Unit - III

Prof. Arun Mishra

arunjimishra@gmail.com
9893686820

Types of Hardware technology in manufacturing. Types of Software technology in manufacturing. Computer Integrated Manufacturing.

Technology is not a cure-all, but managing technology is certainly a major ingredient in virtually all operations decisions, and opportunities for its innovative use exist throughout OM. Excellent vehicle for obtaining competitive advantage.

Numerically controlled machines Automated process controls Vision systems (automated inspection systems) Robots Automated identification systems (AIS) Automated storage and retrieval system (ASRS) Automated guided vehicles (AGV) Automated flow lines Automated Assembly Systems Flexible manufacturing systems (FMS) Computer integrated manufacturing (CIM) Enterprise resource planning (ERP)

Numerical control (NC) - machine can be controlled electronically Computer Numerically Controlled (CNC) machine actually has its own microprocessor and memory Direct Numerical Control (DNC) - wired to a central computer

Is the use of information technology to monitor and control a physical process. For example, process control is used to measure the moisture content and thickness of a paper. To determine and control temperatures, pressures, and quantities in petroleum refineries, petrochemical processes, cement plants, steel mills, nuclear reactors and other product-focused facilities.

 Sensors,

often analog devices, collect data Analog devices read data on some periodic basis, perhaps once a minute or once a second Measurements are translated into digital signals, and transmitted to a digital computer Computer programs read the file (the digital data) and analyze the data Output may be a: message on printer or console, signal to a motor to change a value setting, warning light or horn, process control chart, etc.

Combine video and computer technology Often used in inspection roles Consistently accurate, do not become bored, of modest cost

Image
Acquisition

Image Analysis Image

Interpretation

Robots
Programmable manipulators Follow specified path Better than humans with respect to
Hostile environments Long hours Consistency

Adoption has been slowed by ineffective integration and adaptation of systems Perform monotonous or dangerous tasks Used when speed, accuracy, or strength are needed

Where Used and Applied

Welding Painting

Surface finishing
Aerospace and automotive industries Light assembly such as in the micro-electronics industries, or consumer products industries Inspection of parts Underwater and space exploration Hazardous waste remediation

Uses bar codes, radio frequencies, magnetic strips, optical character recognition to sense & input the data into computers. For example, automatic maintenance of inventory system by reading the bar code on the item and updating the inventory database.

Computer-controlled warehouses that provide for the automatic placement and withdrawal of parts and products into and from designated places in a warehouse. These systems are also found in inventory and test areas of manufacturing firms.

Material handling machines Used to move parts & equipment in manufacturing May be used to deliver mail & meals in service facilities

Aerospace & Defense Automotive Chemical Food & Beverage Government Newsprint Electronics Plastics Primary Metals Recycling And more

Reduced labor and associated costs... Increased dependability and productivity... Less product handling damage... Increased safety...

Includes several automated machines which are linked by automated transfer machines & handling machines. Also known as fixed automation/ hard automation. Suitable for products with high & stable demand. Requires high initial investment. The raw material feeder automatically feeds the machines to carry operations without human intervention.

Automated assembly machines/ equipments are linked together by automated material handling equipments. Ex. Robotic welders are used to join one or more parts. Advantages are;
Low production cost per unit High product quality Higher products flexibility.

When a central computer provides instructions to each workstation and to the material-handling equipment (which moves material to that station), the systems is known as an automated cell work: FMS Is flexible because both the materialhandling deices and the machines themselves are controlled by easily changed electronic signals (computer programs): low volume with high variety.

Using automated machines (DNC) & materials handling equipment together Often connected to centralized computer Also called automated work cell

Auto Tool Chg. Machine 1 Robot or AGV Computer Auto Tool Chg. Machine 2

CNC Machine

Finished goods

Computer control room Pallet CNC Machine

Terminal

Parts

Automatic tool changer

Advantages

Faster, lower-cost changes from one part to another Lower direct labor costs Reduced inventory Consistent, and perhaps better quality

Disadvantages

Limited ability to adapt to product or product mix changes Requires substantial preplanning and capital expenditures Technological problems of exact component positioning and precise timing Tooling and fixture requirements

Manufacturing Software Technology

Computer Aided Design and Computer Aided Manufacturing (CAD/CAM) Computer Integrated Manufacturing (CIM) Enterprise Resource Planning (ERP)

CAD is an electronic system using computers for designing new parts or products or for modifying existing ones. CAD is the use of computers for the synthesis, analysis, and optimization of a design.

CAD is an iterative process

A certain component or subsystem of the overall system is first conceptualized by the designer, is subjected to analysis, then improved through this analysis procedure, and finally redesigned. The process is repeated until the design has been optimized with respect to the criteria of cost, quality, and operating performance. The next phase in the design process is the fabrication of a prototype, and testing the prototype to assess manufacturability, operating performance, quality, reliability, and other criteria. Finally, a database of drawings, material specifications, bill of materials, assembly drawings, etc., is created.

Saves time and money of designers . Eliminates prototype model building to prove the design. Allows designers to determine costs and test such variables as stress, tolerance, product variability, interchangeability & serviceability. Low cost of design. Eliminates manual drafting. Faster development, better products & accurate flow of information to other departments. Product cost can be determined at the design stage itself. Makes review of numerous options in design before final commitments are made.

Use of computer software to direct & control manufacturing equipments. CAM is the use of computer systems to plan, manage, and control the operations of a manufacturing plant through either direct or indirect computer interface with the plant's production resources. CAD/CAM covers a wide spectrum of activities that include production specification, conceptual design, final design, drafting, process planning, manufacturing, assembly, and inspection. CAD/CAM is probably the most common and best known acronym in contemporary manufacturing.

Product Quality Shorter Design Time. Production cost reduction Database availability New range possibilities. Minimum involvement of direct workers. High quality & productivity.

CIM Expands the integration of CAD & CAM to encompass the administrative, engineering, and manufacturing disciplines in a manufacturing business. Manufacturing system that combines CAM with engineering (CAD), & production & inventory control & shipping. CIM integrates the factors of production to organize every event that occurs in a business enterprise - from receipt of a customer's order to delivery of the product.

Top Management decides to make a product based on market opportunities, companys strengths & weaknesses & formulates its strategic plan based on competitive advantage.
OM runs the production process, coordinating supplies, requesting components & materials, planning & scheduling operations, overseeing cost accounting, & arranging outgoing shipments. Computer-aided design (CAD) designs the product, then analyzes it to assure quality & to extract data needed to plan the manufacturing process, design the tools & fixtures & machine loading programs.

Computer-aided |manufacturing (CAM) allows fabrication of raw materials into parts to be sent to the assembly lines.

Automated storage & retrieval system (ASRS) & Automated Guided Vehicles (AGV) moves incoming materials 7 parts, workin-progress, & final product.

Robots put the product together, test them with automated equipments, & box the finished product for shipment.

ERP are comprehensive software packages which integrate most of the business functions in an organization. Software for managing basic requirements of an enterprise, including sales & marketing, finance and accounting, production & materials management, and human resources. Several ERP software packages have been developed by leading software companies such as SAP, Oracle, J.D. Edwards, People soft and Baan. Integration of E-business capabilities id the latest development in ERP systems.

Labor costs Material costs Inventory costs Transportation or distribution costs Quality costs