ADVANCED MANUFACTURING SYSTEMS DESIGN

Submitted By Amit Pandit Paritosh Anand Dhiraj Patil Premanand S Nayan

What is Advanced Manufacturing Systems ?

Advanced manufacturing involves the use of technology to improve products and/or processes, with the relevant technology being described as advanced, innovative, or cutting edge.

The rate of technology adoption and the ability to use that technology to remain competitive and add value define the advanced manufacturing sector

Different Types Of Advanced Manufacturing System

Just-In-Time Manufacturing (JIT) Computer-Integrated Manufacturing (CIM) Flexible Manufacturing Systems (FMS) World Class Business Manufacturing Systems (WCBM)

Just-In-Time Manufacturing: A Definition

a corporate system designed to produce output within the minimum lead time and at the lowest total cost by continuously identifying and eliminating all forms of corporate waste and variance. a corporate strategy a philosophy

Objective of JIT
Produce only the products the customer wants. Produce products only at the rate that the customer wants them. Produce with perfect quality Produce with minimum lead time. Produce products with only those features the customer wants. Produce with no waste of labor, material or equipment -- every movement must have a purpose so that there is zero idle inventory. Produce with methods that allow for the development of people

Just-In-Time Techniques
Inventory Reduction as a Tool for Improvement Supplier Relationships Inventory Pull Uniform Plant Loading Reduced Setup Times Shop-Floor Layout and Production Cells Total Quality Assurance Preventive Maintenance

Theoretical Benefits of JIT

Unpleasant surprises eliminated Less computerization visual control Improved quality WIP reduced Better communications Less pressure on receiving docks and incoming inspection areas Lower costs Change in attitude Defects are treasures

Requirements for JIT

Respond to Customer Requirements Integrate all Processes in the Manufacturing System Employee Participation in Meeting Commitments Use a pull Production System Design products for Manufacturing Develop Controllable Production Processes Company wide Commitment to education Eliminate redundancy Reduce all Inventory Establish Continuous Improvement Goals Have a Defect Prevention Program Reduce Setup Times Build Products to Specification

Computer-Integrated Manufacturing
It was promoted by machine tool manufacturers in the 1980's and the Society for Manufacturing Engineers (CASA/SME). Quite often it was mistaken for the concept of a "lights out" factory.

CIM Includes
CAD/CAM, computer-aided design/computeraided manufacturing, CAPP, computer-aided process planning, CNC, computer numerical control machine tools, DNC, direct numerical control machine tools, FMS, flexible machining systems, ASRS, automated storage and retrieval systems, AGV, automated guided vehicles, use of robotics and automated conveyance, computerized scheduling and production control, a business system integrated by a common data base.

The Elements of CIM

CIM
Integration of design, manufacture & delivery via computer technology CAD - uses software to create & modify designs CAM - uses programmable automation in manufacturing CAE - links functional design to CAD form design CAPP - creates processing instructions for CAM GT- classifies designs to benefit from prior experience

Flexible Manufacturing Systems (FMS)

An FMS is a reprogrammable manufacturing system capable of producing a variety of products automatically. Conventional manufacturing systems have been marked by one of two distinct features: The capability of producing a variety of different product types, but at a high cost (e.g., job shops). The capability of producing large volumes of a product at a lower cost, but very inflexible in terms of the product types which can be produced (e.g., transfer lines).

FMS contd...
An FMS is designed to provide both of these features. Programmable machine tools Controlled by common computer network Combines flexibility with efficiency Reduces setup & queue times

FMS Components
Numerical Control (NC) machine tools Automated material handling system (AMHS)
Automated guided vehicles (AGV) Conveyors Automated storage and retrieval systems (AS/RS)

Industrial Robots Control Software

Flexible Manufacturing System

Tools Computer control room Conveyor

Machine
Pallet

Machine

Load

Unload
Terminal

Parts

Finished goods

Classification of FMS-related Problems

Strategic analysis and economic justification, which provides long-range, strategic business plans. Facility design, in which strategic business plans are integrated into a specific facility design to accomplish long-term managerial objectives. Intermediate-range planning, which encompasses decisions related to master production scheduling and deals with a planning horizon from several days to several months in duration. Dynamic operations planning, which is concerned with the dynamic, minute-to-minute operations of FMS.

FMS Problems
Part type selection (Askin) - selecting parts that will be produced in the FMS over some relatively long planning horizon. Part selection (Stecke) - from the set of parts that have current production requirements and have been selected for processing in the FMS, select a subset for immediate and simultaneous processing. Machine grouping (Stecke) - partition machines into groups where each machine in a group can perform the same set of operations.

Loading (Stecke) - allocate the operations and required tools of the selected part types among the machine groups.
Control - provide instructions for, and monitor the equipment in the FMS so that the production goals identified by the above problems are met.

Strategies for World Class Business Management

Built in Quality Cost Minimization (CM) & Profit Maximization (PM)

Customer Service

Features of World Class Business Management

Forming and Positioning WCB

Corporate Mission
Business Strategy WCM Customer Focus Corporate Governance WCB

World Class Business

World Class business practices facilitate the corporate sectors through integration of latest thinking about built in quality, cost control & customer delight to achieve world class business services.

Why World Class Business?

World Trade organization Opportunities). (World of Threats &

Competitiveness (MIM) State-of-the-Art of Risk Management Pro-Active (and production) to the 21st Century

How to Built a World Class Business ? Increase Your Profits and Decrease Your Risk. Learn How to Take Your Business to the Next Level with Less Stress, Greater Confidence and Better Systems.

THANK YOU