Process Technology Chapter 3, Part 3

Computer-Aided Design & Engineering Computer-aided design (CAD): use of computer software to design products Similar software is used to make animated films Computer-aided engineering (CAE): use of computer software to evaluate and improve product designs Specialized CAD/CAE software is used by architects and landscape architects

Computer-Aided Design & Engineering (2) Advantages of CAD and CAE Products can be designed, tested, and brought to market faster Reduces design and testing costs Lets the firm test more designs  better products Lets designers in different places and different companies work together Can be linked with computer-aided process planning (CAPP) and computer-aided manufacturing (CAM)

Computer Assisted Process Planning (CAPP) A routing specifies the sequence of steps (machine instructions) and the machines or work stations used to make a product Generated from CAD data Used as input to CAM

Computer Aided Manufacturing (CAM) CAM is the use of a computer to program and control re-programmable manufacturing equipment A robot is a mechanical arm with a power supply and a computer that controls the movements of the arm

Computer Aided Manufacturing (2) Uses of robots Monotonous work, such as assembly Work that is hard or unhealthy for people, such as painting or nuclear plant cleanup Work that requires great precision Making integrated circuits Surgery – guided by a surgeon Products: Robot vacuum cleaners, lawn mowers, assistants for disabled people, toys

Computer Aided Manufacturing (3) Other CAM machinery Numerically controlled (NC) machines are controlled by an internal computer, which is programmed at the machine Direct numerical control (DNC) machines are programmed by a central computer, which coordinates the efforts of various machines A machine center is a DNC machine that can change its own tools

Boring Turning Milling Drilling Washing Bar Stock Machine Tool Operations

Computer Aided Manufacturing (4) Vision systems: computer systems with artificial intelligence that can "see" objects and check dimensions of parts Often built into robots. Used for sorting and positioning parts Used for inspection. Suspect parts can be inspected by a second vision system or by a person

Automated Materials Handling Conveyor belts are used in manufacturing & services Robots move materials short distances Automated guided vehicles move materials longer distances in plants, offices, hospitals Automated storage and retrieval systems store and retrieve materials as directed by a computer. Used in manufacturing plants and distribution centers Automated guided vehicle

Automatic Identification of Objects Magnetic stripes are used on credit cards and vending cards Bar codes identify goods and packages Radio frequency identification (RFID) uses memory chips with tiny radio antennas to broadcast the location of goods to a wireless receiver RFID can identify goods inside a box. Useful in retailing and distribution Wal-Mart is requiring its top 100 vendors to supply RFID tags on all goods.

Biometrics: Automatic Identification of People Used to identify people and grant access to facilities, work areas, equipment, etc. Include a vision system, database, and artificial intelligence. Stored image of some portion of each user's body. May use hand, finger, or iris (colored part of eye). Vision system develops and stores images. Artificial intelligence compares body part of person seeking access with stored image.

Transparency Masters to accompany Operations Management, 5E (Heizer & Render) 7s-19 © 1998 by Prentice Hall, Inc. A Simon & Schuster Company Upper Saddle River, N.J Automated manufacturing using DNC’s and robots Automatic tool changes Automated materials handling May include automated inspection Computer-controlled Production Technology Flexible Manufacturing Cells (FMC’s)

Transparency Masters to accompany Operations Management, 5E (Heizer & Render) 7s-19 © 1998 by Prentice Hall, Inc. A Simon & Schuster Company Upper Saddle River, N.J Flexible Manufacturing Cell

Flexible Manufacturing System (FMS) System that links flexible manufacturing cells and/or lines under control of a central computer May include FMC's, robots, and DNC machine tools Includes materials handling Usually includes automated inspection

Parts Finished goods Load Unload Computer control room Machine Tools Conveyor Flexible Manufacturing System

Transparency Masters to accompany Operations Management, 5E (Heizer & Render) 7s-20 © 1998 by Prentice Hall, Inc. A Simon & Schuster Company Upper Saddle River, N.J Advantages of FMS Technology Fast response - short manufacturing lead time High product flexibility High quality Very efficient if total production volume is high

Transparency Masters to accompany Operations Management, 5E (Heizer & Render) 7s-20 © 1998 by Prentice Hall, Inc. A Simon & Schuster Company Upper Saddle River, N.J Advantages of FMS Technology Low unit costs Very little direct labor Less material waste Very low work in process inventory

Transparency Masters to accompany Operations Management, 5E (Heizer & Render) 7s-20 © 1998 by Prentice Hall, Inc. A Simon & Schuster Company Upper Saddle River, N.J Disadvantages of FMS Technology High capital cost - need high total product volume to justify investment Expertise required to design and maintain the system

Computer Integrated Manufacturing (CIM) Flexible Manufacturing System CAD and CAPP Production planning and inventory management Purchasing Common databases and control systems for all these functions Provides product flexibility, cost savings, and short manufacturing lead times