Cad-cam-cim-intro.pdf 453f3x

Computer Integrated Design and Manufacture Integrated Data Models in Design and Manufacture C.S.Kumar CAD-CAM and Robotics Lab. Department of Mechanical Engineering, IIT Kharagpur [email protected] © C.S.Kumar, Mechanical Engineering, IIT Kharagpur

Nature of Manufacturing Operations Globalisation Rapid Product Cycles Widespread proliferation of Information and Communication Technologies (ICT)

The Realities of Modern Manufacturing Globalization - Once underdeveloped countries (e.g., China, India, Mexico, Brazil) are becoming major players in manufacturing International outsourcing - Parts and products once made locally are now being made offshore (in China or India) or near-shore (in Eastern Europe) Local outsourcing - Use of suppliers locally to provide parts and services

More Realities of Modern Manufacturing Contract manufacturing - Companies that specialize in manufacturing entire products, not just parts, under contract to other companies Trend toward the service sector Quality expectations - Customers, both consumer and corporate, demand products of the highest quality Need for operational efficiency - manufacturers must be efficient in in their operations to overcome the labor cost advantage of international competitors

Globalization Design Product Manufacturing     

Costs Transport Labour Local standards / cultures / law Demand – supply and supply chain management (SCM)

Production strategies Assemblies Fully knocked down Semi knocked down Parts / design replacements Quality and functionality

Breaking Down Barriers

Traditional Product Development Customer requirements (sales and marketing)

Conceptual design (Industrial designers)

Detailed design and analysis (engineering)

Manufacturing

Distribution and Sales

and Service

(Now is increasingly relevant)

Disposal ?

Concurrent Product Development Design

Engineering Customer

Sales

Manufacturing

Concurrent Engineering Simultaneous decision making by design teams Integrates product design & process planning Details of design more decentralized Needs careful scheduling - tasks done in parallel

Concurrent Engineering Teams Interdisciplinary, cross-functional Includes customer, marketing, design, engineering, manufacturing, sales, Concurrent engineering teams are physically colocated to promote collaboration

Sequential Vs. Concurrent Product Development Activity A Sequential

Activity B Activity C Time to market

Concurrent Competitive Advantage!

Conventional Collaboration Communication 

face-to-face discussion, memos, telephone, whiteboard, bulletin board, wall charts, etc.

Collaboration 

meetings, colocated workgroup

Knowledge management 

notebooks, binders, printed reports, photocopies, drawings, forms, data files

Geographically Distributed Teams

Enterprise data and information

Company A

Transparent global network

Company B

Virtual Collaboration Communication  

fax, telephone, mail email, discussion groups, shared whiteboard, videoconferencing

Collaboration 

application sharing, shared network workspace (files in shared directories)

Knowledge management 

Product data management system, document management system, distributed databases

Enterprise Functions in Manufacturing

Source: Principles of Comp Intgd Manuf : Jean-Baptiste Waldner / Wikipedia

Source: JTEC Report on Japanese Electronics Industry (1995) : A Typical Implementation

CAD Processes Computer Aided Drafting 3D modelling and representation  

Layers Assemblies

Visualisation -> Drafting Process Planning: 3D Models -> Machining plan : CAM Planners 3D Models -> Products (Rapid Prototyping)

New requirements CAD Models to be shared Shared visualisations Modifications easily reflected -> Consistency and safe data propagation Parametric Design Feature based Design Constraints modelling

Product Life Cycle Constraints Rapid development cycles Thin lead margins Fast turn-around in new feature introduction Fast turn-around in bugs recovery Global and local constraints

Software and Tools Parametric Technologies (PTC)   

Pro/Engineer Windchill PDMLink Windchill ProjectLink

Dassault Systems (3DS)    

CATIA, Solid Works : Design DELMIA : Manufacture ENOVIA, SMARTEAM : Product Life Cycle Mgmt Solidworks

Autodesk (AutoCAD, Inventor) Unigraphics (UGS – SolidEDGE) – now under Siemens Delcam (IDEAS)

Manufacturing Automation Computer Controlled Machines Robotics Automated work handling systems Precision and repeated operations High quality in output

Sales, and market Global Markets ERP and Web based operations Mass Customization Tracking and Life time GM - Onstar

Industrial Automation Machines Storage Systems Handling Systems Assembly Lines  Assembly Cells  Machines  Actuators  Sensors Production Lines  Production Cells  Machines  Actuators  Sensors

Industrial Automation Computing  Computers  Controllers  Actuators  Sensors  Software

Industrial Automation - why? 1. Production Systems 2. Automation in Production Systems 3. Manual Labor in Production Systems 4. Automation Principles and Strategies 5. Organization of the Course

Manufacturing Approaches Automation Flexible manufacturing Quality programs Integration Lean production

Facilities – Factory and Equipment Factory, production machines and tooling, material handling equipment, inspection equipment, and computer systems that control the manufacturing operations

Manufacturing Systems Business functions - sales and marketing, order entry, cost ing, customer billing  Product design - research and development, design engineering, prototype shop  Manufacturing planning - process planning, production planning, MRP, capacity planning  Manufacturing control shop floor control, 

inventory control, quality control

Computer Integrated Manufacturing

Automated System Periodic Automated Examples: Worker System Automated machine tools Transfer lines Automated assembly systems Transformation Process Industrial robots Automated material handling and storage systems Automatic inspection systems for quality control

Three Automation Types

Variety

Programmable Automation

Flexible Automation

Quantity

Fixed Automation

Fixed Automation Sequence of processing (or assembly) operations is fixed by the equipment configuration Typical features: Suited to high production quantities High initial investment for custom-engineered equipment High production rates Relatively inflexible in accommodating product variety

Programmable Automation Capability to change the sequence of operations through reprogramming to accommodate different product configurations Typical features: High investment in programmable equipment Lower production rates than fixed automation Flexibility to deal with variations and changes in product configuration Most suitable for batch production Physical setup and part program must be changed between jobs (batches)

Flexible Automation System is capable of changing over from one job to the next with little lost time between jobs Typical features: High investment for custom-engineered system Continuous production of variable mixes of products Medium production rates Flexibility to deal with soft product variety

Reasons for Automating 1. 2. 3. 4.

5. 6. 7. 8. 9.

To increase labor productivity To reduce labor cost To mitigate the effects of labor shortages To reduce or remove routine manual and clerical tasks To improve worker safety To improve product quality To reduce manufacturing lead time To accomplish what cannot be done manually To avoid the high cost of not automating

Automation Principles 1. Understand the existing process   

Input/output analysis Value chain analysis Charting techniques and mathematical modeling

2. Simplify the process 

Reduce unnecessary steps and moves

3. Automate the process 



Ten strategies for automation and production systems Automation migration strategy

Automation Strategies 1. Specialization of operations 2. Combined operations 3. Simultaneous operations 4. Integration of operations 5. Increased flexibility 6. Improved material handling and storage 7. On-line inspection 8. Process control and optimization 9. Plant operations control 10.Computer-integrated manufacturing

Automation Migration Strategy

Various areas being covered Definition of Industrial Automation Mathematical Models for Manufacturing Industrial Systems           

Control Systems Sensors and Actuators Automated Machine Tools Industrial Robotics Logic Controllers Handling Systems Storage Systems Identification Systems Manufacturing Cells Assembly Lines Flexible Manufacturing Systems

Thank you End of Introductions.

© C.S.Kumar, Mechanical Engineering, IIT Kharagpur