitation Artificial neural networks are used in noise reduction, speech recognition and process control

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Artificial Intelligence
Fuzzy Logic Fuzzy logic is an element in control systems and pattern recognition Fuzzy models are mathematical means of representing vagueness and imprecise information These models have the ability to recognize, represent, manipulate, interpret, and utilize data and information that are vague or lack precision

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Economic Considerations

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FMS which need thorough costbenefit analysis consist of: The cost of capital, energy, materials, and labor Expected markets for the products to be produced Anticipated fluctuations in market demand and in the type of product The time and effort required for installing and debugging the system

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