Professional Documents
Culture Documents
Sep 2012
TABLE OF CONTENTS
Abstract ............................................................................................. 3
Abbreviations .................................................................................... 4
Introduction........................................................................................ 5
Computer Integrated Manufacturing ................................................. 6
CIM Business Case ........................................................................ 7
CIM Technical Analysis ................................................................ 10
Conclusion - Case Study................................................................. 16
Author Info ....................................................................................... 17
2011, HCL Technologies. Reproduction Prohibited. This document is protected under Copyright by the Author, all rights reserved.
Abstract
Manually operated manufacturing lines are giving way to fully
automated lines with minimal manual intervention for the purpose of
reduction in cycle times and to enhance quality, with the prime
purpose of reducing variation in both. With the advent of automation
lines and reduction in manual work, there has been a need to
monitor and report the performance of these lines in terms of
productivity, quality and allied information that could prove vital to
establish the efficiency of the lines and the process. Since manual
reporting is time consuming, erroneous, biased and slow, automatic
reporting, and sometimes feedback, is the need of the day. The
solution lies with the advent and incorporation of Computer
Integrated Manufacturing systems (CIM). This paper describes the
hardware details and the software framework that encompasses a
CIM system.
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
Abbreviations
Sl. No.
Acronyms
Full Form
CIM
QC
Quality Control
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
Introduction
This paper shall elaborate the various aspects that go into
implementing CIM, starting from the need for a CIM system all the
way to deployment. In the process, details of the equipment, the
software essentials, the development team, hardware requirements
and effort shall be discussed. Features that could be a part of CIM,
based on the product being manufactured, shall also be discussed.
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
Sensors
2. Hardware
Server/Computers
Room Requirement
Equipment
The equipment dealt with is either a semi-automatic machine or a
fully automatic machine. A level of intelligence is expected to be
addressed during machine design such as installation of sensors for
safety mechanisms, equipment status signaling encoders, etc.,
which can feed back to a central intelligence system regarding the
status of the equipment.
a. Sensors
Sensors form an integral part of any CIM system. They are the
primary source of feedback to any CIM system. There are different
kinds of sensors used and selected depending upon the precision,
usage scenario and cost. Some sensors use light as a medium of
communication, such as through beam sensors, diffuse sensors,
laser beam sensors and other photoelectric sensors. If a situation
demands the detection of a magnetic material such as iron, reed
sensors are used. In places where safety is a concern, proximity
switches are used. Proximity sensors are also used in places where
positional detection is necessary. Let us analyze a case where a
particular sensor is used and how this would be of use to CIM. A
machine has a high-speed robot, and to ensure safety, a door
switch is installed. At times the door is opened for specific purposes
such as maintenance. Opening the door causes a reduction in
equipment productivity. At a review meeting, the detailed cause of
loss in productivity cannot be explained. With a system like CIM, the
exact cause of the productivity loss can be tabulated and a 5 Why
analysis can be completed. The methodology involves the sensor
communicating with the PLC, which takes note of how long the
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10
sensor is off and the time involved. The data is sent to a server
which decodes the data and presents it in the CIM format.
b. PLC
Programmable Logic Controllers form the electrical heart of the
machine, and are sometimes referred to as the brain of an
automatic machine. They control different mechanisms in a machine
like pneumatic parts, heaters, weld controllers, vision systems,
motors, etc. Apart from controlling, they also collect data from
different sensors like encoders, cam positioners, photoelectric
sensors, and ultrasonic sensors as well as take note of the time, the
occurrence frequency, and in some cases quality parameters. Apart
from the ladder program, PLCs also take input from the touch
screen, joystick controllers and hand-held consoles. Depending on
the program logic, PLCs can act as an activate/de-activate controller
for the entire machinery. In addition, the PLCs also communicate
with the next machine to know their status for acceptance of the
completed product. In short, the PLC is a device that is an interface
between the machine and the server for a CIM system.
Hardware
a. Server/Computers
The server shall store data sent from the equipment and shall be
sized to store and capable of handling huge amounts of data. Since
CIM is also a feature for traceability, care needs to be taken for
sizing the memory of the server. The server should be well isolated
from the development environment which will handle smaller
computers.
b. Room Requirements
The development area shall house computers which might range
from 6-10 for a mid-sized company from an electronics industry
perspective. The room temperature needs to be controlled at
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11
222C. The server room requires tighter control since it houses the
UPS which is comprised of lead acid batteries, which are
themselves heat generating. The server room needs to be
controlled at 211C. Because the server stores data critical to the
sustainability of the organization, measures should be taken to
protect it from accidental fire. A good example would be to have a
smoke alarm which could activate an inert gas like Argon so
combustion could be deterred due to the absence of oxygen. Care
should be taken before purging the entire room with argon, as a lack
of oxygen can asphyxiate personnel in the room. From a security
standpoint, the facility should be monitored by a Closed Circuit
Television Camera (CCTV). The development area and server room
should be accessible only by authorized personnel.
Process
d. Equipment Name
e. Type of Report Xbar R/Xbar - /Histogram
f.
g. Defect Type
h. Pareto Analysis
i.
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12
j.
k.
l.
Production Data
Equipment Name
g. Pareto Analysis
h. Frequency of Reporting
i.
j.
k.
MSDS Input
l.
Equipment Data
Equipment Name
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13
Maintenance Criteria
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14
Manpower Requirements
S.
No
Skill Subset
Requirements
Manpower
Needed
Software
Engineers
Development of
Software System
Wiring and
Interfacing
Electrical
Engineers
1/mc
Mechanical
Engineers
Sensor Selection,
Mounting Design
1/mc
Hard Wiring
Vendor
1 Vendor
Project Lead
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15
2011, HCL Technologies, Ltd. Reproduction prohibited. This document is protected under copyright by the author. All rights reserved.
16
Author Info
Sandeep Venkatraman
Sandeep has over eight years of experience,
five of which have been in manufacturing,
vendor quality, new plant set-up, automation
equipment
design/development,
Lean
implementation, Six Sigma and Plant Kaizen.
The remaining three years were with factory
automation design, and his current role
involves creating solutions for the industrial
and sustainability divisions.
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17
About HCL
About HCL Technologies
HCL Technologies is a leading global IT services company, working
with clients in the areas that impact and redefine the core of their
businesses. Since its inception into the global landscape after its IPO in
1999, HCL focuses on transformational outsourcing, underlined by
innovation and value creation, and offers integrated portfolio of services
including software-led IT solutions, remote infrastructure management,
engineering and R&D services and BPO. HCL leverages its extensive
global offshore infrastructure and network of offices in 26 countries to
provide holistic, multi-service delivery in key industry verticals including
Financial Services, Manufacturing, Consumer Services, Public Services
and Healthcare. HCL takes pride in its philosophy of 'Employees First,
Customers Second' which empowers our 84,319 transformers to create
a real value for the customers. HCL Technologies, along with its
subsidiaries, has reported consolidated revenues of US$ 4 billion (Rs.
21031 crores), as on TTM ended Jun 30 '12.
For more information, please visit www.hcltech.com
About HCL Enterprise
HCL is a $6.2 billion leading global technology and IT enterprise
comprising two companies listed in India - HCL Technologies and HCL
Infosystems. Founded in 1976, HCL is one of India's original IT garage
start-ups. A pioneer of modern computing, HCL is a global
transformational enterprise today. Its range of offerings includes
product engineering, custom & package applications, BPO, IT
infrastructure services, IT hardware, systems integration, and
distribution of information and communications technology (ICT)
products across a wide range of focused industry verticals. The HCL
team consists of over 90,000 professionals of diverse nationalities, who
operate from 31 countries including over 500 points of presence in
India. HCL has partnerships with several leading global 1000 firms,
including leading IT and technology firms.
For more information, please visit www.hcl.com