Week's Slides PDF

Advanced Manufacturing Systems
Design
2000 John W. Nazemetz
Concurrent
Engineering
Lecture 3 Topic :
Introduction to
Simultaneous and Asynchronous
Engineering
Segment A Topic:
ADVANCED
MANUFACTURING
SYSTEMS DESIGN
Concurrent Engineering
Introduction to Simultaneous and
Asynchronous Engineering
Activities
Slide 2
Computer Integrated
Manufacturing Systems
Overview
Definition
Concepts
New Products
Existing Products
Slide 3
Computer Integrated
Computer Integrated
Definition Revisited
Systems which enable the integrated,

rationalized design, development,
implementation, operation and
improvement of production facilities
and their output over the life cycle of
the product. These systems identify and
use appropriate technology to achieve
their goals at minimum cost and effort.
Slide 4
Computer Integrated
Concurrent Engineering -Definition

Concurrent Engineering is a systematic
approach to the integrated, concurrent
design of products and their related
processes, including manufacturing and
support. This approach is intended to
cause the developers, from the outset,
to consider all elements of the product
life cycle from conception to disposal,
including quality, cost, schedule, and
user requirements. (Pennell and Winner,
1989)
Slide 5
Computer Integrated
Concurrent Engineering Definition Problems

Name Implies only Engineering Involved
Activity is Really Concurrent (DESIGN)
CONCEPTUALIZATION and EVALUATION
(ENGINEERING)
Require Broad View of Design
Must Assure that Correct Concepts Are
Incorporated into the Design
Must Assure that Principles of
Engineering/Nature are Followed
Slide 6
Computer Integrated
Goals of Concurrent
Engineering in CIM (1)
Primary Goal is to Assure
Rationalization in Early Stages to Avoid
Cost/Improve Product
Slide 7
Operational Concept
Physical Concept
Manufacturing Concept
Maintenance Concept
Disposal Concept
Computer Integrated
Goals of Concurrent
Engineering in CIM (2)
Secondary Goal is Lead Time Reduction
Administrative Lead Time
Design and Rationalization of Product
Approval and Acquisition of Facilities
Manufacturing Lead Time

Scheduling and Execution
Storage and Distribution
Measure of Exposure to Risk/Changes
Slide 8
Computer Integrated
Traditional Process of
Serial Engineering
Functions Separated
Functions Serially Executed
No Interaction
Maintenance Usually an Afterthought
Time Consuming
Costly
Product a Series of Suboptimal
Reconsiderations
Slide 9
Computer Integrated
Serial Engineering
SUPPORT??
DESIGN
Slide 10
MANUFACTURING
PLANNING
MANUFACTURING
Computer Integrated
CUSTOMER
Concurrent vs. Serial

Engineering
All Viewpoints Solicited

Interdisciplinary Teams
Life Cycle Cost Considered
Attempt to Embody Concept Early Before Committing to Detail Design
Data/Information/Knowledge Exchange
Planned and Encouraged
Cycle Time and Cost Reduced
Slide 11
Computer Integrated
A Concurrent Engineering
Model
PRODUCT
FUNCTIONAL
CONCEPT
PRODUCT
MANUFACTURING
CONCEPT
DISCIPLINE INPUTS
ENGINEERING
CONCURRENT
DESIGN
PRODUCTION
CUSTOMERS
WORKERS
PRODUCT
MAINTENENCE
CONCEPT
Slide 12
MARKETING
Computer Integrated
Virtual Concurrent
Engineering
Always a Virtual Endeavor
Groups Are Always Geographically (and
Culturally) Distributed
How Far is Too Far Apart?
Information Generated/Stored in Various

Formats and Locations
Single Plant + Customers
Multiple Plants (Same Organization) + Customers
Multiple Organizations + Customers
Slide 13
Computer Integrated
Keys to Concurrent
Engineering
Supportive Culture
Clear Understanding and
Documentation of Requirements
Technical Competence/Experiences
Technical Tool Availability (CAx Tools)
Communication Competence
Communication and Information Tool
Availability
Slide 14
Computer Integrated

Design
Concurrent
Engineering
Segment A Topic: Introduction to
Simultaneous and Asynchronous
Engineering
Lecture 3 Topic :
END OF SEGMENT

Design
Concurrent
Engineering
Lecture 3 Topic :
Computer Aided
Process Planning
Segment B Topic:
Overview
Computer Aided Process Planning
The Use of Computer To Develop and
Analyze Alternative Manufacturing
Processes
Part of Design
Slide 17
Computer Integrated
Computer Aided Process

Planning
Definition
Use of computer and information
technologies to assist in the cost effective
development and assessment of alternative
methods of production and sequences for a
specific product specification and
identification of areas for potential
improvement in specifications from the
process/manufacturing viewpoint.
Slide 18
Computer Integrated
Manufacturing Processes
Casting and Molding Processes

Forming Processes
Chip Formation Processes
Finishing Processes
Small Chip Removal Processes
Treatment (Mechanical and Chemical)
Processes
Coating Processes
Slide 19
Computer Integrated
Manufacturing Process
Review
How To Determine Process/Cost
Process To Be Used (Shape)
Process Ability to Hold Dimensional
Tolerance
Surface Finish (How Determined)
Set Up Times
Machining Parameter
Selection/Specification
Part Processing Times
Cost Optimization
Slide 20
Computer Integrated
Knowledge Requirements
for Process Planning
Manufacturing Processes/Capabilities
Design Specification/Process
Interaction
Machine Tool Options/Capabilities
Tool and Tooling Options
Capacity Availability
Real and Accounting Costs of
Manufacture
Cost - Volume Life Cycle Relationships
Computer Integrated
Slide 21
Actual Floor Operations
Types of Process Planning

Manual Process Planning
Variant Process Planning
Existing Plan Retrieval
Composite (Master) Part Plans
Generative Process Planning

Computer Generated Process Plans
Use of Artificial Intelligence
Slide 22
Computer Integrated
Manual Process Planning
Study Design and Specifications

Recall Past Relevant Experiences
Discuss Tight Specifications
Develop Alternative Process Sequences
Specification/Capabilities
Volume/Tooling/Cost Requirements
Capacity Availability
Select and Document Best Process

Implement and Monitor
Slide 23
Computer Integrated
Manual Process Planning Drawbacks

Completely Dependant on Experience of
Process Planner
Number of Alternatives Generated
Limited
Relatively Slow Process
Documentation Usually Poor
Incorporation of Past Investment in
Process Design not Assured
Slide 24
Computer Integrated
Variant Process Planning

Identify/Find Similar Parts
Compare Existing Parts with Current
Delete Unneeded Part Features in
Retrieved Part
Add Part Features/Process Not in
Retrieved Part
Add New Design into System for Later
Use
Slide 25
Computer Integrated
Variant Process Planning Retrieval Systems

System for Associating/Locating Past
Process Plans/Designs Crucial to
Success
Group Technology Based Systems
As Up Front Design Philosophy to Limit Variation
As Key to Access Previous Plans
Part Features
Process Sequence Based Systems

Problem of Pattern Recognition
Slide 26
Computer Integrated
Variant Process Planning Composite (Master) Parts

Develop Composite Part
Defines Characteristics of a Class of Parts
Contains all Possible Features that Can Be
Incorporated in the Design of Parts in this
Class
Generally Defined Parametrically
Not All CAD Systems Support Parametric Features
Manual Intervention Required in Non-Parametric
CAD Systems
Generally Assumes Infinite Capacity

Slide 27
Computer Integrated
Variant Process Planning Drawbacks

New Process Plan is Generally No Better
Than Retrieved Design
Use of Archived Plan Does Not Always
Reflect Current Situation
Part Family Formation is Natural
Fallout
No New Technologies are Considered in
Planning
Slide 28
Computer Integrated
Generative Process Planning

Part Specification (CAD Model)
Recognize Part Features From CAD
Model
Generate Feasible Methods for
Production of Part Features
Evaluate Operational Feasibility
Evaluate Economics of Alternatives
Specify Process
Regenerate Each Time Part is Produced
Slide 29
Computer Integrated
Generative Process
Planning (2)
Part Specification (CAD Model)
Must Conform to Standard
Current Standards not Unambiguous
Recognize Part Features From CAD

Model
Slide 30
Lines, Arcs => Surfaces

Surfaces => Part Features
Part Features Have Specifications
Recognize Relations Between Part Features
Computer Integrated
Generative Process
Planning (3)
Generate Feasible Methods for
Production of Part Features
All Technically Feasible Methods Considered
Alternate Sequences Considered
Evaluate Operational Feasibility

Map Technically Feasible Methods Against
Those Available to Company
Subcontracting Difficult to Incorporate
Tooling Difficult to Incorporate
Slide 31
Computer Integrated
Generative Process
Planning (4)
Evaluate Economics of Alternatives
For this Part
For this Part and Existing Similar Parts
For this Part, Existing, and Contemplated
Parts
Specify Process
Regenerate Each Time Part is Produced
Incorporates Temporal Information
Increased Variation ???
Slide 32
Computer Integrated
Generative Process
Planning - Drawbacks
Part Feature Recognition is Not a
Mature Technology
CAD Model Data Exchange (Precision,
Format)
May Depend on Missing Material
Expensive (Artificial Intelligence)

Must Be Tailored to Specific Firm
Incorporation of Proprietary Processes
Difficult
Slide 33
Computer Integrated

Design
Concurrent
Engineering
Lecture 3 Topic :
Computer Aided
Process Planning
END OF SEGMENT
Segment B Topic:

Design
Concurrent
Engineering
Lecture 3 Topic :
Segment C Topic:
Quantitative Analysis
ADVANCED
MANUFACTURING
SYSTEMS DESIGN
Slide 36
Computer Integrated
Overview
Quantitative Analysis in Concurrent
Engineering
Singhs Mathematical Model
Uses Manufacturing Method/Process
Capabilities, Tolerance Limits, Input and
Processing Costs, and Time Estimates to
Compare Alternatives
Source: Singh, Nanua, Systems Approach to Computer
Integrated Design and Manufacturing, John Wiley and
Sons, Inc., New York, New York, c1995
Slide 37
Computer Integrated
Singhs Quantitative
Analysis (Eq. 4.1, 4.2)
Tolerance
Alternatives and
Process Capabilities
Standard Normal
Variate of upper
Tolerance
Standard Normal
Variate of lower
Tolerance
Slide 38
t
t
u
k
l
k
j
j
Z ujk
Z ljk
t = tolerance limit
k= tolerance system (design alt.)
j= machining system
Computer Integrated
Singhs Quantitative
Analysis (Eq. 4.3)
i
jk
o
jk
Y ,Y ,Y
s
jk
output, input, scrap units
SCrap Fraction
SC
Slide 39
jk
Y
Y
s
jk
i
jk
( Z ) [1 ( Z )]
l
jk
Computer Integrated
u
jk
Singhs Quantitative
Analysis (Eq. 4.4)
i
jk
o
jk
Y ,Y ,Y
s
jk
Mass Balance
Y Y Y
i
jk
Slide 40
o
jk
s
jk
Computer Integrated
Singhs Quantitative
Analysis (Eq. 4.5, 4.6)
i
jk
o
jk
Y ,Y ,Y
s
jk
Technological Coefficients (input per

unit of output, scrap per unit of output)
k
i
jk
Slide 41
Y
Y
i
jk
o
jk
k
s
jk
Computer Integrated
Y
Y
s
jk
o
jk
Singhs Quantitative
Analysis (Eq. 4.7)
Combining (Percent Acceptable in
Output Stream)
k
s
jk
Y
Y
s
jk
o
jk
i
jk
SC jk
1 SC jk
o
jk
Y ,Y ,Y
Slide 42
s
jk
( Z ) [1 ( Z )]
l
jk
u
jk
( Z ) ( Z )
u
jk
l
jk
Computer Integrated
Singhs Quantitative
Analysis (Eq. 4.8)
Combining (Ratio of Input to Output
Obtained Will be >1)
i
jk
o
jk
1
k
1 k
u
l
Y
( Z jk ) ( Z jk )
i
jk
i
jk
s
jk
o
jk
Y ,Y ,Y
Slide 43
s
jk
Computer Integrated
Singhs Quantitative
Analysis (Eq. 4.4, 4.9, 4.10)
Combining to Reform Material Balance
Equations
Y Y Y
i
jk
o
jk
i
jk
o
jk
Y ,Y ,Y
Slide 44
s
jk
s
jk
Y k Y
o
jk
Y k Y
o
jk
s
jk
i
jk
s
jk
i
jk

Computer Integrated
Singhs Quantitative
Analysis (Eq. 4.11)
Cost Equation (Cost of Output and Scrap
= Cost of Input and Processing
X Y X Y X Y Y f (Y )
o
jk
o
jk
s
jk
s
jk
X ,X ,X
i
jk
o
jk
s
jk
f (Y )
i
jk
Slide 45
i
jk
i
jk
i
jk
i
jk
Unit Cost of input, output,scrap

Processing Cost per Unit
Computer Integrated
Singhs Quantitative
Analysis (Eq. 4.11)
Dividing by
o
to get output cost/unit
jk
X Y X Y
o
jk
o
jk
s
jk
Y
X
Slide 46
o
jk
s
jk
o
jk
Y
Y
i
jk
o
jk
X
i
jk
X Y Y f (Y )
i
jk
i
jk
i
jk
Y
Y
Y
s
jk
o
jk
o
jk
Computer Integrated
s
jk
i
jk
Y
Y
i
jk
o
jk
fY
i
jk
Singhs Quantitative
Analysis (Eq. 4.12)
Or, by substituting technological
factors, unit cost of output (good units)
Slide 47
o
jk
k X k X k f (Y )
i
jk
i
jk
s
jk
s
jk
Computer Integrated
i
jk
i
jk
Singhs Quantitative
Analysis (Eq. 4.13)
Developing an expression for
Manufacturing Lead Time:
Tj S j t j k Y
i
jk
o
jk
t j Processing time, j th method

S j Set-up Time
Slide 48
Computer Integrated
Using Singhs Quantitative

Analysis
Given a Set of Production Methods
With Process Capabilities,

Unit Production Cost Estimates,
Unit Production Time Estimates, and
Set up Times
and a Set of Precision Alternatives,

Assuming Precision is Relevant to Customer
Definition of Quality
Then, Quantitative Assessment Possible.

Slide 49
Computer Integrated
Problems with Singh

Quantification (1)
Product Manufacturing Centric
Viewpoint
No Design Cost Data
No Service/Maintenance Cost Data
No Value to Increase/Decrease in Lead Time
No Administrative Lead Time Factor
No Material/Capacity Lead Time
Slide 50
Computer Integrated
Problems with Singh

Quantification (2)
Product Manufacturing Centric
Viewpoint
Scrap Defined by Designer, not Customer,
no Customer Definition of Quality
No Differential Cost Savings/Cost (Serial vs.
Concurrent)
NOT AN ANALYSIS OF CONCURRENT

ENGINEERING !!! -- IT IS A
DESIGN/PROCESS COMPARISION
METHOD
Slide 51
Computer Integrated
Benefits of Quantification
Forces Focus upon Measurable Factors
To Extent These are the Right Factors,
Drives Organizations Direction
Shows Changes/Provides Basis for

Comparison of Alternatives
Slide 52
Computer Integrated
Concurrent ReEngineering
of Products
No Real Difference in Organization and
Process Execution
Only Change is Inclusion of Existing
Plant and Facilities
Cost (Current) Known, Not Estimated
Slide 53
Computer Integrated

Design
Concurrent
Engineering
Lecture 3 Topic :
Segment C Topic:
END OF SEGMENT

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Advanced Manufacturing Systems

2000 John W. Nazemetz

2000 John W. Nazemetz

Systems which enable the integrated,

2000 John W. Nazemetz

Concurrent Engineering -Definition

2000 John W. Nazemetz

Concurrent Engineering Definition Problems

2000 John W. Nazemetz

2000 John W. Nazemetz

Manufacturing Lead Time

2000 John W. Nazemetz

2000 John W. Nazemetz

Concurrent vs. Serial

All Viewpoints Solicited

2000 John W. Nazemetz

2000 John W. Nazemetz

Information Generated/Stored in Various

2000 John W. Nazemetz

2000 John W. Nazemetz

Advanced Manufacturing Systems

Advanced Manufacturing Systems

2000 John W. Nazemetz

Computer Aided Process

2000 John W. Nazemetz

Casting and Molding Processes

2000 John W. Nazemetz

2000 John W. Nazemetz

Types of Process Planning

Generative Process Planning

2000 John W. Nazemetz

Manual Process Planning

Study Design and Specifications

Select and Document Best Process

2000 John W. Nazemetz

Manual Process Planning Drawbacks

2000 John W. Nazemetz

Variant Process Planning

2000 John W. Nazemetz

Variant Process Planning Retrieval Systems

Process Sequence Based Systems

2000 John W. Nazemetz

Variant Process Planning Composite (Master) Parts

Generally Assumes Infinite Capacity

2000 John W. Nazemetz

Variant Process Planning Drawbacks

2000 John W. Nazemetz

Generative Process Planning

2000 John W. Nazemetz

Recognize Part Features From CAD

Lines, Arcs => Surfaces

2000 John W. Nazemetz

Evaluate Operational Feasibility

2000 John W. Nazemetz

2000 John W. Nazemetz

Expensive (Artificial Intelligence)

2000 John W. Nazemetz

Advanced Manufacturing Systems

Advanced Manufacturing Systems

2000 John W. Nazemetz

2000 John W. Nazemetz

2000 John W. Nazemetz

output, input, scrap units