1. Computer-Aided Design, Manufacture and Testing (CADMAT) p234-245 Mr P Mulholland St Joseph’s HS Crossmaglen

2. CADMAT Systems that fully integrate the use of computers at every level and stage in the manufacturing process can be described as CADMAT systems. Systems that fully integrate the use of computers at every level and stage in the manufacturing process can be described as CADMAT systems. Computers are used in decision making within CADMAT in a variety of ways: Computers are used in decision making within CADMAT in a variety of ways: –Gathering, storing, retrieval and organisation of data, information and knowledge. –Computer simulated models to test new production systems. –Analysis of designs. –Communication between project team and clients. –Monitoring safety and quality. –Scheduling routine maintenance. Definition: Definition: CADMAT is an extension of CAD/CAM and fully integrates the use of computers at every level and stage of manufacturing.

3. Computer Integrated Manufacture (CIM) A company’s operations are production, business and manufacturing information. A company’s operations are production, business and manufacturing information. A CIM system uses ICT to integrate all aspects of a company’s operations in order to create more efficient production lines. A CIM system uses ICT to integrate all aspects of a company’s operations in order to create more efficient production lines. Tasks within a CIM system include: Tasks within a CIM system include: –The design of components. –Planning the most effective production sequences. –Control of machining operations. –Invoicing customers and ordering materials.

4. Computer Integrated Manufacture (CIM) On automated production lines computers will control the transfer of components to the required point on the assembly line. On automated production lines computers will control the transfer of components to the required point on the assembly line. The various computers and microprocessors automate the processes of monitoring and provide (feedback) to a main computer. The various computers and microprocessors automate the processes of monitoring and provide (feedback) to a main computer. The main computer informs operators about the state of the system. The main computer informs operators about the state of the system.

5. Flexible Manufacturing Systems (FMS) In the 1960’s the Japanese used the flexible factory as a competitive advantage. In the 1960’s the Japanese used the flexible factory as a competitive advantage. With increasing global competition and the creation of open markets, consumers are demanding increased product diversity and regular product updating beyond cosmetic changes. With increasing global competition and the creation of open markets, consumers are demanding increased product diversity and regular product updating beyond cosmetic changes. This influences manufacturers to invest in more flexible plant and equipment. This influences manufacturers to invest in more flexible plant and equipment. A piece of flexible equipment is one that has the ability to perform multiple processing tasks on a wide range of products, e.g. CNC machines for machining a variety of parts. A piece of flexible equipment is one that has the ability to perform multiple processing tasks on a wide range of products, e.g. CNC machines for machining a variety of parts. Flexibility allows manufacturers to explore various processing sequences that might be available through alternative configurations of plant and equipment. Flexibility allows manufacturers to explore various processing sequences that might be available through alternative configurations of plant and equipment.

6. Flexible Manufacturing Systems (FMS) Characteristics of FMS include: Characteristics of FMS include: –The system responds quickly to changes in demand or supply. –Multi-purpose equipment and techniques are used to increase flexibility. –Lead times from design to manufacture reduced. –Designs can be modified rapidly. –Minimum stock levels. –Close relationships between suppliers, manufacturer and retailers. –Increased sales and stock turnover.

7. Creative and Technical Design Computer Aided Engineering (CAE) Computer Aided Engineering (CAE) A CAD model system provides the surface modelling tools to design the ergonomic body for the appliance with all necessary controls and displays. A CAD model system provides the surface modelling tools to design the ergonomic body for the appliance with all necessary controls and displays. The CAE application will allow the design to be converted into a thin shelled case that can be made from a plastic material. The CAE application will allow the design to be converted into a thin shelled case that can be made from a plastic material. Computers are used to simulate different conditions to test product performance. Computers are used to simulate different conditions to test product performance. This is convenient and relevantly inexpensive. This is convenient and relevantly inexpensive. Shortens time needed for product development. Shortens time needed for product development.

8. Modelling and Testing Examples include: Examples include: –Experimenting with different 3D forms and layouts –Testing models using specialist software, e.g. manufacturing processes can be simulated to test suitability of the design for production –Virtual interactive models and environments are created using virtual reality modelling language (VRML).

9. Rapid Prototyping RPT is a rapidly growing area of CAD modelling. RPT is a rapidly growing area of CAD modelling. RPT builds up layers of a material whose physical shapes are representations of electronic ‘slices’ taken through a digital model. RPT builds up layers of a material whose physical shapes are representations of electronic ‘slices’ taken through a digital model. In simple terms digital data is used to create a 3D physical object. In simple terms digital data is used to create a 3D physical object. By using Rapid Prototyping, the manufacturing time for complex prototypes is measured inn days instead of hours. By using Rapid Prototyping, the manufacturing time for complex prototypes is measured inn days instead of hours.

10. Virtual Reality Modelling Language 3D virtual product modelling is a developing technique. 3D virtual product modelling is a developing technique. VRML extends the power of product modelling as a design tool. VRML extends the power of product modelling as a design tool. It is a specification for displaying 3D objects on the internet. It is a specification for displaying 3D objects on the internet. The VRML produces a virtual world on the computer screen. The VRML produces a virtual world on the computer screen. The viewer can move through the world or around an object to look at it. The viewer can move through the world or around an object to look at it.

11. Production Planning This is an area where computational aids can be used to good effect. This is an area where computational aids can be used to good effect. Careful planning is needed to make full use of all resources Careful planning is needed to make full use of all resources Scheduling is part of the planning process. Scheduling is part of the planning process. Scheduling is used to specify the Scheduling is used to specify the –detail of work –production start date –production deadline –machinery and processes required –labour requirements

12. Production Planning Finite Capacity Scheduling Finite Capacity Scheduling –Bases planning on available production capacity Infinite Capacity Scheduling Infinite Capacity Scheduling –Bases planning on customer deadlines –Assumes sufficient capacity will always be available –A Master Production Schedule (MPS) is used to set short term production targets based on known demand, forecasts and planned stock levels.

13. Time

14. Control of Complex Manufacturing Processes Computer systems are used to: Computer systems are used to: –Optimise factory layout of plant and equipment –Provide effective deployment of labour –Schedule work tasks –Monitor and control workflow –Manage and disseminate (break down and analyse) production data

15. Managing Workflow Production plans and control systems manage the input of materials and components, work in progress and output to ensure orders meet deadlines to cost. Production plans and control systems manage the input of materials and components, work in progress and output to ensure orders meet deadlines to cost.

16. Monitoring workflow Laser and barcode (data recognition tags) technology is used to record and monitor the progress of production. Laser and barcode (data recognition tags) technology is used to record and monitor the progress of production. Data is sent to a supervising computer controlling the production line. Data is sent to a supervising computer controlling the production line.

17. Controlling Workflow Project management software coordinates production cells within a master production schedule. Project management software coordinates production cells within a master production schedule. Workflow software ensures that individuals responsible for particular tasks are notified and provided with information to complete the task. Workflow software ensures that individuals responsible for particular tasks are notified and provided with information to complete the task.

18. Integrated and Concurrent Manufacturing Sequential Manufacturing Sequential Manufacturing Product development follows a straight forward path. Each stage of a product life cycle is dependent upon the completion of all the stages that have went before hand. Product development follows a straight forward path. Each stage of a product life cycle is dependent upon the completion of all the stages that have went before hand. This system has several disadvantages: This system has several disadvantages: –To trace and correct faults the product has to go back through each preceding stage. –Slow to respond to changes in demand. –Longer lead times (start to finish). –Quality problems due to separation and isolation of each design department and expensive redesign loops.

19. Integrated and Concurrent Manufacturing Concurrent Manufacturing Concurrent Manufacturing Also known as simultaneous manufacturing is applicable to batch and mass production. Features and advantages include: Also known as simultaneous manufacturing is applicable to batch and mass production. Features and advantages include: –Team based approach –All departments represented to allow quality decision making –Shorter lead times –Product life cycle considered by all –Suppliers and retailers involved early in product development –Production deadlines are the responsibility of each individual team member.