Automation (21-541) Sharif University of Technology Session # 3 Advanced Manufacturing Laboratory Department of Industrial Engineering Sharif University of Technology Session # 3

Automation (21541), Session # 3 Session Schedule ‎‎CIM hardware and software considerations Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 2

Automation (21541), Session # 3 Introduction to manufacturing automation and CIM (Computer Integrated Manufacturing) Automation: set of all measures aiming at replacing human work through machines (e.g. automation is applied science) the technology used for this purpose (e.g. this company has an automation department) replacement of human work through machines (e.g. the automatisation of the textile factory caused uproar of the workers) replacement of conscious activity by reflexes (e.g. drill of the sailors allows the automatisation of ship handling) The use of computers and machines instead of people to do a job Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 3

CIM history (Continued… ) CIM scope within the enterprises: Marketing Product Design Planning Purchase Manufacturing Engineering Factory Automation Hardware Warehousing Logistics and Supply Chain Management Finance Information Management Marketing: The need for a product is identified by the marketing division. The specifications of the product, the projection of manufacturing quantities and the strategy for marketing the product are also decided by the marketing department. Marketing also works out the manufacturing costs to assess the economic viability of the product. ii. Product Design: The design department of the company establishes the initial database for production of a proposed product. In a CIM system this is accomplished through activities such as geometric modeling and computer aided design while considering the product requirements and concepts generated by the creativity of the design engineer. Configuration management is an important activity in many designs. Complex designs are usually carried out by several teams working simultaneously, located often in different parts of the world. The design process is constrained by the costs that will be incurred in actual production and by the capabilities of the available production equipment and processes. The design process creates the database required to manufacture the part. iii. Planning: The planning department takes the database established by the design department and enriches it with production data and information to produce a plan for the production of the product. Planning involves several subsystems dealing with materials, facility, process, tools, manpower, capacity, scheduling, outsourcing, assembly, inspection, logistics etc. In a CIM system, this planning process should be constrained by the production costs and by the production equipment and process capability, in order to generate an optimized plan. iv. Purchase: The purchase departments is responsible for placing the purchase orders and follow up, ensure quality in the production process of the vendor, receive the items, arrange for inspection and supply the items to the stores or arrange timely delivery depending on the production schedule for eventual supply to manufacture and assembly. v. Manufacturing Engineering: Manufacturing Engineering is the activity of carrying out the production of the product, involving further enrichment of the database with performance data and information about the production equipment and processes. In CIM, this requires activities like CNC programming, simulation and computer aided scheduling of the production activity. This should include online dynamic scheduling and control based on the real time performance of the equipment and processes to assure continuous production activity. Often, the need to meet fluctuating market demand requires the manufacturing system flexible and agile. vi. Factory Automation Hardware: Factory automation equipment further enriches the database with equipment and process data, resident either in the operator or the equipment to carry out the production process. In CIM system this consists of computer controlled process machinery such as CNC machine tools, flexible manufacturing systems (FMS), Computer controlled robots, material handling systems, computer controlled assembly systems, flexibly automated inspection systems and so on. vii. Warehousing: Warehousing is the function involving storage and retrieval of raw materials, components, finished goods as well as shipment of items. In today’s complex outsourcing scenario and the need for just-in-time supply of components and subsystems, logistics and supply chain management assume great importance. viii. Finance: Finance deals with the resources pertaining to money. Planning of investment, working capital, and cash flow control, realization of receipts, accounting and allocation of funds are the major tasks of the finance departments. Information Management: Information Management is perhaps one of the crucial tasks in CIM. This involves master production scheduling, database management, communication, manufacturing systems integration and management information systems Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 4

CIM hardware and software considerations CIM equipment: CNC machines Computerized work centers Robotic work cells DNC/FMS systems Work handling and tool handling devices Storage devices Sensors, shop floor data collection devices Inspection machines Computers, controllers CAD/CAM systems, workstations / terminals, data entry terminals, bar code readers, RFID tags Printers, plotters and other peripheral devices, modems, cables, connectors Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 5

CIM hardware and software considerations CIM software comprises computer programs like: Management Information System; Database Management Sales, Order Entry Marketing Finance Analysis; Modeling and Design Simulation Inventory Control; Materials Handling Monitoring; Shop Floor Data Collection Process Planning Manufacturing Facilities Planning; Production Control Work Flow Automation Quality Management Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 6

Automation (21541), Session # 3 Introduction to manufacturing automation and CIM (Computer Integrated Manufacturing) Computer Integrated Manufacturing (CIM) encompasses The entire range of product development and manufacturing activities with all the functions being carried out With the help of dedicated software packages. The data required for various functions are passed from one application software to another in a seamless manner CIM considers All activities from the design of the product to customer support in an integrated way, Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 8

CIM Database management The information required for manufacturing cover a wide range of disciplines and serving a multitude of inter-related yet vastly differing needs. A database can be defined as a collection of data in a single location designed to be used by different programmers for a variety of applications. A database is a collection of logically related data stored together in a set of files intended to serve one or more applications in an optimal fashion. Database must also have a predetermined structure and organization suitable for access, interpretation, or processing either manually or automatically Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 9

CIM Database management The CIM database comprises basically four classes of data: Product Data: Data about parts to be manufactured. It includes text and geometry data. Manufacturing Data: The information as to how the parts are to be manufactured is available in production data. Operational Data: Closely related to manufacturing data but describes the things specific to production, such as lot size, schedule, assembly sequence, qualification scheme. Resource Data: This is closely related to operational data but describes the resources involved in operations, such as materials, machines, human resources and money Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 10

CIM Database management Varied tasks one might expect to accomplish in a CIM environment: Designing assemblies and performing tolerance analysis on those assemblies. Preparing production drawings of assemblies, individual parts, tooling, fixtures and other manufacturing facilities. Preparing part lists and bill of materials (BOM). Preparing process plans for individual part manufacture and assembly. Programming CNC machines for processing complete parts (CAM). Designing work cells and programming the movement of components in those cells using work handling devices like robots, conveyors, AGV’s/ RGV’s. Preparing inspection programs including programs for CNC machines. Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 11

Make your own CIM database !! To understand the necessities of a CIM data base: Groups with 5-6 students will be established Each group starts the essential activities for forming a CIM database in the class theoretically The implementation of theoretical activities will be conducted during the weeks in manufacturing laboratory The implementation results will form the groups CIM databases during the course Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 12

Make your own CIM database !! First step: Definition of the groups You can introduce your group members : You will be assigned to random defined groups. Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 13

Make your own CIM database !! Second step: Choose a programming language e.g. Microsoft SQL server Oracle Microsoft Access Visual studio C++ C Pascal Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 14

Make your own CIM database !! Third step: Theoretically plan the procedures which enable: The storage of object related data (attributes) The sort of data related to an array of objects (Tables, Primary keys) The storage of relation among related objects (relational database, Foreign keys) The retrieve operation of a definite object by means of its attributes ( Select) The modification/delete operation of a definite object by means of its attributes (Update/Delete) Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 15

Make your own CIM database !! Third step: (Continued …) Theoretically plan the procedures which enable: The transfer of your data base from one computer to another (Back up operation) The extract of information from an array objects (Information) The extract of knowledge from a series of information (knowledge) Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology Automation (21541), Session # 3 16