Computer-integrated-manufacturing Rules of elimination Design process Concurrent engineering Design Automation Design for manufacturing and assembly Just-in-time manucfacturing seven wastes Flexible manufacturing systems Quality: six sigma design Reference
The fundamental goal of manufacturing is to use these activities to convert raw materials into finished goods on a profitable basis.
A manufacturing strategy is a plan or process that forces congruence between the corporate objectives and the marketing goals and production capability of a company.
<fig 1-4 p.11 order-winning criteria model>
<fig 1-6 p. 14 manufacturing standards>
Solution
world-class measures
<fig 1-8 p.23 manufacturing enterprise wheel>
CIM process
step 1 Assesment of the enterprise in : technology, human resources,
systems.
step 2 Elimination of waste
step 3 Implement with performance measure (7 measures above)
Example
Performance report card case history
baseline 6 months 18 months
cycle time
18 weeks 6 weeks 1 week
inventory turns
4 8
48
quality (finished part) 85%
95% 99.8%
floor space
800 ft2 400 ft2 89 ft2
<fig 2-13 p.61 production sequence>
benefit
<fig 2-15 p.67 enterprise improvement>
- form
- fit (marketing fit)
- function
concept design is the application of the design process for the creation of a new product that is unique, with no similarity to any product currently produced.
Synthesis
- design enrichment
- design for assembly
- design for manufacturing
<fig 3-13 p.84 traditional product development process>
<fig 3-15 p.86 concurrent engineering >
Production engineering
1 process planning
2 production machine programming
3 tool and fixture engineering
4 work and production standards
5 plant engineering
6 analysis for manufacturability and assembly
7 manufacturing cost estimating
<fig 3-16 p.90 process planning>
<fig 3-17 p.91-92 manufacturing processes>
Ten guidelines for design for assembly (Welter 1989)
Design analysis
- static
- dynamic
- natural frequency
- heat transfer
- motion
- fluid
Design verification
- dimensioning, tolerancing
Tolerance analysis
Process planning
<fig 5-23 p.167 example of process planning>
<fig 5-25-26 p.170 process planning system>
<fig 5-33 p.177 APT program>
<fig 5-38 p. 187 enterprise network>
inventory management
product data management: bill of materials
<fig 7-12 p.240 BOM>
<case study production systems ford + toyota p.256>
- have only the required inventory when needed
- zero defects
- reduce lead times by: reducing setup times, queue lengths, lot sizes.
- revise incrementally the operations
- accomplish these activities at minimum cost.
zero-inventory manufacturing
MRP pushes, JIT pulls
<fig 10-22 p. 369 FMS>
Five levels of technology in FMS
1 enterprise : scheduling
2 system
3 cell : machine cells, tool gauge, load/unload etc.
4 machine : CNC, testing machines
4 device : motors, sensors
Fixed high volume production
<fig 10-26 p.377-378 rear-axle production line>
automated warehousing
<fig 12-2 p.429 cell controller>
work-cell management software
- product monitoring
- process monitoring
- equipment monitoring
- program distribution
- alert and alarm management
- statictical quality and process control
- data and event logger
- work dispatching and scheduling
- tool tracking and control
- inventory tracking and management
- report generator on cell activity
- problem determination
- operator support
- off-line programming
Manufacturing message specification (MMS ISO standard 9506)
Programmable logic controllers (PLC)
<fig 12-12 p.442 PLC>
<fig 12-16 p.447 PLC programming>
proces variance +- 3 sigma
99.74 % of all production falls +- 3 sigma
(0.26 % lies outside)
if +- 1.5 sigma, 0.62% lies outside
1 million parts defects 6200
+- 5 sigma defects 200 parts per million
+- 6 sigma, near zero defect, a shift of +- 1.5 sigma on critical spec. yields 3.4 defects per million.
The basis for six sigma design is a focuses effort on making the maximum
limits on critical dimensional tolerance of parts twice the width of process
variability.