Bai Giang FMS & CIM - Chuong 1

7/25/2019 Bai Giang FMS & CIM - Chuong 1

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HC VIN K THUT QUN S

KHOA HNG KHNG V TR

BI GiNG MN HC

H THNG SN XUT LINH HOT

TS. Trn c Tng

B mn CNTB & HKVTin thoi: 0973 991486

Email: [email protected]

TS. Trn c Tng Khoa HKVT

5. Xu hng linh hot ha QTSX

4. M hnh, cu trc ca HTSX

2. Lch s pht trin ca cc HTSX

Ni dung

3. Vai tr ca my tnh trong SX

1. Khi nim cbn v QTSX

Chng 1: Cc khi nim c bn v FMS

6. H thng sn xut linh hot FMS

7. H thng sn xut tch hp CIM


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1. Khi nim c bn v qu trnh SX

Qu trnh sx l qu trnh mcon ngi, bng tr lc v vt lc

ca mnh, thng qua cc cng c sx, tc ng ln i tngsx, thay i cc thuc tnh ca n bin n thnh sn phm,tha mn yu cu tiu dng ca x hi.

- Hot ng sn xut chduy nht c con ngi.

- Trong hot ng sx, con ngi phi vn dng tr lc v vt lc

- Cng c sx l khu trung gian truyn tc ng ca con ngiln i tng. Trnh ca cng c sx phn nh trnh casx: lao ng th cng, cgii ha hay t ng ha.


- Hiu qu ca sx c gi l cao nu nhvi mt chi ph nhtnh cho sx m nhn c sn phm c gi tr cao, hay nhnc sn phm c gi tr nht nh vi chi ph sx thp.

Vai tr ca cng c sn xut, trnh v tnh cht ca cng csn xut quyt nh trnh v tnh cht ca qu trnh snxut, cn c vo ngi ta phn bit cc dng sn xut.Dng sn xut tin tin hin nay: FMS (Flexible ManufacturingSystems), CIM (Computer Integrated Manufacturing)


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2. Lch s pht trin ca cc HTSX

SX cng nghip tri qua cc giai on:

- SX th cng

- Ckh ha

- T ng ha

- v tip theo lgiai on ca s tch hp cc qu trnh sx t ng.

S tch hp ca cng ngh t ng c bit n vi tn gi SXtch hp my tnh (Computer Integrated Manufacturing-CIM).

S tch hp cho php t chc dng thng tin v vt liu tt hn.Mc ch chnh l loi b bottle-necks, bng vic khai thc tthn kh nng ca nh my. Mt phn ca khi nim CIM l ngdng ca cng ngh sn xut linh hot FMS.

Khi nim v FMS c a ra bi Williamson ti London nm1960s. H thng ny lc u c gi l H thng 24, v nclp hot ng 24h/ngy di s iu khin ca my tnh.


Lch s pht trin ca cc HTSX

1700s

1800s

1900s

SX th cng

Ckh ha

T ng ha

Transistor, Mch tch hp,My tnh s, My vi tnh

Cc my CNC, robot, my tnh c lp

Networks

S tch hp ca cc phn xng

2000s

Cc t bo SX


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S pht trin ca cng ngh sx

Sc lao ng ca con ngi vng vtNgh th cng

Ckh ha cc nh my u tin

Sn xut hng khi (s lng trung bnh)

Sn xut hng khi (s lng ln)

Bt u pht trin NC (Numerical Control) t ng ha

Bt u pht trin CAD trong NC nh: CNC, DNC

Pht trin CAD, CAM, khi nim v CIM

Cc h thng CIM tin tin: CAD, CAPP, FMS, . . .

Khi nim v CIM lin kt ton cu1997

1990

1980

1970

1955

1950

1930

1900

1750

1600

SX ton cu trn cs CIM lin kt ton cu


3. Vai tr ca my tnh trong sn xut

My tnh c nh hng rt ln n tt c cc hot ng camt nh my. Trong mt nh my hin i, mi qu trnh, mib phn c tch hp thnh mt h thng di s iu khinca my tnh (CIM).

So vi cng ngh truyn thng CIM c th:- Gim 15-30% gi thnh thit k- Gim 30-60% thi gian ch to chi tit- Tng nng xut 40-70%- Nng cao cht lng sn phm, gim ph liu 20-25%

- Nng cao cht lng thit k Cng da vo s tch hp my tnh vo HTSX, quan nim v

CIM vquan im ng dng CIM cc nc c s khcnhau:


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- Cc nc chu u c kinh nghim v cng ngh truyn thng

v SXLH, ci ng k thut c o to tt,Do vy, ccnc chu u nhn mnh vai tr ca cc h thng SXLH, tchhp kinh nghim qun l, k thut, th lnh ngh vo CIM

- Cc cng ty Nht nhn mnh sn lng, quan tm nhiu sxsn lng sn phm ln trong thi gian ngn. V vy u tins dng cc thit b kh trnh, cc trung tm gia cng linhhot,

- Cc c.ty M quan tm nhiu n tnh n nh ca sx,quan tmn vn ca cc c.ty u tvo thit b, hn ch s dnglao ng r tin. Chnh sch ca M l cung cp thit b vdng c thay cho con ngi trong h thng CIM


4. M hnh, cu trc ca HTSX

4.1 M hnh sn xut hin i- c trng cbn ca mt nh my hin i l s dng my tnh

trong mi hot ng k thut, sx v kinh doanh: thit k, lp khoch,iu hnh, gim st,iu khin thit b,


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H thng trn gm:

- 3 thit b gia cng, 1 Robot lp rp, 1 trm kim tra

- u vo c mt kho vt liu

- u ra c kho thnh phm

- Mt xe t hnh (AGV) lm nhim v vn chuyn vt liu vbn thnh phm

- H c tch hp vi mt h thng my tnh c ni mng,gip cc cng vic t k thut, k hoch,iu , gim st ntrc tip iu khin cc thit b.

- Phn mm gm c mt h thng CSDL (d liu v phng

php, ch CN, ngun lc cho sx, yu cu v cht lng vs lng sn phm)


Cc chc nng chnh ca HTSX


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Hot ng ca mi chc nngnhsau:

- Thng tin vo c cha trong b

m (buffer)

- Khi c tn hiu vo h thng gi lnh

start n im quyt nh 1 kch hot h thng,ng thi

gi tn hiu phn hi v trung tm bo thit b sn sng

- Khi thc hin xong,thng tin c gi n im quyt nh 2

kch hot chc nng tip theo

- Thng tin c x l c cha trong b m ra- Qu trnh x l vt liu cng xy ra theo cch tng t


V d:

- Gi s mt quy trnh gia cng tin

v vt liu th c a n u

vo buffer.

- H thng gi mt tn hiu start ti

im quyt nh 1

- Mt tn hiu phn hi t my cng c bo my sn sngcho gia cng

- Phi c gi sang my gia cng

- Khi gia cng hon tt, mt tn hiu c to im quyt nh2 bo cho h thng l chi tit c gia cng xong.

- Thng tin ny c s dng chuyn chi tit ra buffer ura.


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4.2 Cc thnh phn ca CIM

CAD: s dng my tnh trgip cng vic thit k, tnh

ton k thut

CAPP: s dng my tnh trongvic thit k qu trnh cngngh ch to sn phm (chunb cng ngh)

CAM: s dng my tr giptrong qu trnh sx: to chngtrnh gia cng,iu khin hthng sx, h thng m bovt tthit b

CAQ: s dng my tnh trong

cng tc m bo, qun l chtlng sn phm

PP&C: bao gm kha cnh t chc caCIM, nhk hoch ha ngun lc

(MRPI), k hoch ha cung ng vt t(MRPII), k hoch tin , x l nhng,iu hnh sx.


4.3 Cu trc theo chc nng ca HTSX

Xt theo chc nng, cc thnh phn ca mt HTSX c th cchia thnh 2 nhm:

- Nhm t chc sn xut, gm cc chc nng:

Nhn, lp k hoch thc hin viu khin sx theo n hng. MtCSDL trung tm cha d liu v s l n hng, cc know-howcng ngh

- Nhm k thut v sn xut, c cc chc nng: pht trin snphm, thit k, cng ngh, v.v

- Hai nhm ny c lin h mt thit vi nhau m bo cc chtiukinh t, k thut ca c qu trnh.

- Vng logistics biu din hng dch chuyn ca lung thng tin vvt liu trong sx theo kha cnh kinh t-t chc sx (theo phngngang) v k thut-sx (theo phng dc)

- Vng kim sot cht lng biu din chc nng kim sot chtlng trong qu trnh thit k v sx.


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Cu trc theo chc nng ca HTSX


4.4 Cu trc theo th bc ca HTSX

HTSX, kinh doanhcu doanh nghipc b tr theoth bc.

Cao nht l xnghip.

Tip theo l cccp: sx, phnxng, thit b.

Mi cp c hthng my tnhring v gia cccp l h thngmng truynthng


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Cu trc theo th bc ca HTSX

Cp x nghip: tp trung cc chc nng

- Pht trin sn phm (thit k, chun b cng ngh, lp khoch cht lng sn phm)

- K hoch sx (lp danh mc sn phm, k hoch cung ng,.)

- Kinh doanh (hch ton, tiu th sn phm,)

- cp ny my tnh s l lng thng tin ln trong cc CSDLtrung tm. Mng my tnh c t chc theo din rng (WideArea Network-WAN).

Cp sn xut: thc hin mi cng vic trc tip to ra snphm.

- Cc nhu cu v thit b chnh (my cng c, t bo sx,); thitb vn chuyn v dng c c xc nh v gim st


- Cc my tnh m bo chc nng qun l khu vc viukhin ton b cc h thng thit b sx v l my ch trong ccmng cc b ca cc phn xng.

- QTSX c chia nh, thc hin ni tip hoc song song vphn phi cho cc phn xng.

Cp phn xng:- m bo gim st viu khin sx trong cc phn xng

ring bit.- Thng tin cp ny c x l theo thi gian thc.

Cp iu khin thit b:- C chc nng gim st viu khin cc thit b ring l- Cc my tnh l cc microcomputer, cung cp chng trnh

hoc cc thng s cng ngh


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5. Xu hng linh hot ha QTSX

5.1 Cc dng t chc SXCc HTSX hin i c th c phn thnh 5 dng, ty theo

tnh linh hot ca chng


My CNC:- L thit b linh hot nht. Khi cn thay i sn phm chcn

t cc tham s ca phi, thay dao v np chng trnh mi.- Vi cc tin ch lp trnh ngy cng phong ph, cc cng c

tr gip lp trnh CAD/CAM, to cho my CNC c kh nngthch ng rt linh hot vi s thay i sn phm.

T bo sx- L mt nhm thit b, gm vi my CNC hoc mt vi trung

tm gia cng CNC, c nhim v gia cng mt nhm sn phmnht nh.- Cc trung tm gia cng thng c nhiu trc, c cc h thng

cp phi v thay dao t ng nn c th gia cng cc chi titphc tp, nng sut cao, t i hi s can thip ca con ngi.


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V d: trung tm gia cng CNC 5-trc


H thng sn xut linh hot

- Gm c mt s my CNC c b tr theo trnh t cng nghv lin kt vi nhau bng cc thit b vn chuyn.

- Ngoi cc thit b ging nht bo sx, trong FMS cn c mytnh trung tm iu phi hot ng ca ton h thng.

- Nu mt FMS c kh nng ng thi gia cng mt nhm(batch) sn phm th ncn c gi l dy chuyn nhm.

Dy chuyn sx

- L dng t chc sx cng nht.

- Gm cc thit b (ch yu l chuyn dng),c b tr chtch theo tin trnh cng ngh, lin kt vi nhau bng 1 hthng thit b vn chuyn lin hon.


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- Cc nguyn cng cng ngh c thit k cht ch khng chtheo ni dung m c theo thi gian,m bo nhp sx.

- Dy chuyn sx cho nng xut cao, cht lng sn phm nnh

- Tuy nhin n khng c kh nng thch ng vi s thay i casn phm. Khi thay i sn phm th phi thit k, lp t lidy chuyn


5.2 Nhu cu p dng SXLH

- Dy chuyn cng tuy m bo cht lng tt v gi thnhthp nhng khng p ng c nhu cu ca th trng. Doth hiu ca ngi tiu dng thay i nhanh, khin cho chu ktn ti ca sn phm ngn i. Ngha l s loi sn phm tngv s lng mi loi gim.

- Do vy, nhu cu v dng sn xut linh hot ngy cng tng.

Tnh kinh t- Gim thi gian chun b mi khi chuyn sang loi sn phm

mi

- Nng sut gia cng cao nh gim thiu thi gian my- Gim chi phlng cng nhn do khng i hi tay ngh cao.

Cht lng sn phmc m bo bi- Cng ngh n nh- T ng ha gia cng v lp rp


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- T ng ha vn chuyn v cung cp vt liu- T ng ha kim tra cht lng gia cc giai on- S dng cc dng c, g tiu chun- Hn ch cc cng vic i hi s can thip trc tip ca con

ngi

Tnh linh hot- H thng c th p ng cc n hng nhanh vi s lng

khc nhau.- H thng d dng thch ng vi s thay i phng n sn

phm v nhng yu cu ca khch hng mi hi t s thayi g, dng c, chng trnh

- H thng d dng nng cp p ng s tng sn phm hocthay i cng ngh.


6. HTSX linh hot (FMS)

6.1 M t vnh ngha v FMS

nh ngha v FMS tng i phong ph v trong nhiu khacnh n ph thuc vo quan im ca ngi s dng, nh:FMS bao gm ci g v n s c s dng nhth no?

- FMS gm mt lot cc my cng c t ng hay cc thit b sxkt ni cng nhau cng vi mt h thng vn chuyn vt liu,h thng my tnh iu khin

- FMS gm mt nhm my NC c th sn xut mt nhm sn

phm, c h thng cp vt liu t ng v my tnh iu khintrung tm cn bng vic khai thc ngun lc, gip h thng cth thch nghi t ng vi s thay i cc chi tit sx v khilng sn phm


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- FMS l mt h thng t ng da trn cng ngh nhm, linkt vi iu khin tch hp my tnh v mt nhm my sx

v vn chuyn cc chi tit t ng cho vic gia cng lin hon.

- Mt cng ngh gip cc nh my t c thi gian yu cu

ca khch hng tt hn, gi thnh sn phm thp hn, v cht

lng cao hn do s pht trin qun l viu khin ngun

lc

- Theo quan im t ng ha: Mt h thng sx linh hot l mt

dng ca t ng ha linh hot trong mt s my cng c

c lin kt cng nhau bi h thng vn chuyn vt liu, v

tt c cc b phn ca h thng c iu khin bi mt my

tnh trung tm


- Da trn quan im v my cng c: mt nhm t bo sx linkt bi mt h thng vn chuyn vt liu v mt my tnh trungtm c gi l mt h thng sx linh hot. Vic kt hp viu khin my tnh lm cho cc sn phm c sx vi githnh c khi chsx vi khi lng nh

Mt h thng FMS tht s c kh nng x l vi nhiu chngloi sn phm khc nhau, khi cn thit c th sn xut bt kmt sn phm no trong s chng, khng theo th t.


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p ng yu cu trn, FMS cn c mt s kiu linh hot:

N cn linh hot p ng s thay i v khi lng sx vs thay i sn phm, nhn cc sn phm mi, v thch ngvi s thay i v cng ngh v thit k.

FMS cng i hi s linh hot trong vic x l cc tnh hungkhng c d bo trc nhvn thi gian hng my,thay i k hoch t xut, kh nng pht trin khi m rng hthng.



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6.2 Cu trc ca FMS

V c bn, FMS c to bi cc phn t phn cng v phnmm

- Cc phn t phn cng l xc thc v c th nhn thy c,nhcc my CNC, thit b vn chuyn vt liu (robot hay xe thnh), h thng dao c, my o ta , trm lm sch chi tit,thit b phn cng my tnh.

- Cc phn t phn mm khng hin hu v s c, nhccchng trnh NC, phn mm qun l v s lu thng, thng tinv dao, file th t lm vic ca my CMM,

Theo cu trc th FMS l mt t hp ca t bo gia cng tng v t bo kim tra t ng,c lin kt vi nhau thnhmt h thng nht, theo dng vt liu vi s tr gip ca h

thng vn chuyn phi t ng viu khin nh mng mytnh


6.3 Phn loi FMS

Da vo kinh nghim ng dng FMS cc nc ngi taphn FMS ra 3 loi:

Loi 1: khng ph thuc vo dng vt liu ca t bo gia cngt ng (ng ngha vi m un t ng)

- Loi ny c cu to t cc my vn nng vi iu khintheo chng trnh s, cho php lin kt vi my tnh iukhin.

- FMS loi 1c s dng trong nhng trng hp m chi titc thi gian gia cng ln (qu trnh gia cng c tp trungtrn mt my)


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Loi 2: Gm cc t bo gia cng t ng vn nng c iukhin t mng my tnh v h thng vn chuyn phi t ng.

- Trong FMS loi 2 cc chi tit cng loi c th c gia cngtheo nhiu tin trnh cng ngh khc nhau trn mt t bo giacng t ng (m un sx t ng).

- FMS loi 2c s dng rng ri trong nhng trng hp khichi tit c thi gian gia cng khng ln

Loi 3: l dy chuyn t ng linh hot. Trong FMS loi nymi nguyn cng c thc hin chtrn mt my

- H thng vn chuyn phi m bo tin trnh cng cho mi chi

tit vthng thng nc thc hin di dng bng tihay my qua vng.


Ngoi ra ngi ta cn phn kiu FMS ra:

- FMS tun t: sx tng lot chi tit sau lp k hoch vchun b cho sx lot tip theo (ging nhdy chuyn sx linhhot lot nh)

- FMS ngu nhin: SX bt k mt chi tit no mt thi gian.

- FMS m un: cho php ngi s dng m rng ra cc loitrn.


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6.4 S cn thit ca FMS

Mc tiu chnh trong sx l my nhn c vt liu hoc chi titng thi gian. Qu nhiu hoc qu sm to s ng. Qu

t hoc qu chm gy ra s chm tr tin v my khnghot ng. Kt qu trong nhiu trng hp l s dng khnght kh nng khai thc ca thit b.



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Gii php FMS

FMS gip qun l viu khin cc nhn t kh kim sottrong khi vn p ng yu cu ca khch hng bng cch:

Nng cao iu khin sn xut qua:

- Gim s thay i kh kim sot

- Trang b cc phng tin nhn bit v s l nhanh vinhng sai lch trong k hoch sn xut

- Gim s ph thuc vo con ngi

Gim lao ng trc tip qua:

- Gim s vn hnh ca cng nhn

- Loi b s ph thuc vo k nng ca th my


Nng cao vic sl vi

- Nhng thay i v k thut- Thi gian dng my- Li dao- Vn chuyn vn liu chm

Nng cao s thch nghi qua s ng b ha nhanh v d dngvi khi lng sn phm thay i, v thm sn phm mi

Tng kh nng khai thc my qua vic loi b thi gian setupmy, khai thc cc tnh nng t ng thay th s can thipbng tay


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6.4 ng dng ca FMS

FMS c p chnh trong cc lnh vc sn xut sau:

- Gia cng ct kim loi- To hnh kim loi

- Lp rp

- Hn

- X l b mt

- Kim tra

- Kim nghim

Trong

cng ngh FMS

c s

d

ng ph

bin nh

t ltrong gia cng ct kim loi


7. HTSX tch hp (CIM)

7.1 Cc nh ngha v CIM

CIM l gii php ng dng cc my tnh v mng lin kt chuyncc cng ngh ring l thnh cc h thng sx tch hp trnh cao. C nhiu nh ngha v CIM, ty thuc vo mc ch ng dngca n:

- Theo hi ca nhng nh sx- SME (Society of ManufacturingEngineers): CIM l mt h thng tch hp c kh nng cung cp str gip ca my tnh cho tt c cc chc nng thng mi, baogm cc hot ng t khu tip nhn n hng cho n cung cpsn phm ca mt nh my sx.

- Theo t in cng ngh tin tin: CIM l mt nh my t ng haton phn, ni m tt c cc qu trnh sx c tch hp vciu khin ca my tnh.


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- Theo nh ngha ca cng ty my tnh IBM: CIM l mt ngdng, c kh nng cung cp cs nhn thc cho vic tchhp dng thng tin ca thit k sn phm, ca k hoch sx,ca vic thit lp viu khin cc nguyn cng

- Theo hng SEMENS: CIM khng phi l mt sn phm honthin m l mt chin lc v l mt khi nim t cc mcch th trng ca mt nh my.

Mc ch ca CIM ltng li nhun ca nhsx. tng linhun cc nh sx phi ko ngng nng cao nng sut v chtlng sn phm,ng thi phi tng tnh linh hot ca HTSX

nh cng ngh tin tin ca CIM.


CIM cu im:- Tnh linh hot ca sn phm v ca sn lng- Nng cao nng sut v cht lng gia cng- Hon thin giao din gia thit k v sx- Gim lao ng trc tip vlao ng gin tip- Thit k cnng sut v chnh xc cao- Tiu chun ha cao- Tit kim thi gian v mt bng sx

- To cs d liu chung loi tr cc b phn cha d liuc lp.- Loi tr cc cng vic lp li khng cn thit- Gim thi gian gim st sx v s cn b thc hin cng vic

ny


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7.2 Cc thnh phn ca CIM


Phm vi ca CAD/CAM v CIM

CIM bao gm tt c ccchc nng cng ngh caCAD/CAM cng nhhotng kinh doanh ca cngty.

Mt h thng CIM l tngthng p dng cng nghmy tnh vo tt c cchot ng sn xut v x

l thng tin trong sn xut,t nhn n hng, thit kv sn xut n vnchuyn hng ha v h trsau bn hng.


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Cc phn t t ng ha ca h CIM


7.3 Xu hng pht trin ca CIM

C2 hng tip cn CIM: tip cn trn xung (top - down)hoc di ln (bottom-up)

Tip cn trn xung

u im:

- Cu trc h thng (cc loi m un, quan h th bc gia ccm un v dng thng tin qua chng) c th c xc nhmt cch cht ch

- S dng tt hn cc phn mm tiu chun

- Vic thit lp cc m un theo th bc t trn xung lm chovic kim tra tng cp mt cch d dng (nh m phng)trc khi chuyn xung cp sau


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Nhc im:

- Thng cc m un c mua t bn ngoi nn c th kohon ton ph hp vi trnh qun l v sx hin ti

- Gy khkhn cho vic nng cp trong tng lai

Tip cn di ln

u im:

- Cc m un c th xy dng ng thi v vn hnh c lpvi nhau, v vy thi gian c th c rt ngn

- Nu iu kin ti chnh khng cho php th c th hin i hatng phn ca h thng.

Nhc im:- Khm bo s ng b ca phn cng v phn mm


Cng c th tip cn CIM t cc nhn t ring bit:

- Xut pht tCAM: do cc nh cng ngh tin hnh, nhm tng ha qu trnh sx, vn chuyn, kho tng, kim tra

- Xut pht tPP&C(Production Planning & Control): Gii phpny xut pht t pha t chc vi mc tiu ci thin cng tck hoch ha,iu sx, ci thin cc chtiu kinh t: gim

th

i gian chun b

sx, ho

ch

nh h

p l lo

t s

n ph

m, gi

mchu k sx v sn phm tn trong phn xng.


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- Xut pht tCAD/CAM: l s ng dng ng b cc phn

h CAD, CAM, CAQ. Gii php ny khc phc tnh trng mtng b, trng lp cc yu t k thut.

- Gii php CIM: l kt hp gia CAD/CAM v PP&C, c th btu bng tch hp cc cng on c t ng ha vimng truyn thng vc s d liu trung tm.

Bai Giang FMS & CIM - Chuong 1

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Transcript of Bai Giang FMS & CIM - Chuong 1