world class technologies for manufacturing world class technologies for manufacturing patrick j....

World Class Technologies for World Class Technologies for ManufacturingManufacturing

Patrick J. Delaney, CFPIM, CIRM, CPM

World Class Technologies for Manufacturing


National Manufacturing WeekNational Manufacturing Week

ChicagoChicago

McCormick PlaceMcCormick Place

February 23-26, 2004February 23-26, 2004 Manufacturing Enterprise AutomationManufacturing Enterprise Automation Manufacturing Process AutomationManufacturing Process Automation Product Design AutomationProduct Design Automation Facility Security & AutomationFacility Security & Automation Data Capture and Data Tracking AutomationData Capture and Data Tracking Automation


Computer-Integrated Computer-Integrated ManufacturingManufacturing

Purdue University Purdue University 30 Engineering 30 Engineering SchoolsSchools

Manufacturing Manufacturing Technology Technology ProgramProgram

Rehg & Kraebber, Prentice Hall, 3rd Ed. 2004


Are You Ready To Go ?Are You Ready To Go ?


The Untouched The Untouched ProcessesProcesses


World Class World Class TechnologiesTechnologies

for for ManufacturinManufacturin

gg

Electronic Commerce [www.com+EDI]Electronic Commerce [www.com+EDI] Internet Supply Chain Systems SuiteInternet Supply Chain Systems Suite Enterprise Resource Planning SystemsEnterprise Resource Planning Systems Advanced Planning & Scheduling SystemsAdvanced Planning & Scheduling Systems Integrated ERP/CRM/SRM Integrated ERP/CRM/SRM Wireless WANs [over 30 miles]Wireless WANs [over 30 miles] RFID Tracking TechnologyRFID Tracking Technology Global Tracking SystemsGlobal Tracking Systems Internet B2B Server ApplicationsInternet B2B Server Applications Sales & Field Force Automation [SFA]Sales & Field Force Automation [SFA] Mobile Connectivity [MC]Mobile Connectivity [MC] Computer Aided Design CAD/PLMComputer Aided Design CAD/PLM Computer Aided Manufacturing [CAM]Computer Aided Manufacturing [CAM] Manufacturing Automation ControllersManufacturing Automation Controllers Device and cell controllersDevice and cell controllers


DuPont InnovationDuPont Innovation

Automotive Coatings Automotive Coatings TechnologyTechnology

Wet on Wet Paint SystemsWet on Wet Paint Systems Rust coatingRust coating Primer coatPrimer coat Color coatColor coat Clear coatClear coat

Final stage oven dryFinal stage oven dry


Robotic Robotic EvolutionEvolution Hydraulic in early 1980sHydraulic in early 1980s

Electric/electronic todayElectric/electronic today Newer vision systemsNewer vision systems Higher accuracy & repeatabilityHigher accuracy & repeatability Proprietary controllers Proprietary controllers

[Motorola][Motorola] Advanced CAD/CAMAdvanced CAD/CAM SimulationSimulation Greater path accuracy [0.05mm]Greater path accuracy [0.05mm] Dual robotic cellsDual robotic cells Jig-less manufacturingJig-less manufacturing

Betty Boop


Manufacturing Manufacturing Software Software Development PathDevelopment Path APS

ERP/ERO

SCM

MES

SFC

MRP IIMRPInventory

control

Forecasting DRP

Order Entry CRMSFA


S upply Chain Suite

Order Management Sys tems

OMS

Enterprise Resource P lanning

ERP

Warehouse Management Sys tem

WMS

Advanced P lanning & Scheduling

AP S

T ransportation Management Sys tem

TMS

Supplier Relationship Management

SRM/SCOR

Des ign Engineering/ CAD

G2G

Elec tronic Commerce Suite

B2B

Customer Relationship Management

CRM


Supply Chain Event Supply Chain Event Managers [SCEM]Managers [SCEM]

Monitor all E-commerce Monitor all E-commerce transactionstransactions

Business rule basedBusiness rule based Create action messages Create action messages

and flagsand flags Check each event for Check each event for

validity and accuracyvalidity and accuracy Accommodates all trading Accommodates all trading

partnerspartners Order status, shipping, Order status, shipping,

inventory, billing, etc.inventory, billing, etc.

Computer Associates BizWorks

i2 Global Logistics Monitor


Ford CaseFord Case

E-commerce graphics E-commerce graphics applicationapplication

Internet transfer of Internet transfer of engineering documents & engineering documents & graphicsgraphics

Utilizing a translation software Utilizing a translation software to interface with incompatible to interface with incompatible supplier applicationssupplier applications

Internet CAD


Daimler-Chrysler CaseDaimler-Chrysler Case Laser based 100% inspectionLaser based 100% inspection Automatic collection of SPC Automatic collection of SPC

datadata Line stopping feedbackLine stopping feedback Machine analysis and Machine analysis and

preventive maintenance preventive maintenance warningswarnings

Bi-lingual inspection Bi-lingual inspection instructionsinstructions

Automated display of ISO Automated display of ISO 9000 procedures9000 procedures

Intranet sharing of QA data Intranet sharing of QA data across plant sitesacross plant sites


Honda SupplierHonda Supplier

Inbound items are bar-codedInbound items are bar-coded Outbound items are bar-codedOutbound items are bar-coded WIP isn’t bar-coded WIP isn’t bar-coded Warehouse isn’t bar-codedWarehouse isn’t bar-coded Cycle counts dailyCycle counts daily Physical inventory every 30 Physical inventory every 30

daysdays


Old Rand-McNally Publishing Co. Old Rand-McNally Publishing Co. CaseCase

Cycle Counting Cycle Counting ApproachApproach

Largest printing plant in the U. S.Largest printing plant in the U. S. Very large warehousesVery large warehouses F.G. Four racks highF.G. Four racks high Lose signaturesLose signatures Cycle countersCycle counters

FlashlightsFlashlights BinocularsBinoculars Computer print outComputer print out


Data Capture Data Capture DevicesDevices Hand held devicesHand held devices

Pen based devicesPen based devices Scanner/data input devicesScanner/data input devices RFID trackingRFID tracking ERP integratedERP integrated Windows CE - OSWindows CE - OS Finger size point & scanFinger size point & scan Micro-chip theft controlMicro-chip theft control Electronic asset tracking [EAT]Electronic asset tracking [EAT] RackrunnersRackrunners MicroStamp RFID TechnologyMicroStamp RFID Technology


Voice Recognition TechnologyVoice Recognition Technology

InfoWorld 100 InfoWorld 100

Technology Winner 2003Technology Winner 2003 Warehouse picking applicationWarehouse picking application Headset communicationsHeadset communications Belt clip display systemBelt clip display system Two-way communicationsTwo-way communications Improved pick accuracy to one error Improved pick accuracy to one error

in 3,000 picksin 3,000 picks


Technology Assessment TeamTechnology Assessment Team

Technology AssessmentTechnology Assessment Investment prioritiesInvestment priorities Integration issuesIntegration issues Benchmarking studyBenchmarking study New employee profilesNew employee profiles Technology trainingTechnology training Payback measurementsPayback measurements University relationshipsUniversity relationships Technology VisionTechnology Vision


Today’s Typical Systems Environment

Most technologies are only partially Most technologies are only partially implemented or interfacedimplemented or interfaced

Budget constraints constantly cut back Budget constraints constantly cut back deploymentsdeployments

Acquisitions & divestments force major steps Acquisitions & divestments force major steps backwardbackward

E-commerce skill sets are weakE-commerce skill sets are weak Short term needs interfere with obtaining Short term needs interfere with obtaining

quality deliverablesquality deliverables End to end supply chain initiatives have End to end supply chain initiatives have

overwhelmed the development queueoverwhelmed the development queue Outsourcing has built more islands of Outsourcing has built more islands of

automation automation


World Class Technologies World Class Technologies AssessmentAssessment

INTEGRATION

SO

PH

ISTIC

ATIO

N


Today’s Purdue GraduatesToday’s Purdue Graduates Database structuring and administration [Quick BASIC, C+]Database structuring and administration [Quick BASIC, C+] Design techniques of Expert Systems [PC Easy & EXSYS]Design techniques of Expert Systems [PC Easy & EXSYS] PC based ERPPC based ERP Distributed system design & networkingDistributed system design & networking Hands-on PLC programming [programmable controllers]Hands-on PLC programming [programmable controllers] Apply CAD and CAE software toolsApply CAD and CAE software tools Work in a $10 million CIM laboratoryWork in a $10 million CIM laboratory

CIM softwareCIM software CNC workstationsCNC workstations automated materials handling with robotsautomated materials handling with robots automated data capture [RFID]automated data capture [RFID] vision systemsvision systems


PPR HubPPR Hub

Product

Process

Resource

HUB

Production System

Process Planning

Robotics

Factory Flow Simulation

Scheduling & Control

Efficiency

Cost Analysis

QA

Ergonomics

System Integrators: Rockwell/ IBM/ Dassault/ ABB/ EDS/ MIT


National Manufacturing WeekNational Manufacturing Week

Chicago McCormick PlaceChicago McCormick Place

February 23-26, 2004February 23-26, 2004

www.manufacturingweek.comwww.manufacturingweek.com

What industries are using your product?What industries are using your product? What new features have been added to your product since What new features have been added to your product since

last year?last year? What are the integration features of your product?What are the integration features of your product?


Speaker Contact Speaker Contact DataData

Patrick J. DelaneyPatrick J. Delaney

NWU Research ParkNWU Research Park E:mail: E:mail:

[email protected]@aol.com Phone:Phone:

1-800-806-51771-800-806-5177

world class technologies for manufacturing world class technologies for manufacturing patrick j....

Documents

accuracy n

flags n

manufacturing slide

n dual robotic cells

s n electricelectronic

procedures n intranet

feedback n machine analysis

manufacturing patrick