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Part VI MANUFACTURING SUPPORT SYSTEMS

Chapters:23. Product Design and CAD/CAM in the Production System24. Process Planning and Concurrent Engineering25. Production Planning and Control Systems26. Just-In-Time and Lean Production

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Manufacturing Support Systems in the Production System

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Ch 23 Product Design and CAD/CAM in the Production System

Sections:1. Product Design and CAD2. CAD System Hardware3. CAM, CAD/CAM, and CIM4. Quality Function Deployment

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Manufacturing Support Systems

The procedures and systems used by a firm to manage its production operations and solve the technical and logistics problems associated with:

Designing the products, Planning the processes, Ordering materials, Controlling work-in-process as it moves through the plant, and Delivering quality products to customers

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The Design Process

The general process of design is characterized as an iterative process consisting of six phases:

1. Recognition of need - someone recognizes the need that can be satisfied by a new design

2. Problem definition - specification of the item 3. Synthesis - creation and conceptualization 4. Analysis and optimization - the concept is analyzed and

redesigned5. Evaluation - compare design against original specification6. Presentation - documenting the design (e.g., drawings)

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The Design Process

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Computer-Aided Design (CAD)

Any design activity that involves the effective use of the computer to create, modify, analyze, or document an engineering designCommonly associated with the use of an interactive computer graphics system, referred to as a CAD systemThe term CAD/CAM is also used if the computer system supports manufacturing applications as well as design applications

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Reasons for Using a CAD System

To increase the productivity of the designerTo expand the available geometric forms in design - wider range of mathematically defined shapes possibleTo improve the quality of the design - more engineering analysis possible, consideration of more alternativesTo improve design documentation - better drawings than with manual draftingTo create a manufacturing database - creation of the design documentation also creates manufacturing dataTo promote design standardization - use of design rules to limit the number of hole sizes, fasteners, etc.

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The Design Process Using CAD

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How a CAD System is Used in Product Design (Steps 3 - 6)

3. Geometric modelingCAD system develops a mathematical description of the geometry of an object, called a geometric model

4. Engineering analysisMass properties, interference checking for assemblies, finite element modeling, kinematicanalysis for mechanisms

5. Design evaluation and reviewAutomatic dimensioning, error checking, animation

6. Automated draftingPreparation of engineering drawings quickly

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Geometric Models in CAD

Wire-frame model

Solid model

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CAD System Hardware

The hardware for a typical CAD system consists of the following components:

1. One of more design workstations2. Digital computer3. Plotters, printers, and other output devices4. Storage devices

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Typical CAD System Configuration

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Design Workstations

The interface between the computer and the user in the CAD systemFunctions:1. Communicate with the CPU2. Continuously generate a graphical image3. Provide digital descriptions of the image4. Translate user commands into operating functions5. Facilitate interaction between the user and the system

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CAD System Configurations

1. Host and terminalMainframe serves as host for graphics terminalsThe original configuration in the 1970s and 1980s when CAD technology was first developing

2. Engineering workstationStand-alone computer system dedicated to one user Often networked for sharing data and plotters

3. CAD system based on a personal computerPC with high-performance CPU and high resolution graphics display monitor

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Host and Terminal Configuration

Original CAD system configuration in 1970s and 1980sHost computer is a mainframe or large mini computer

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Engineering Workstation Configuration

An engineering workstation is a stand-alone computer system dedicated to one user and capable of executing graphics software and other programs requiring high-speed computational power

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CAD System based on a PC

This is a personal computer with a high-performance CPU and high resolution graphics display screenPC-based CAD systems can be networked (as shown) to share files, output devices, and for other purposes

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Computer-Aided Manufacturing

The effective use of computer technology in manufacturing planning and controlMost closely associated with functions in manufacturing engineering, such as process planning and NC part programmingCAM applications can be divided into two broad categories:1. Manufacturing planning2. Manufacturing control

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CAM Applications in Manufacturing Planning

Computer-aided process planning (CAPP)Computer-assisted NC part programmingCAD/CAM assisted NC part programmingComputerized machinability data systemsComputerized work standardsCost estimatingProduction and inventory planningComputer-aided assembly line balancing

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CAM Applications in Manufacturing Control

Process monitoring and controlQuality controlShop floor controlInventory controlJust-in-time production systems

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CAD/CAM

Concerned with the engineering functions in both design and manufacturingDenotes an integration of design and manufacturing activities by means of computer systems

Goal is to not only automate certain phases of design and certain phases of manufacturing, but to also automate the transition from design to manufacturingIn the ideal CAD/CAM system, the product design specification residing in the CAD data base would be automatically converted into the process plan for making the product

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Computer Integrated Manufacturing

Includes all of the engineering functions of CAD/CAMAlso includes the firm's business functions that are related to manufacturingIdeal CIM system applies computer and communications technology to all of the operational functions and information processing functions in manufacturing

From order receipt, Through design and production, To product shipment

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The Scope of CAD/CAM and CIM

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Computerized Elements of a CIM System

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Quality Function Deployment

A systematic procedure for defining customer desires and requirements and interpreting them in terms of product features and process characteristicsA series of interconnected matrices are established between customer requirements and the technical features of a proposed new product

The matrices are a progression of phases in which customer requirements are first translated into product features, then into manufacturing requirements, and finally into quality procedures for controlling the manufacturing operations

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Quality Function Deployment

Shown as a series of matrices that relate customer requirements to successive technical requirements in a typical progression

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The Starting Matrix: The House of Quality

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Steps in QFD: The House of Quality

1. Identify customer requirements2. Identify product features needed to meet customer

requirements3. Determine technical correlations among product features4. Develop relationship matrix between customer

requirements and product features5. Comparative evaluation of input customer requirements6. Comparative evaluation of output technical requirements