capc & computer monitoring

ME 2402 – COMPUTER INTEGRATED MANUFACTURING (CIM)

YEAR/SEMESTER : IV/VII

UNIT V COMPUTER AIDED PLANNING AND CONTROL AND COMPUTER MONITORING

Prepared By MANIMARAN.MASSISTANT PROFESSORK.RAMAKRISHNAN COLLEGE OF ENGINEERINGTRICHY 05/01/2023 1

MANIMARAN M 8115 KRCE TRICHY

manimaran

manimaran

05/01/2023 MANIMARAN M 8115 KRCE TRICHY 2

UNIT V COMPUTER AIDED PLANNING AND CONTROL AND COMPUTER MONITORING

Production planning and control – cost planning and control – inventory management – material requirements planning (MRP) – shop floor control. Lean and Agile Manufacturing. Types of production monitoring systems – structure model of manufacturing – process control and strategies – direct digital control


Production planning and control (PPC)It may be defined as the direction and coordination of firm’s material and physical facilities towards the attainment of pre-specified production of goods with highest production of efficiency

PPC = production planning +production control


Production planning It is a pre-production activity. It is defined as the determination, acquisition and arrangement of all facilities necessary for future production of products

Activities of production planning • Aggregate production planning • Master production planning • Master requirements planning • Capacity planning


Production control It is concerned with determining whether the necessary resources to implement the production plan have been provided or not

Activities of production control• Shop floor control • Inventory control • Manufacturing resource planning (MRP II)• Just in time (JIT) production system


ACTIVITIES IN A PPC (FUNCTIONS OF PPC)Aggregate production planning

• Aggregate planning is a high-level corporate planning activity.

• Aggregate planning plan must be coordinated with the plans of

the sales and marketing departments. (inventory, employment

and subcontracting)


ACTIVITIES OF PPCMASTER PRODUCTION SCHEDULE

• Aggregate production planning must be converted into master

production schedule (MPS)

• It is a listing of the products to be manufactured, when they are

to be delivered, and in what quantities

• It is developed from customer order and forecasts of the future


ACTIVITIES OF PPCMATERIAL REQUIREMENT PLANNING • Material requirements planning (MRP) is a computational technique

that converts the master schedule for final products into a detailed schedule for the raw materials and components used in the final products.

CAPACITY PLANNING • Capacity planning is concerned with determining what labor and

equipment resources are required to meet the current MPS as well as long-term future production.


ACTIVITIES OF PPCSHOP FLOOR CONTROL A shop floor control system is defined as a system for utilizing data from as well as data processing files to maintain and communicate information on shop orders and work centers. It also known as Production Activity Control (PAC).INVENTORY CONTROL

• Minimize the cost of holding inventory( investment, storage and spoilage )

• Maximize customers service.


ACTIVITIES OF PPCMANUFACTURING RESOURCE PLANNING (MRP II)

• It combines MRP and capacity planning as well as shop floor control and other functions

related to PPC

• It can be defined as a computer-based system for planning, scheduling, and controlling the

materials, resources, and supporting activities needed to meet the Master production schedule

JUST-IN-TIME PRODUCTION SYSTEM

It is a management philosophy that strives to eliminate source of manufacturing waste by

producing the right part in the right place at the right time.


MATERIAL REQUIREMENTS PLANNING (MRP)Material requirements planning (MRP) is a computational technique that

converts the master schedule for final products into a detailed schedule for

the raw materials and components used in the final products.

Inputs of MRP

1. Master production schedule (MPS)

2. Bill of materials file and

3. Inventory record file


MATERIAL REQUIREMENTS PLANNING (MRP)


1.MASTER PRODUCTION SCHEDULE (MPS)

The production quantities of the major product lines listed in the aggregate plan must the

converted into a very specific schedule of individual products, known as the master

production schedule (MPS).

Master production schedule (MPS) is a detailed plan that how many final product will be

available for sale during specific periods.

Inputs to MPS

1. Market requirements

2. Production plan from aggregate planning

3. Resource available


2.Bill of materials The bill of materials (BOM) file is used to compute the raw material and component requirements for end products listed in the master schedule.


3. INVENTORY RECORD FILEItem master data This provides the item's identification (part number) and

other data about the part such as order quantity and lead times.

Inventory status This gives a time-phased record of inventory status.

Subsidiary data It provides subsidiary data such as purchase orders, scrap or

rejects, and engineering changes.


Benefits of MRP Reduced inventory levels

Better production scheduling

Reduced production lead time

Reduced setup cost

Better machine utilization

Improved product quality

Quicker response to changes in demand


COST PLANNING AND CONTROLCost planning and control system consist of the database to determine the

expected costs of manufacture each products of the company

• Cost estimating is the process of determining the probable cost of the product

before the start of the product and before the start of its manufacture.

• Cost accounting is the determination of an actual cost of a component after

adding different expenses in various departments.


REQUIREMENTS FOR COST ESTIMATING General design specification of product (function, performance and

purpose) Assembly or layout drawings Subassemblies of the product Detail drawings and bill of materials for the product Test and equipment procedures and equipment Machine tool and equipment requirement Packaging and transportation requirements Standard time data Material release data Operation analysis and workplace studies


INVENTORY MANAGEMENTIt may be defined as the scientific method of determining what to order, when to

order and how much to order and how much to stock so that costs associated

with buying and storing are optimal without interrupting production and sales.

Objectives of inventory control

• To ensure the continuous supply

• To maintain the overall investment

• To minimize the holding, storage and replacement cost

• To avoid over and under stocking


INVENTORY COST1. Ordering costs

Cost of staff purchase dept. Cost of stationary Inspection cost of incoming materials

2. Holding costs Cost of storage facilities Handling cost Costs of record keeping

3. Shortage cost and Loss of future sales Loss of goodwill

4. Purchase cost Price paid to labour, material and overhead charge


Economic order quantity (EOQ)Economic ordering quantity (EOQ) is that size of order which minimizes the total cost of carrying inventory and ordering.


TYPES OF INVENTORY SYSTEM1. Fixed-order quantity models (Q-models)

1. Re-order quantity (how much to order)2. Re-order level (when to order)


TYPES OF INVENTORY SYSTEM2.Fixed-time periods models (p-models)


MANUFACTURING RESOURCE PLANNING (MRP II)

• It combines MRP and capacity planning as well as shop floor control and

other functions related to PPC

• It can be defined as a computer-based system for planning, scheduling, and

controlling the materials, resources, and supporting activities needed to

meet the Master production schedule


MANUFACTURING RESOURCE PLANNING (MRP II)

• Management planning. Business strategy, aggregate production planning, master production scheduling, rough-cut capacity planning and budget planning

• Customer service. Sales for recasting, order entry, sales analysis, and finished goods inventory.

• Operations planning. This is the MRP module. enhanced with capacity requirements planning. The output consists of purchase order and work order releases.

• Operations execution. This includes purchasing, production scheduling and control, WIP inventory control, shop floor control. and labor hour tracking.

• Financial functions These include cost accounting, accounts receivable, account, payable, general ledger. and payroll.


Commercial software for MRP II Enterprise Resource Planning (ERP)

Customer-oriented Manufacturing Management Systems (COMMS)

Manufacturing Execution System

Customer-oriented Management Systems (COMS)


JUST-IN-TIME PRODUCTION SYSTEMSJust-In-Time (JIT) is a management philosophy that strives to eliminate sources of manufacturing waste by producing the right part in the right place at the right time. JIT also known as stockless production.objectives of JIT1. Zero defects 2. Zero setup time3. Zero inventories 4. Zero handling5. Zero breakdowns 6. Zero lead time7. Lot of size one.


Elements of JIT Eliminate setup times

Reducing manufacturing and purchasing lot sizes

Reducing production and delivery lead times

Preventive maintenance

Stabilize and level the production schedule with uniform plant loading

Flexible workforce

Small unit conveyance


Kanban production system• Production Kanban (P-Kanban)

It signals the need to produce more parts

• Transport Kanban (T-Kanban)

It signals the need to deliver more parts to the next work center

Pull system

product is made-to-order

Push system

the product is made-to-stock


Benefits of JIT Lower inventory cost

Lower scrap and waste cost

Improved quality and zero defect products

Improved worker involvement

Higher motivation and morale

Increased productivity

Reduced manufacturing lead time


LEAN PRODUCTION Lean manufacturing may be defined as an adaption of mass production in

which workers and work Cells are made more flexible and efficient by adapting

method that reduce waste in all form.

“more and more with less and less-less human effort, less equipment, less

time, and less space-while coming closer and closer to providing customers

with exactly what they want“

Lean manufacturing is a set of tools and methodologies that aims for the

continuous elimination of all wastes in the production process


LEAN PRODUCTIONLean production is based on four principles

1. minimize waste

2. perfect first-time quality

3. flexible production lines

4. continuous improvement


LEAN MANUFACTURING CONCEPTS Value creation and waste

Main kinds of waste

Pull production

Continuous flow

Continuous improvement

Worker improvement

Standard work


Mass Production vs Lean Production

S.No Mass Production Lean Production

1 Inventory Buffers Minimum wasteMinimum inventory

2 Just in-case deliveries Just in-time deliveries

3 Acceptable quality level Perfect first time quality

4 Taylor made to production Worker teamsWorker involvement


AGILE MANUFACTURINGAgile manufacturing is an enterprise levels manufacturing strategy of introducing new

product into rapidly changing market, an organizational ability to thrive in a competitive

environment characterized by continuous and sometimes unforeseen changePrinciples of Agile manufacturing

• Organize to Master change

• Leverage the Impact of People and Information

• Cooperate to Enhance Competitiveness

• Enrich the Customer


Mass production vs Agile production

S.no Mass production Agile production

1 Standardized products Customized products

2 Longer market life Shorter market life

3 Produce-to-forecast Produce-to-order

4 Low information content High information content

5 Single time sales Continuing relationship

6 Pricing by production cost Pricing by customer value


COMPUTER PROCESS MONITORING

Computer production monitoring is a data collection system in which

the computer is connected directly to the workstation and associated

equipment for the purpose of observing the operation. It is also known

as computer process monitoring.


STRUCTURE OF MANUFACTURING PROCESS

Manufacturing system

MaterialEnergyLabour

Technology

Inputs outputsDecisions Disturbances

Product Scrap

Waste


PROCESS CONTROL STRATEGIES

Feedback control strategy

Regularity control strategy

Feed forward control strategy

Preplanned control strategy

Steady-state optimal control strategy

Adaptive control strategy


FEEDBACK CONTROL STRATEGY


REGULARITY CONTROL STRATEGY


FEED FORWARD CONTROL STRATEGY


STEADY-STATE OPTIMAL CONTROL


ADAPTIVE CONTROL STRATEGY


DIRECT DIGITAL CONTROL (DDC)DDC is computer process control system in which certain components in a conventional analog

control system are replaced by the digital computer.

BENEFITS OF DIRECT DIGITAL CONTROL DDC is more efficient control actions

DDC provides more control options than traditional analog control system

DDC has the ability to integrate feedback measurements multiple loops and to implement

optimizing strategies to improve overall performance

A digital computer in DDC makes editing the control programs much easier and less costlier


DIRECT DIGITAL CONTROL (DDC)

capc & computer monitoring

Engineering