Operations Technology in Manufacturing

7/30/2019 Operations Technology in Manufacturing

1/39

Prof. Arun [email protected]

9893686820

Unit - III


2/39

Types of Hardware technology inmanufacturing. Types of Software technology inmanufacturing. Computer Integrated Manufacturing.


3/39

Technology is not a cure-all, but managingtechnology is certainly a major ingredient invirtually all operations decisions, and

opportunities for its innovative use existthroughout OM.

Excellent vehicle for obtaining competitiveadvantage.


4/39

Numerically controlled machines

Automated process controls

Vision systems (automated inspection systems)

Robots

Automated identification systems (AIS) Automated storage and retrieval system (ASRS)

Automated guided vehicles (AGV)

Automated flow lines

Automated Assembly Systems Flexible manufacturing systems (FMS)

Computer integrated manufacturing (CIM)

Enterprise resource planning (ERP)


5/39

Numerical control (NC) - machine can becontrolled electronically

Computer Numerically Controlled (CNC) -machine actually has its ownmicroprocessor and memory

Direct Numerical Control (DNC) - wired toa central computer


6/39


7/39

Is the use of information technology tomonitor and control a physical process. Forexample, process control is used to

measure the moisture content andthickness of a paper.

To determine and control temperatures,pressures, and quantities in petroleum

refineries, petrochemical processes, cementplants, steel mills, nuclear reactors andother product-focused facilities.


8/39

Sensors, often analog devices, collect data

Analog devices read data on some periodicbasis, perhaps once a minute or once a second

Measurements are translated into digital

signals, and transmitted to a digital computerComputer programs read the file (the digital

data) and analyze the data

Output may be a: message on printer or

console, signal to a motor to change a valuesetting, warning light or horn, process controlchart, etc.


9/39


10/39

Combine video and computer technology

Often used in inspection roles

Consistently accurate, do not become

bored, of modest cost


11/39

Image

Acquisition

Image Analysis

Image

Interpretation


12/39

Robots

Programmable manipulators

Follow specified path

Better than humans with respect to Hostile environments

Long hours

Consistency

Adoption has been slowed by ineffectiveintegration and adaptation of systems

Perform monotonous or dangeroustasks

Used when speed, accuracy, or strengthare needed


13/39


14/39

Where Used and Applied

Welding

Painting

Surface finishing

Aerospace and automotive industries

Light assembly such as in the micro-electronics industries,or consumer products industries

Inspection of parts

Underwater and space exploration

Hazardous waste remediation


15/39

Uses bar codes, radio frequencies, magneticstrips, optical character recognition to sense& input the data into computers.

For example, automatic maintenance ofinventory system by reading the bar code onthe item and updating the inventorydatabase.


16/39

Computer-controlled warehouses thatprovide for the automatic placement andwithdrawal of parts and products into andfrom designated places in a warehouse.

These systems are also found in inventoryand test areas of manufacturing firms.


17/39

Material handlingmachines

Used to move parts& equipment inmanufacturing

May be used to

deliver mail &meals in servicefacilities


18/39

Aerospace &Defense Automotive Chemical Food & Beverage Government Newsprint Electronics Plastics Primary Metals Recycling And more
http://www.usps.com/


19/39

Reduced labor and associated costs... Increased dependability andproductivity...

Less product handling damage... Increased safety...


20/39

Includes several automated machines which are

linked by automated transfer machines &handling machines. Also known as fixed automation/ hard

automation.

Suitable for products with high & stabledemand. Requires high initial investment. The raw material feeder automatically feeds the

machines to carry operations without humanintervention.


21/39

Automated assembly machines/ equipments

are linked together by automated materialhandling equipments.

Ex. Robotic welders are used to join one ormore parts.

Advantages are; Low production cost per unit

High product quality

Higher products flexibility.


22/39

When a central computer providesinstructions to each workstation and tothe material-handling equipment (whichmoves material to that station), the

systems is known as an automated cellwork: FMS

Is flexible because both the material-handling deices and the machines

themselves are controlled by easilychanged electronic signals (computerprograms): low volume with high variety.


23/39

Using automatedmachines (DNC) &

materials handlingequipment together

Often connected tocentralized

computer Also called

automated work cell

Computer

Machine 1

Machine 2

Robotor AGV

Auto ToolChg.

Auto ToolChg.


24/39

Parts

Finished

goods

Computer

control

room Terminal

CNC

Machine

CNC

Machine

Pallet

Automatictool changer


25/39

Advantages Faster, lower-cost changes from one

part to another Lower direct labor costs Reduced inventory Consistent, and perhaps better

quality

Disadvantages Limited ability to adapt to product or product mix

changes

Requires substantial preplanning and capitalexpenditures

Technological problems of exact componentpositioning and precise timing

Tooling and fixture requirements


26/39

Manufacturing Software Technology

Computer Aided Design and Computer AidedManufacturing (CAD/CAM)

Computer Integrated Manufacturing (CIM)

Enterprise Resource Planning (ERP)


27/39

CAD is an electronic system using computers for designing newparts or products or for modifying existing ones.

CAD is the use of computers for the synthesis, analysis, andoptimization of a design.

CAD is an iterative processA certain component or subsystem of the overall system is

first conceptualized by the designer, is subjected to analysis,

then improved through this analysis procedure, and finallyredesigned.

The process is repeated until the design has been optimizedwith respect to the criteria of cost, quality, and operatingperformance.

The next phase in the design process is the fabrication of aprototype, and testing the prototype to assessmanufacturability, operating performance, quality, reliability,and other criteria.

Finally, a database of drawings, material specifications, bill ofmaterials, assembly drawings, etc., is created.


28/39

Saves time and money of designers .

Eliminates prototype model building to prove thedesign.

Allows designers to determine costs and test suchvariables as stress, tolerance, product variability,interchangeability & serviceability.

Low cost of design.

Eliminates manual drafting.

Faster development, better products & accurate flowof information to other departments.

Product cost can be determined at the design stageitself.

Makes review of numerous options in design beforefinal commitments are made.


29/39

Use of computer software to direct & control

manufacturing equipments. CAM is the use of computer systems to plan,

manage, and control the operations of amanufacturing plant through either direct orindirect computer interface with the plant'sproduction resources.

CAD/CAM covers a wide spectrum of activities thatinclude production specification, conceptual design,final design, drafting, process planning,

manufacturing, assembly, and inspection. CAD/CAM is probably the most common and best

known acronym in contemporary manufacturing.


30/39

Product Quality Shorter Design Time.

Production cost reduction

Database availability New range possibilities.

Minimum involvement of direct workers.

High quality & productivity.


31/39


32/39


33/39

CIM Expands the integration of CAD & CAM to encompass

the administrative, engineering, and manufacturingdisciplines in a manufacturing business.

Manufacturing system that combines CAM withengineering (CAD), & production & inventory control &

shipping. CIM integrates the factors of production to organize

every event that occurs in a business enterprise - fromreceipt of a customer's order to delivery of theproduct.


34/39


35/39

Top Management decides to make a product based on market

opportunities, companys strengths & weaknesses & formulates

its strategic plan based on competitive advantage.

OM runs the production

process, coordinating

supplies, requesting

components &

materials, planning &

scheduling operations,

overseeing cost

accounting, & arrangingoutgoing shipments.

Computer-aided design

(CAD) designs the product,

then analyzes it to assure

quality & to extract data

needed to plan the

manufacturing process,

design the tools & fixtures

& machine loadingprograms.

Computer-aided

|manufacturing

(CAM) allows

fabrication of raw

materials into parts to

be sent to the

assembly lines.

Automated storage &

retrieval system

(ASRS) & Automated

Guided Vehicles (AGV)

moves incoming

materials 7 parts, work-

in-progress, & final

product.

Robots put the

product together,

test them with

automated

equipments, & box

the finished product

for shipment.


36/39

ERP are comprehensive software packageswhich integrate most of the businessfunctions in an organization.

Software for managing basic requirements ofan enterprise, including sales & marketing,

finance and accounting, production &materials management, and human resources.

Several ERP software packages have beendeveloped by leading software companies

such as SAP, Oracle, J.D. Edwards, People softand Baan.

Integration of E-business capabilities id thelatest development in ERP systems.


37/39

Labor costs

Material costs

Inventory costs Transportation or distribution costs

Quality costs


38/39


39/39

Operations Technology in Manufacturing

Documents

Transcript of Operations Technology in Manufacturing