Introduction to Computer Integrated Manufacturing (CIM)iradcim/Joomla/images/stories/CIM...
Transcript of Introduction to Computer Integrated Manufacturing (CIM)iradcim/Joomla/images/stories/CIM...
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Introduction to Computer Integrated Manufacturing
(CIM)
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Learning Objectives• Modern manufacturing process and its
various components, highlighting the different systems (e.g., CAD, CAE, MRP/ERP, CAM, CNC, CMM and PDM), showing:– different types of information – what happens in each system– integration challenges
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Basic Flow of InformationCustomerRequirements
DesignRequirements
EngineeringDesign
ProductCharacteristics
Manufacturing / SupplierProcesses
ProductionQualityControls
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Manufacturing Systems• Computer Aided Design (CAD)• Computer Aided Engineering (CAE)
– Finite Element Analysis (FEA)– Computational Fluid Dynamics (CFD)
• Manufacturing Resource Planning (MRP)• Enterprise Resource Planning (ERP)• Computer Aided Manufacturing (CAM)• Product Data Management (PDM)• Co-ordinate Measuring Machine (CMM)• Computer Numerical Control (CNC)
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Manufacturing Data• Request for Quote (RFQ)• Process Plan• Bill of Material (BOM)• Customer order• Supplier and component
data• Product design• Analysis & simulation data• NC program• Tooling and fixture design
• Engineering Change data• Purchase Order (PO)• Assembly instructions• Operating, maintenance and
user manual• Design specification• Inspection & verification data• Test plan, test instruction,
test cases and test results• QC & QA data
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Typical Design to Production Flow
Concept PreliminaryDesign
EngineeringAnalysis
DetailedDesign
Engineering
ManufacturingPrelim Production Planning
Prelim Tool Design
Production Planning
Final Tool Design NC Programming
CAD Systems
CAE Systems
ERP or MRP Systems
CAM Systems
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Typical Design to Production Flow
Concept PreliminaryDesign
DetailedDesign
Engineering
Manufacturing
CAD Systems
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What is CAD?• Computer-Aided Design
– I-DEAS, CATIA, Unigraphics, ProE• Use of computers in the product design
process; can be used for sketching, schematics, analysis, and prototyping
• CAD systems can be used for Geometric Modeling (parametric, features); and Automatic Drafting (sectional views, projections, etc.)
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I-DEAS CAD Systems
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Unigraphics CAD System
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Typical Design to Production Flow
Concept PreliminaryDesign
EngineeringAnalysis
DetailedDesign
Engineering
Manufacturing
CAD Systems
CAE Systems
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What is CAE?
• Computer-Aided Engineering– StarCD, Ansys, and Abaqus
• Use of computer simulation as a tool for Engineering Analysis :– Minimize part weight, – increase part robustness, etc.
• Integrate with CAD and CAM
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Types Of CAE
Thermal Analysis
Stress AnalysisFEA (Finite Element Analysis)
Flow AnalysisCFD (Computational
Fluid Dynamics)
Dynamic Analysis
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Typical Design to Production Flow
Concept PreliminaryDesign
EngineeringAnalysis
DetailedDesign
Engineering
ManufacturingPrelim Production Planning
Prelim Tool Design
Production Planning
Final Tool Design NC Programming
CAD Systems
CAE Systems
ERP or MRP Systems
CAM Systems
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What is CAM?• Computer-Aided Manufacturing• Determine the accuracy of designs prior to
manufacture• Uses CAD drawings to produce the machine
code needed to make the actual part• Eliminates unnecessary production cost as
well as reducing time needed to produce part
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CAM Systems
Automatic Lathe CNC
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CAM Systems
CMMcoordinate measuring machine
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Typical Design to Production Flow
Concept PreliminaryDesign
EngineeringAnalysis
DetailedDesign
Engineering
ManufacturingPrelim Production Planning Production Planning
CAD Systems
CAE Systems
MRP or ERP Systems
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PDM Systems
(Product Data Management)
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What is PDM?
• Product Data Management• Giving people the right information to do
their job at the right time• On average people spend 40% of time
looking finding right data only 20% of the time
• Used mainly for concurrent engineering
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Detailed Example of the Engineering Process at Wescast Industries
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Wescast Industries• World’s largest supplier of exhaust manifolds for
passenger cars and light trucks• Work with customers globally• Manufacturing facilities in Ontario (5), as well as
the USA and Hungary • Sales and design locations in Canada, Germany,
the USA and the UK • Use I-DEAS, CATIA, Unigraphics and ProE
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Engineering Process
Rapid ToolingVerification Validation
RapidPrototyping
ProcessSimulation
StressSimulation
FlowSimulation 3-D CAD
Design
Production
PartApproval
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Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerificationRapid ToolingValidationPart ApprovalProduction
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Wescast Engineering Process FlowConcept Design
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Concept Design
3-D CAD Design StageThis is where the customer & manufacturingrequirements are captured and modeled into a 3-D Computer Aided Virtual Design. This data is used in all subsequent stages.
Outputs• 3-D CAD model ready for translation to other formats
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Concept Design
3-D CAD Design StageThis is where the customer & manufacturing requirements are captured and modeled into a 3-D Computer Aided Virtual Design. This data is used in all subsequent stages.
Challenges• lack of information• incompatiblegeometry
• tight time-line• lack of resources
Workarounds• chair initial design review meetings.• use outside resources to create or improve geometry.• work shifts or take advantage of Global time difference.
Potential Errors• miscommunication• incomplete design• incorrect data
Outputs• 3-D CAD model ready for translation to other formats
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Wescast Engineering Process FlowConcept DesignFlow Simulation
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FlowSimulation
Flow Simulation StageComputational Fluid Dynamics is used to virtually simulate the exhaust gas flow thru the manifold. Gas elements are checked such as; velocity, temperature, pressure and dispersement across the exit opening. This information is used to optimize the manifolds flow rate and improve emissions.
Outputs• Analysis data report• Interactive 3-D visual flow image
Flow Simulation
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Challenges• lack of information• incompatiblegeometry
• tight time-line• lack of resources
Workarounds• use outside resources to create or improve geometry.• work shifts or take advantage of Global time difference.• make assumptions
Potential Errors• miscommunication• incorrect assumption• incorrect data
FlowSimulation
Flow Simulation StageComputational Fluid Dynamics is used to virtually simulate the exhaust gas flow thru the manifold. Gas elements are checked such as; velocity, temperature, pressure and dispersement across the exit opening. This information is used to optimize the manifolds flow rate and improve emissions.
Outputs• Analysis data report• Interactive 3-D visual flow image
Flow Simulation
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Wescast Engineering Process FlowConcept DesignFlow SimulationStress Simulation
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StressSimulation
Stress Simulation StageFinite Element Analysis is used to virtually apply stress forces to the manifolds exterior design. In a virtual environment the manifold is mounted onto the cylinder head of the engine. Next, virtual forces are applied bringing the weak areas to the surface, which are highlighted in a colour map. This information is used to increase robustness and eliminate redundancy. Outputs
• Analysis data report• Multiple colour images
Stress Simulation
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StressSimulation
Challenges• lack of information• incompatiblegeometry
• tight time-line• lack of resources
Workarounds• use outside resources to create or improve geometry.• work shifts or take advantage of Global time difference.• make assumptions
Stress Simulation StageFinite Element Analysis is used to virtually apply stress forces to the manifolds exterior design. In a virtual environment the manifold is mounted onto the cylinder head of the engine. Next, virtual forces are applied bringing the weak areas to the surface, which are highlighted in a colour map. This information is used to increase robustness and eliminate redundancy.
Outputs• Analysis data report• Multiple colour images
Potential Errors• miscommunication• incorrect assumption• incorrect data
Stress Simulation
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Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess Simulation
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Process Simulation StageThis is where the manufacturing process is simulated using computer aided technologies. During this stage process related defects are projected. This virtual information is used to help refine the process design in order to reduce scrap rates and improve yield.
Outputs• Interactive 3-D visual images showing solidification results.
Process Simulation
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Potential Errors• incorrect data• incorrect material parameters.
Process Simulation StageThis is where the manufacturing process is simulated using computer aided technologies. During this stage process related defects are projected. This virtual information is used to help refine the process design in order to reduce scrap rates and improve yield.
Outputs• Interactive 3-D visual images showing solidification results.
Workarounds• use outside resources for computing power, or to create or improve geometry.
Challenges• incompatible
geometry• tight time-line• lack of resources• slow computer process speeds• obtaining material parameters.
Process Simulation
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Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid Prototyping
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Rapid Prototyping StageIn this stage the 3-D Computer Aided Virtual Design is transformed into a physical replication. This hand held replica is used by all team members to better visualize the design intent. It can be mounted to an engine to check for interference issues, and it can also be used to perform physical testing.
Outputs• Full size physical representation of the final product.
Rapid Prototyping
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Potential Errors• incorrect data• poor assembly and build.
Workarounds• use outside resources to create or improve geometry, or to create the physical prototype.
Challenges• incompatible
geometry• tight time-line• lack of resources
Rapid Prototyping StageIn this stage the 3-D Computer Aided Virtual Design is transformed into a physical replication. This hand held replica is used by all team members to better visualize the design intent. It can be mounted to an engine to check for interference issues, and it can also be used to perform physical testing.
Outputs• Full size physical representation of the final product.
Rapid Prototyping
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Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerification
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Verification StageUsing a Rapid Prototype, air is pressurizedthru the manifold design. Elements that are checked range from: air velocity, volumetric flow, and dispersment across the exit opening. The resulting information here is used to substantiate data that is derived from the CFD results. This test is also used when computational resources are limited.
Outputs• Analysis data report with volumetric flow results. Results compare inlet ports for balance.
Verification
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Challenges• lack of information• tight time-line• lack of resources
Workarounds• use outside resources to create or improve geometry.• work shifts or take advantage of Global time difference.• make assumptions
Verification StageUsing a Rapid Prototype, air is pressurized thru the manifold design. Elements that are checked range from: air velocity, volumetric flow, and dispersment across the exit opening. The resulting information here is used to substantiate data that is derived from the CFD results. This test is also used when computational resources are limited.
Potential Errors• incorrect set-up• machine out of calibration
Outputs• Analysis data report with volumetric flow results. Results compare inlet ports for balance.
Verification
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Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerificationRapid Tooling
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Rapid Tooling StageThis stage is where rapid tooling is created using the 3-D Computer Aided Virtual Design CAD data.
Outputs• Rapid tooling designed to support low volume production runs.
Rapid Tooling
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Workarounds• use outside resources to create or improve geometry.• use outside resources to create tooling.• use outside resource overseas.
Rapid Tooling StageThis stage is where rapid tooling is created using the 3-D Computer Aided Virtual Design CAD data.
Outputs• Rapid tooling designed to support low volume production runs.
Challenges• incompatible geometry• tight time-line• lack of resources• Overseas deliveries
Potential Errors• incorrect CAD data• incorrect tool designRapid Tooling
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Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerificationRapid ToolingValidation
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Validation StageThe Engine Exhaust Simulator is used to validate the manifold design. It replicates the engine testing that is used by the customer (better known as the Dynamometer test). The information gathered here will be used to help validate the manifold design.
Inferred Images
Outputs• Analysis report on durability, failures, warping, cracking, breakage & meltdown.
Validation
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Workarounds• make assumptions to customers dyno set-up.
Potential Errors• incorrect manifold• incorrect set-up
Validation StageThe Engine Exhaust Simulator is used to validate the manifold design. It replicates the engine testing that is used by the customer (better known as the Dynamometer test). The information gathered here will be used to help validate the manifold design.
Challenges• tight time-line• lack of resources• matching the customers Dyno set-up
Inferred Images
Outputs• Analysis report on durability, failures, warping, cracking, breakage & meld down.
Validation
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Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerificationRapid ToolingValidationPart Approval
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Part Approval StageThe Dyno test is performed by the customer on a prototype engine. The engine cycles hot (900C) & cold (200C) for 200 hours.
Outputs• Observation comments pertaining to crack, warp, breakage, leak and melt down
Part Approval
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Workarounds• use a mock-up of a similar production part
Potential Errors• incorrect manifold design• late delivery
Challenges• tight time-line• capturing all design changes
Part Approval StageThe Dyno test is performed by the customer on a prototype engine. The engine cycles hot (900C) & cold (200C) for 200 hours.
Outputs• Observation comments pertaining to crack, warp, breakage, leak and melt down
Part Approval
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Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerificationRapid ToolingValidationPart ApprovalProduction
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Production StageOnce the manifold design has been validated by the Dyno test, the customer will give the approval to begin the production tooling.
Outputs• A production part that meets and/or exceeds the customer expectations.
Production
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Production StageOnce the manifold design has been validated by the Dyno test, the customer will give the approval to begin the production tooling.
Workarounds
• NONE
Potential Errors• manifold design is not production intent
Challenges• tight time-line• capturing design intent from prototype designs to production designs• meeting quoted target ratesOutputs
• A production part that meets and/or exceeds the customer expectations.
Production
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Summary• CAD systems generate the product design
– Can be expensive and some designers struggle to make the 2-D to 3-D paradigm shift
• CAE systems support design improvements through virtual simulations– Not widely accepted yet and expensive to operate
• CAM systems used to manufacture tooling from CAD designs– Compatibility with CAD systems is still a problem
• ERP/MRP systems used to monitor and manage entire business
• PDM systems used to tie design management with manufacturing management– Need company-wide buy-in, may be a high cost
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“Islands of Automation”Systems evolution
2D drafting1960’s 1970’s 1980’s 1990’s 2000’s
GT
NC
Robotics
CAM
FMS CNC
DNC
CAPPCAD
MRP
JITQC QA
FMC
OPTTPM
TQM
CAECIM
PDM
VM
CAPM MRPII
LMWCM
AMERP
SCM
B2BB2C
6σ
OO
GUI
WWW
Deming’s 14 rules
PDM
IBM vs SAP: Evolution of complex system: open / data driven