advanced manufacturing systems design © 2000 john w. nazemetz lecture 2 topic : computer integrated...

Advanced Manufacturing Advanced Manufacturing Systems DesignSystems Design

© 2000 © 2000 John W. NazemetzJohn W. Nazemetz

Lecture 2 Topic :Lecture 2 Topic : Computer Computer Integrated ManufacturingIntegrated Manufacturing

Segment A Topic:Segment A Topic: Definition and Key Definition and Key Concepts 1 and 2Concepts 1 and 2

Computer Integrated Manufacturing Systems © 2000 John W. NazemetzSlide 2

ADVANCED ADVANCED MANUFACTURING MANUFACTURING SYSTEMS DESIGNSYSTEMS DESIGN

Computer Integrated Computer Integrated ManufacturingManufacturing

Definition andDefinition and

Key Concepts 1 and 2Key Concepts 1 and 2


Computer Integrated Computer Integrated Manufacturing SystemsManufacturing Systems• DefinitionDefinition

– Systems which enable the integrated, rationalized design, development, implementation, operation and improvement of production facilities and their output over the life cycle of the product. These systems identify and use appropriate technology to achieve their goals at minimum cost and effort.


Initial Reaction to Initial Reaction to DefinitionDefinition

• Long DefinitionLong Definition– Quite a Mouthful?

• A Long List of Adjectives and NounsA Long List of Adjectives and Nouns– Trying to be Too Encompassing?

• Lot of “Buzz-Words”Lot of “Buzz-Words”– What Does It Really Mean?

• Need to Break into Components to Need to Break into Components to Understand the ConceptsUnderstand the Concepts


Key Concept in CIM Key Concept in CIM Definition (1)Definition (1)

• Systems which enable theSystems which enable the

integrated, rationalizedintegrated, rationalized,, design, development, design, development, implementation, operation and implementation, operation and improvement of production facilities improvement of production facilities and their output over the life cycle of and their output over the life cycle of the product. These systems identify the product. These systems identify and use appropriate technology to and use appropriate technology to achieve their goals at minimum cost achieve their goals at minimum cost and effort.and effort.


What is Integrated and What is Integrated and Rationalized??Rationalized??

• Operational ConceptOperational Concept

• Physical Concept Physical Concept

• Manufacturing Concept Manufacturing Concept

• Maintenance Concept Maintenance Concept


Operational Concept for Operational Concept for Part/DesignPart/Design

• Function(s)Function(s)• Factors of SafetyFactors of Safety• QualityQuality• Service LifeService Life• MaintenanceMaintenance• CompetitionCompetition• ......


Physical Concept for Physical Concept for Part/DesignPart/Design

• Form/Features Form/Features • Existing Forms Existing Forms • Precision/Process CapabilitiesPrecision/Process Capabilities• Excess/Available CapacityExcess/Available Capacity• Materials in UseMaterials in Use• Embody All ConceptsEmbody All Concepts• … …


Manufacturing Concept Manufacturing Concept for Part/Designfor Part/Design

• VolumeVolume• VarianceVariance• PrecisionPrecision• Existing ProductsExisting Products• Existing FacilitiesExisting Facilities• Existing and Evolving Production Existing and Evolving Production

TechnologyTechnology• ……


Maintenance Concept Maintenance Concept for Part/Designfor Part/Design

• AuthorityAuthority– Configuration Management

• ResponsibilityResponsibility

• Customer ExpectationsCustomer Expectations

• Available Skills and Tools Available Skills and Tools

• … …


Key Concepts in CIM Key Concepts in CIM Definition (2)Definition (2)

• Systems which enable the Systems which enable the integrated, rationalizedintegrated, rationalized design, design, development, implementation, development, implementation, operation and improvement of operation and improvement of production facilities and their production facilities and their outputoutput over the life cycle of the over the life cycle of the product. These systems identify product. These systems identify and use appropriate technology to and use appropriate technology to achieve their goals at minimum achieve their goals at minimum cost and effort.cost and effort.


What is “Design”?What is “Design”?• Set of ActivitiesSet of Activities

– Define Requirements (All Viewpoints)– Conceptualize Candidate Solutions to

Meet Each Requirement– Analyze Concepts

• Operational Feasibility

– Synthesis of Concepts into Alternatives– Analysis of Alternatives

• Gather Data• Quantify Using Same Basis, Customer

Viewpoint

– Select “Current Best” Solution/Solutions


What is What is “Development”?“Development”?

• Addition of Details to Initial Design Addition of Details to Initial Design Concepts (Reduction of Uncertainty)Concepts (Reduction of Uncertainty)– Geometric Model(s)– Simulation and Analysis– Prototyping and Testing

• Product Configuration• Facility Configuration• Personnel and Support Organization• Operation• Maintenance• Disposal


Development Occurs Development Occurs Until ImplementationUntil Implementation

• Concepts are Continuously Concepts are Continuously (Re)Analyzed in Light of the New Data (Re)Analyzed in Light of the New Data and New Viewpoints Concerning the and New Viewpoints Concerning the Product and Its Production Product and Its Production

• Developers Must Be Willing to Developers Must Be Willing to ReconceptualizeReconceptualize

• Continues Until Reasonably Certain Continues Until Reasonably Certain that Design Will “Work” or Available that Design Will “Work” or Available Time/$ Exhausted and Risk Is Time/$ Exhausted and Risk Is Taken/AvoidedTaken/Avoided


ImplementationImplementation

• Begins When Design is “Frozen” Begins When Design is “Frozen” and the Contractual Arrangements and the Contractual Arrangements for Securing of Production Facilities for Securing of Production Facilities are Madeare Made

• Continues until First Acceptable Continues until First Acceptable Products are Produced via the Products are Produced via the Facilities for Delivery to CustomersFacilities for Delivery to Customers


OperationOperation

• ProductProduct– Done by the Consumer

• Requirement Definitions and Functionality Tested– As Stand Alone Product– As Part of a Product

• New Requirements Fed-Back

• Production FacilitiesProduction Facilities– Done by Manufacturer

• Actual Results Compared to Design Predictions• Unanticipated Results Identified


ImprovementImprovement• Improvement is “Design-Improvement is “Design-

Development-Implement” Based on Development-Implement” Based on “Real World” Experience Rather than “Real World” Experience Rather than Conjecture and PrototypeConjecture and Prototype

• Often Done in “Spurts”, Frequency Is Often Done in “Spurts”, Frequency Is Strategic DecisionStrategic Decision

• Limited by Cost to Change Physical Limited by Cost to Change Physical Facilities and Inability to Abandon Facilities and Inability to Abandon Investments (Financial and Emotional) Investments (Financial and Emotional)



Lecture 2 Topic :Lecture 2 Topic : Computer ComputerIntegrated Manufacturing Integrated Manufacturing

SystemsSystems

Segment A Topic:Segment A Topic: Definition and Definition and Key Concepts 1 and 2Key Concepts 1 and 2

END OF SEGMENTEND OF SEGMENT



Lecture 2 Topic :Lecture 2 Topic : Computer Computer Integrated Manufacturing Integrated Manufacturing

SystemsSystems

Segment B Topic:Segment B Topic: Definition and Key Definition and Key Concepts 3 through 6Concepts 3 through 6



Computer Integrated Computer Integrated Manufacturing Manufacturing

Systems:Systems:Definition Key ConceptsDefinition Key Concepts

3 through 63 through 6



• Systems which enable the integrated, Systems which enable the integrated, rationalized design, development, rationalized design, development, implementation, operation and implementation, operation and improvement of production facilities improvement of production facilities and their outputand their output over the life cycle over the life cycle of the product.of the product. These systems These systems identify and use appropriate identify and use appropriate technology to achieve their goals at technology to achieve their goals at minimum cost and effort.minimum cost and effort.


Entire Life Cycle Must Entire Life Cycle Must Be CoveredBe Covered

• ““What is to Be”What is to Be”• ““Initial Production”Initial Production”• ““Improvement”Improvement”• ““Sustainment”Sustainment”

– Reduction in Volume– Changes in Suppliers, Environment, Use

• Several Improvement/Sustainment Several Improvement/Sustainment Cycles LikelyCycles Likely

• ““Disposal”Disposal”


Evolution of a ProductEvolution of a ProductProduct “Life Cycles” Run Concurrently

Product Development Life Cycle

Product Operation Life Cycle

Product Support Life Cycle

ProductConcept

DesignProduct

ManufactureProduct

Test/AcceptProduct

DeployProduct

OperationalConcept

SupportConcept

OperationalRequirements

DefineSupportSystems

ImplementSupportSystems

Define StandardOperationProcedures

Test/AcceptSupport Systems

TrainOperators

OperateProduct

SupportProduct

WithdrawProduct

Dispose ofProduct


Evolution of a Product’s Evolution of a Product’s Production FacilityProduction Facility

Production Facility “Life Cycles” Run ConcurrentlyFacility Development Life Cycle

Facility Operation Life Cycle

Facility Support Life Cycle

ProductConcept

DesignProduct

ManufactureProduct

Test/AcceptProduct

DeployProduct

OperationalConcept

SupportConcept

OperationalRequirements

DefineSupportSystems

ImplementSupportSystems

Define StandardOperationProcedures

Test/AcceptSupport Systems

TrainOperators

OperateProduct

SupportProduct

WithdrawProduct

Dispose ofProduct



• Systems which enable the integrated, Systems which enable the integrated, rationalized design, development, rationalized design, development, implementation, operation and implementation, operation and improvement of production facilities improvement of production facilities and their output over the life cycle of and their output over the life cycle of the product. These systemsthe product. These systems identify identify and use appropriate technologyand use appropriate technology to achieve their goals at minimum to achieve their goals at minimum cost and effort.cost and effort.


Appropriate Appropriate TechnologyTechnology

• CIM is NOT ALWAYS HIGH TECHCIM is NOT ALWAYS HIGH TECH• Early Decisions Suffer from Lack of Early Decisions Suffer from Lack of

DataData• Common Sense and Simplicity Must Be Common Sense and Simplicity Must Be

AppliedApplied• Cost/Benefit of Information Must Cost/Benefit of Information Must

Always be AssessedAlways be Assessed– Cost of Developing Model– Cost of Organizing Data– Time to Decision/Cost of Delay



• Systems which enable the integrated, Systems which enable the integrated, rationalized design, development, rationalized design, development, implementation, operation and implementation, operation and improvement of production facilities improvement of production facilities and their output over the life cycle of and their output over the life cycle of the product. These systems identify the product. These systems identify and use appropriate technology toand use appropriate technology to achieve their goalsachieve their goals at minimum at minimum cost and effort.cost and effort.


GoalsGoals

• Must Be System-Wide, not ParochialMust Be System-Wide, not Parochial• Measurable Goals are a MustMeasurable Goals are a Must• Not Only a Vision, Also a Stopping Not Only a Vision, Also a Stopping

PointPoint– Key to Balanced Design

• Requirements Based on Goal Requirements Based on Goal StatementsStatements

• Requirements Drive the Design Requirements Drive the Design DecisionsDecisions



• Systems which enable the integrated, Systems which enable the integrated, rationalized design, development, rationalized design, development, implementation, operation and implementation, operation and improvement of production facilities improvement of production facilities and their output over the life cycle of and their output over the life cycle of the product. These systems identify the product. These systems identify and use appropriate technology to and use appropriate technology to achieve their goals atachieve their goals at minimum minimum cost and effort.cost and effort.


Minimum Cost and Minimum Cost and EffortEffort

• Measured Across the Full Life CycleMeasured Across the Full Life Cycle– Internal– Externalized

• Short TermShort Term– Concerned with Payback/Recovery of

Investment

• Long TermLong Term– Concerned with Operation/Continuing

Costs



Lecture 2 Topic :Lecture 2 Topic : Computer ComputerIntegrated Manufacturing Integrated Manufacturing

SystemsSystems

Segment B Topic:Segment B Topic: Definition Key Definition Key Concepts 3 through 6Concepts 3 through 6





SystemsSystems

Segment C Topic:Segment C Topic: CIM Systems CIM Systems EvolutionEvolution




Systems:Systems:

CIM Systems EvolutionCIM Systems Evolution


CIM Systems Evolution CIM Systems Evolution (Recognition of Need)(Recognition of Need)

•A Need is Identified

•It is Accepted as Valid (Requirements Defined)

NEED


CIM Systems Evolution CIM Systems Evolution (Ideation)(Ideation)

IDEAS

Ideas/Concepts for Solutions are Generated

•Concepts are Documented. Concept not Detailed - Used to Communicate, Convey, and Document

NEED


CIM Systems Evolution CIM Systems Evolution (Conceptualization)(Conceptualization)

IDEAS

•Concept Synthesis

•Preliminary (Feasibility) Assessment

•All Viewpoints Assess Concepts

•Iteration on Concepts Occurs

•“Current Best” Concept Emerges

NEED

Conceptfor Solution

Different Usersand Viewpoints

Current Best

Input andAssessment

Feed

back


CIM Systems Evolution CIM Systems Evolution (Concept Development)(Concept Development)

IDEAS

NEED

Conceptfor Solution

Different Usersand Viewpoints

Current Best

Input andAssessment

Feed

back

New Current Best Concept

DEVELOPMENT

CAD

CAPP

FE

LINE BALANCE

DFM

ETC. ...


CIM Systems Evolution CIM Systems Evolution (Development Details)(Development Details)

Current Best


DEVELOPMENT

CAD

CAPP

FE

LINE BALANCE

DFM

ETC. ...

After Concept(s) Firmed Up • More Details Added

•Formal Documentation

•Additional Modeling and Analysis Undertaken

•Computer Aided Tools Used

•Optimization of Current Best (ONLY!!) Sought


CIM Systems Evolution CIM Systems Evolution (Implementation)(Implementation)


DEVELOPMENT

CAD

CAPP

FE

LINE BALANCE

DFM

ETC. ...

Drawings

Models

Specifications

Materials

Design Logic

Layout

Equipment

Staffing

Production Strategy

IMPLEMENTATION

PRODUCT FACILITY


CIM Systems Evolution CIM Systems Evolution (Implementation Details)(Implementation Details)

Drawings

Models

Specifications

Materials

Design Logic

Layout

Equipment

Staffing

Production Strategy

IMPLEMENTATION

PRODUCT FACILITY

IMPLEMENTATION

•Physical Realization of Plans•Plant•Equipment•Product

•Execution of Plans•Production Schedules•Planned Processes•Distribution•Marketing•Quality•Operations•Maintenance•Support


CIM Systems Evolution CIM Systems Evolution (Operation)(Operation)

Drawings

Models

Specifications

Materials

Design Logic

Layout

Equipment

Staffing

Production Strategy

IMPLEMENTATION

PRODUCT FACILITY

OPERATE

•Improvement•Feedback•Iterate


DISPOSAL/DECOMMISIONING

•Arrange for Continued Support

•Archive Records

•Recycle Assets

•Dispose of Assets

A Model of CIM SystemsA Model of CIM Systems (Disposal and Decommissioning)(Disposal and Decommissioning)

OPERATE

•Improvement•Feedback•Iterate




Systems Systems

Segment C Topic:Segment C Topic: CIM Systems CIM Systems EvolutionEvolution





SystemsSystems

Segment D Topic:Segment D Topic: Alternate Names Alternate Names and Historical Perspectiveand Historical Perspective




Systems:Systems: Alternate Names and Alternate Names and Historical PerspectiveHistorical Perspective


Alternate NamesAlternate Names

• NamesNames– CAx Systems– CAD/CAM Systems– CAE Systems (E => Engineering or

Enterprise)

– Integrated Enterprises– Virtual Enterprises– Computer Integrated Manufacturing

• Systems Concepts are KeySystems Concepts are Key


Historical Historical Interpretation Interpretation Problems (1)Problems (1)

• CAD/CAMCAD/CAM– CAD Was Simply Drafting, CAM Was

Simply NC– “Design” Was Too Narrowly Defined

and Interpreted– “Manufacturing” Was Too Narrowly

Defined and Interpred– Definition Was Divided by Discipline

(CAD=>ME’s, CAM =>IE’s)



• CAx SystemsCAx Systems– Systems Nature Not Included– Functionally Focused, Discipline

“Ownership”– No Appreciation for Data

Sharing/Exchange

• CAECAE– Became “Computer Aided Everything”– Too Broad, Subjective, Essentially

Meaningless



• Integrated EnterprisesIntegrated Enterprises– Too Broad, Subjective– No “Buy In” to Term by Small Businesses

Who Find “Enterprises” Too Pretentious

• Virtual EnterprisesVirtual Enterprises– New Term -- “Virtual” not Well Understood– Small Business Do Not Feel Part of

“Virtual” World– Large Business Do Not Regard Themselves

as “Virtual”


Historical Historical Interpretation Interpretation Problems (4)Problems (4)• Computer Integrated ManufacturingComputer Integrated Manufacturing

– No Systems Perspective Included in Definition

– CIM is Interpreted as “CAM”– Implies Manufacturing Only

• Computer Integrated Manufacturing Computer Integrated Manufacturing SystemsSystems– May be Best by Elimination– Requires Broad Interpretation of

“Manufacturing”


Historical Problems In Historical Problems In CIM Systems (1)CIM Systems (1)

• Independent Simultaneous Independent Simultaneous DevelopmentDevelopment– Discipline Based– No Overall Application

Coordination/Guidance• No Universal Data Models• No Universal Data Standards• De Facto Standards Evolution

– DXF– IGES


Historical Problems In Historical Problems In CIM Systems (2)CIM Systems (2)

• Integration Occurred at Company LevelIntegration Occurred at Company Level– Culture Slow to Change

• No Intra-Company IntegrationNo Intra-Company Integration– Tools

• CAD Precision Problems• File Translation Problem• Vendor Cooperation

– Partners/SubContractors• Different Systems of Choice• Manual Translation/Interpretaion Requirements• Non-Digital Communication Used


Those Affected By Those Affected By Problems (1)Problems (1)

• The Defense Logistics AgencyThe Defense Logistics Agency– Acquisition of Parts for Aging Weapons

Systems• Legacy Data• Manufacturing Base

– Loss of OEM’s– Cost Savings with SME’s

• Large OEM’sLarge OEM’s– Coordination of World Wide Activities

• Round the Clock Design Activities• International Communication• Internal Communication• External Communication


Those Affected By Those Affected By Problems (2)Problems (2)

• SME’sSME’s– Working with “Larger Partners”– Forming Own Partnering (VE’s)

• CustomersCustomers– Cost Pressures/Esculation– Customization of Products– Smaller Lot Sizes– Lead Time Reduction (JIT)– Reliable Suppliers (JIT)

• In a Word - “Everybody”In a Word - “Everybody”


““Solutions” Attempted Solutions” Attempted (1)(1)

• Interdisciplinary TrainingInterdisciplinary Training– Industrial Programs– Academic Programs

• Interdisciplinary Work GroupsInterdisciplinary Work Groups– Co-Location of Discipline Experts– Cross training and Job Sharing– Project Grouping (Matrix

Organizations)– Incorporation of Workers, Marketing,

Etc. in Project/Design Groups


““Solutions” Attempted Solutions” Attempted (2)(2)

• Common Data Models/Exchange Common Data Models/Exchange FormatsFormats– Numerical Control– IGES– Vendor De Facto Standards– Common Systems/Vendors– Duplicate/Satellite Data Bases (One-

Way)– Customized (to Recipient) Download of

Data– Proactive Standards Development


Two Solution DriversTwo Solution Drivers

• Communication Networks Communication Networks – Internet– Integrated Data

• Exchanged• Shared via Repositories/Warehouses

• Accepted, Publicly Available Data Accepted, Publicly Available Data Models and StandardsModels and Standards– STandard for Exchange of Product

Model Data - STEP (ISO 10303)– eXtensible Mark-up Language (XML)


InternetInternet• Instantaneous, World-Wide Instantaneous, World-Wide

CommunicationCommunication• Established InfrastructureEstablished Infrastructure• Can be SecuredCan be Secured• Standard Access ToolsStandard Access Tools• Links to Files/DataLinks to Files/Data

– Local Maintenance– Global Access– Single Copy of Data


Integrated Data Integrated Data ConceptConcept

• Data Sharing/Warehousing using Data Sharing/Warehousing using Standardized, Neutral Data Standardized, Neutral Data Formats (e.g. STEP)Formats (e.g. STEP)

• Information Model (Standardized) Information Model (Standardized) is Distinct from Data is Distinct from Data Implementation (Customized)Implementation (Customized)

• Existing Systems used as Existing Systems used as appropriateappropriate

• New Systems Easily Incorporated.New Systems Easily Incorporated.


Integrated Data UseIntegrated Data Use

Users Views Single LogicalDatabase

Source Data

STEP technologies are used to extract data from various sources and presents views of the data needed by each end-user


ConceptConcept

Data Flow - Neutral and Standard Formats

Data Interface

DataInterface

Requisition

Shipping Order

Technical Data

Bid

Query

DataInterface

LOCAL

LOCAL




SystemsSystems

Segment D Topic:Segment D Topic: Alternate Names Alternate Names and Historical Perspectiveand Historical Perspective

END OF SEGMENTEND OF SEGMENTEND OF LECTUREEND OF LECTURE

advanced manufacturing systems design © 2000 john w. nazemetz lecture 2 topic : computer integrated...

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