Capc & computer monitoring
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Transcript of Capc & computer monitoring
ME 2402 – COMPUTER INTEGRATED MANUFACTURING (CIM)
YEAR/SEMESTER : IV/VII
UNIT V COMPUTER AIDED PLANNING AND CONTROL AND COMPUTER MONITORING
Prepared By MANIMARAN.MASSISTANT PROFESSORK.RAMAKRISHNAN COLLEGE OF ENGINEERINGTRICHY 05/01/2023 1
MANIMARAN M 8115 KRCE TRICHY
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UNIT V COMPUTER AIDED PLANNING AND CONTROL AND COMPUTER MONITORING
Production planning and control – cost planning and control – inventory management – material requirements planning (MRP) – shop floor control. Lean and Agile Manufacturing. Types of production monitoring systems – structure model of manufacturing – process control and strategies – direct digital control
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Production planning and control (PPC)It may be defined as the direction and coordination of firm’s material and physical facilities towards the attainment of pre-specified production of goods with highest production of efficiency
PPC = production planning +production control
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Production planning It is a pre-production activity. It is defined as the determination, acquisition and arrangement of all facilities necessary for future production of products
Activities of production planning • Aggregate production planning • Master production planning • Master requirements planning • Capacity planning
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Production control It is concerned with determining whether the necessary resources to implement the production plan have been provided or not
Activities of production control• Shop floor control • Inventory control • Manufacturing resource planning (MRP II)• Just in time (JIT) production system
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ACTIVITIES IN A PPC (FUNCTIONS OF PPC)Aggregate production planning
• Aggregate planning is a high-level corporate planning activity.
• Aggregate planning plan must be coordinated with the plans of
the sales and marketing departments. (inventory, employment
and subcontracting)
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ACTIVITIES OF PPCMASTER PRODUCTION SCHEDULE
• Aggregate production planning must be converted into master
production schedule (MPS)
• It is a listing of the products to be manufactured, when they are
to be delivered, and in what quantities
• It is developed from customer order and forecasts of the future
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ACTIVITIES OF PPCMATERIAL REQUIREMENT PLANNING • Material requirements planning (MRP) is a computational technique
that converts the master schedule for final products into a detailed schedule for the raw materials and components used in the final products.
CAPACITY PLANNING • Capacity planning is concerned with determining what labor and
equipment resources are required to meet the current MPS as well as long-term future production.
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ACTIVITIES OF PPCSHOP FLOOR CONTROL A shop floor control system is defined as a system for utilizing data from as well as data processing files to maintain and communicate information on shop orders and work centers. It also known as Production Activity Control (PAC).INVENTORY CONTROL
• Minimize the cost of holding inventory( investment, storage and spoilage )
• Maximize customers service.
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ACTIVITIES OF PPCMANUFACTURING RESOURCE PLANNING (MRP II)
• It combines MRP and capacity planning as well as shop floor control and other functions
related to PPC
• It can be defined as a computer-based system for planning, scheduling, and controlling the
materials, resources, and supporting activities needed to meet the Master production schedule
JUST-IN-TIME PRODUCTION SYSTEM
It is a management philosophy that strives to eliminate source of manufacturing waste by
producing the right part in the right place at the right time.
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MATERIAL REQUIREMENTS PLANNING (MRP)Material requirements planning (MRP) is a computational technique that
converts the master schedule for final products into a detailed schedule for
the raw materials and components used in the final products.
Inputs of MRP
1. Master production schedule (MPS)
2. Bill of materials file and
3. Inventory record file
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MATERIAL REQUIREMENTS PLANNING (MRP)
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1.MASTER PRODUCTION SCHEDULE (MPS)
The production quantities of the major product lines listed in the aggregate plan must the
converted into a very specific schedule of individual products, known as the master
production schedule (MPS).
Master production schedule (MPS) is a detailed plan that how many final product will be
available for sale during specific periods.
Inputs to MPS
1. Market requirements
2. Production plan from aggregate planning
3. Resource available
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2.Bill of materials The bill of materials (BOM) file is used to compute the raw material and component requirements for end products listed in the master schedule.
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3. INVENTORY RECORD FILEItem master data This provides the item's identification (part number) and
other data about the part such as order quantity and lead times.
Inventory status This gives a time-phased record of inventory status.
Subsidiary data It provides subsidiary data such as purchase orders, scrap or
rejects, and engineering changes.
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Benefits of MRP Reduced inventory levels
Better production scheduling
Reduced production lead time
Reduced setup cost
Better machine utilization
Improved product quality
Quicker response to changes in demand
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COST PLANNING AND CONTROLCost planning and control system consist of the database to determine the
expected costs of manufacture each products of the company
• Cost estimating is the process of determining the probable cost of the product
before the start of the product and before the start of its manufacture.
• Cost accounting is the determination of an actual cost of a component after
adding different expenses in various departments.
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REQUIREMENTS FOR COST ESTIMATING General design specification of product (function, performance and
purpose) Assembly or layout drawings Subassemblies of the product Detail drawings and bill of materials for the product Test and equipment procedures and equipment Machine tool and equipment requirement Packaging and transportation requirements Standard time data Material release data Operation analysis and workplace studies
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INVENTORY MANAGEMENTIt may be defined as the scientific method of determining what to order, when to
order and how much to order and how much to stock so that costs associated
with buying and storing are optimal without interrupting production and sales.
Objectives of inventory control
• To ensure the continuous supply
• To maintain the overall investment
• To minimize the holding, storage and replacement cost
• To avoid over and under stocking
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INVENTORY COST1. Ordering costs
Cost of staff purchase dept. Cost of stationary Inspection cost of incoming materials
2. Holding costs Cost of storage facilities Handling cost Costs of record keeping
3. Shortage cost and Loss of future sales Loss of goodwill
4. Purchase cost Price paid to labour, material and overhead charge
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Economic order quantity (EOQ)Economic ordering quantity (EOQ) is that size of order which minimizes the total cost of carrying inventory and ordering.
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TYPES OF INVENTORY SYSTEM1. Fixed-order quantity models (Q-models)
1. Re-order quantity (how much to order)2. Re-order level (when to order)
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TYPES OF INVENTORY SYSTEM2.Fixed-time periods models (p-models)
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MANUFACTURING RESOURCE PLANNING (MRP II)
• It combines MRP and capacity planning as well as shop floor control and
other functions related to PPC
• It can be defined as a computer-based system for planning, scheduling, and
controlling the materials, resources, and supporting activities needed to
meet the Master production schedule
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MANUFACTURING RESOURCE PLANNING (MRP II)
• Management planning. Business strategy, aggregate production planning, master production scheduling, rough-cut capacity planning and budget planning
• Customer service. Sales for recasting, order entry, sales analysis, and finished goods inventory.
• Operations planning. This is the MRP module. enhanced with capacity requirements planning. The output consists of purchase order and work order releases.
• Operations execution. This includes purchasing, production scheduling and control, WIP inventory control, shop floor control. and labor hour tracking.
• Financial functions These include cost accounting, accounts receivable, account, payable, general ledger. and payroll.
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Commercial software for MRP II Enterprise Resource Planning (ERP)
Customer-oriented Manufacturing Management Systems (COMMS)
Manufacturing Execution System
Customer-oriented Management Systems (COMS)
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JUST-IN-TIME PRODUCTION SYSTEMSJust-In-Time (JIT) is a management philosophy that strives to eliminate sources of manufacturing waste by producing the right part in the right place at the right time. JIT also known as stockless production.objectives of JIT1. Zero defects 2. Zero setup time3. Zero inventories 4. Zero handling5. Zero breakdowns 6. Zero lead time7. Lot of size one.
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Elements of JIT Eliminate setup times
Reducing manufacturing and purchasing lot sizes
Reducing production and delivery lead times
Preventive maintenance
Stabilize and level the production schedule with uniform plant loading
Flexible workforce
Small unit conveyance
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Kanban production system• Production Kanban (P-Kanban)
It signals the need to produce more parts
• Transport Kanban (T-Kanban)
It signals the need to deliver more parts to the next work center
Pull system
product is made-to-order
Push system
the product is made-to-stock
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Benefits of JIT Lower inventory cost
Lower scrap and waste cost
Improved quality and zero defect products
Improved worker involvement
Higher motivation and morale
Increased productivity
Reduced manufacturing lead time
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LEAN PRODUCTION Lean manufacturing may be defined as an adaption of mass production in
which workers and work Cells are made more flexible and efficient by adapting
method that reduce waste in all form.
“more and more with less and less-less human effort, less equipment, less
time, and less space-while coming closer and closer to providing customers
with exactly what they want“
Lean manufacturing is a set of tools and methodologies that aims for the
continuous elimination of all wastes in the production process
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LEAN PRODUCTIONLean production is based on four principles
1. minimize waste
2. perfect first-time quality
3. flexible production lines
4. continuous improvement
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LEAN MANUFACTURING CONCEPTS Value creation and waste
Main kinds of waste
Pull production
Continuous flow
Continuous improvement
Worker improvement
Standard work
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Mass Production vs Lean Production
S.No Mass Production Lean Production
1 Inventory Buffers Minimum wasteMinimum inventory
2 Just in-case deliveries Just in-time deliveries
3 Acceptable quality level Perfect first time quality
4 Taylor made to production Worker teamsWorker involvement
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AGILE MANUFACTURINGAgile manufacturing is an enterprise levels manufacturing strategy of introducing new
product into rapidly changing market, an organizational ability to thrive in a competitive
environment characterized by continuous and sometimes unforeseen changePrinciples of Agile manufacturing
• Organize to Master change
• Leverage the Impact of People and Information
• Cooperate to Enhance Competitiveness
• Enrich the Customer
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Mass production vs Agile production
S.no Mass production Agile production
1 Standardized products Customized products
2 Longer market life Shorter market life
3 Produce-to-forecast Produce-to-order
4 Low information content High information content
5 Single time sales Continuing relationship
6 Pricing by production cost Pricing by customer value
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COMPUTER PROCESS MONITORING
Computer production monitoring is a data collection system in which
the computer is connected directly to the workstation and associated
equipment for the purpose of observing the operation. It is also known
as computer process monitoring.
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STRUCTURE OF MANUFACTURING PROCESS
Manufacturing system
MaterialEnergyLabour
Technology
Inputs outputsDecisions Disturbances
Product Scrap
Waste
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PROCESS CONTROL STRATEGIES
Feedback control strategy
Regularity control strategy
Feed forward control strategy
Preplanned control strategy
Steady-state optimal control strategy
Adaptive control strategy
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FEEDBACK CONTROL STRATEGY
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REGULARITY CONTROL STRATEGY
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FEED FORWARD CONTROL STRATEGY
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STEADY-STATE OPTIMAL CONTROL
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ADAPTIVE CONTROL STRATEGY
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DIRECT DIGITAL CONTROL (DDC)DDC is computer process control system in which certain components in a conventional analog
control system are replaced by the digital computer.
BENEFITS OF DIRECT DIGITAL CONTROL DDC is more efficient control actions
DDC provides more control options than traditional analog control system
DDC has the ability to integrate feedback measurements multiple loops and to implement
optimizing strategies to improve overall performance
A digital computer in DDC makes editing the control programs much easier and less costlier
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DIRECT DIGITAL CONTROL (DDC)
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