CAD-CAM-CIM-Intro.pdf
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© C.S.Kumar, Mechanical Engineering, IIT Kharagpur Computer Integrated Design and Manufacture C.S.Kumar CAD-CAM and Robotics Lab. Department of Mechanical Engineering, IIT Kharagpur [email protected] Integrated Data Models in Design and Manufacture
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Transcript of CAD-CAM-CIM-Intro.pdf
© C.S.Kumar, Mechanical Engineering, IIT Kharagpur
Computer Integrated Design and Manufacture
C.S.Kumar
CAD-CAM and Robotics Lab.
Department of Mechanical Engineering, IIT Kharagpur
Integrated Data Models in Design and Manufacture
Nature of Manufacturing Operations
Globalisation
Rapid Product Cycles
Widespread proliferation of Information and Communication Technologies (ICT)
The Realities of Modern Manufacturing
Globalization - Once underdeveloped countries (e.g., China, India, Mexico, Brazil) are becoming major players in manufacturing
International outsourcing - Parts and products once made locally are now being made offshore (in China or India) or near-shore (in Eastern Europe)
Local outsourcing - Use of suppliers locally to provide parts and services
More Realities of Modern Manufacturing
Contract manufacturing - Companies that specialize in manufacturing entire products, not just parts, under contract to other companies
Trend toward the service sector
Quality expectations - Customers, both consumer and corporate, demand products of the highest quality
Need for operational efficiency - manufacturers must be efficient in in their operations to overcome the labor cost advantage of
international competitors
Globalization
Design
Product Manufacturing
Costs
Transport
Labour
Local standards / cultures / law
Demand – supply and supply chain management (SCM)
Production strategies - Assemblies
Fully knocked down
Semi knocked down
Parts / design replacements
Quality and functionality
Breaking Down Barriers
Traditional Product Development
Customer requirements
(sales and marketing)
Conceptual design
(Industrial designers)
Support and
Service
Distribution
and Sales Manufacturing
Detailed design
and analysis
(engineering)
Disposal ?
(Now is increasingly relevant)
Concurrent Product Development
Customer
Sales Manufacturing
Design
Support Engineering
Concurrent Engineering
Simultaneous decision making by design teams
Integrates product design & process planning
Details of design more decentralized
Needs careful scheduling - tasks done in parallel
Concurrent Engineering Teams
Interdisciplinary, cross-functional
Includes customer, marketing, design, engineering, manufacturing, sales, support
Concurrent engineering teams are physically colocated to promote collaboration
Activity C
Activity B
Sequential Vs. Concurrent Product Development
Activity A
Time to market
Sequential
Concurrent
Competitive
Advantage!
Conventional Collaboration
Communication face-to-face discussion, memos, telephone,
whiteboard, bulletin board, wall charts, etc.
Collaboration meetings, colocated workgroup
Knowledge management notebooks, binders, printed reports,
photocopies, drawings, forms, data files
Geographically Distributed Teams
Transparent
global network
Enterprise data
and information
Company A Company B
Virtual Collaboration
Communication fax, telephone, mail
email, discussion groups, shared whiteboard, videoconferencing
Collaboration application sharing, shared network workspace
(files in shared directories)
Knowledge management Product data management system, document
management system, distributed databases
Enterprise Functions in Manufacturing
Source: Principles of Comp Intgd Manuf : Jean-Baptiste Waldner / Wikipedia
Source: JTEC Report on Japanese Electronics Industry (1995) : A Typical Implementation
CAD Processes
Computer Aided Drafting
3D modelling and representation
Layers
Assemblies
Visualisation -> Drafting
Process Planning: 3D Models -> Machining plan : CAM Planners
3D Models -> Products (Rapid Prototyping)
New requirements
CAD Models to be shared
Shared visualisations
Modifications easily reflected -> Consistency and safe data propagation
Parametric Design
Feature based Design
Constraints modelling
Product Life Cycle Constraints
Rapid development cycles
Thin lead margins
Fast turn-around in new feature introduction
Fast turn-around in bugs recovery
Global and local constraints
Software and Tools
Parametric Technologies (PTC) Pro/Engineer Windchill PDMLink Windchill ProjectLink
Dassault Systems (3DS) CATIA, Solid Works : Design DELMIA : Manufacture ENOVIA, SMARTEAM : Product Life Cycle Mgmt Solidworks
Autodesk (AutoCAD, Inventor) Unigraphics (UGS – SolidEDGE) – now under Siemens Delcam (IDEAS)
Manufacturing
Automation
Computer Controlled Machines
Robotics
Automated work handling systems
Precision and repeated operations
High quality in output
Sales, support and market
Global Markets
ERP and Web based operations
Mass Customization
Tracking and support
Life time support
GM - Onstar
Industrial Automation - Machines
Storage Systems
Handling Systems
Assembly Lines
Assembly Cells
Machines
Actuators
Sensors
Production Lines
Production Cells
Machines
Actuators
Sensors
Industrial Automation - Computing
Computers
Controllers
Actuators
Sensors
Software
Industrial Automation - why?
1. Production Systems
2. Automation in Production Systems
3. Manual Labor in Production Systems
4. Automation Principles and Strategies
5. Organization of the Course
Manufacturing Approaches
Automation
Flexible manufacturing
Quality programs
Integration
Lean production
Facilities – Factory and Equipment
Factory, production machines and tooling, material handling equipment, inspection equipment, and computer systems that control the manufacturing operations
Manufacturing Support Systems Business functions - sales and marketing,
order entry, cost accounting, customer billing
Product design - research and development, design engineering, prototype shop
Manufacturing planning - process planning, production planning, MRP, capacity planning
Manufacturing control
shop floor control,
inventory control, quality control
Computer Integrated Manufacturing
Automated System
Examples:
Automated machine tools
Transfer lines
Automated assembly systems
Industrial robots
Automated material handling and storage systems
Automatic inspection systems for quality control
Automated System
Periodic Worker
Transformation Process
Three Automation Types
Programmable Automation
Flexible Automation
Fixed Automation
Variety
Quantity
Fixed Automation
Sequence of processing (or assembly) operations is fixed by the equipment configuration
Typical features:
Suited to high production quantities
High initial investment for custom-engineered equipment
High production rates
Relatively inflexible in accommodating product variety
Programmable Automation
Capability to change the sequence of operations through reprogramming to accommodate different product configurations
Typical features:
High investment in programmable equipment
Lower production rates than fixed automation
Flexibility to deal with variations and changes in product configuration
Most suitable for batch production
Physical setup and part program must be changed between jobs (batches)
Flexible Automation
System is capable of changing over from one job to the next with little lost time between jobs
Typical features:
High investment for custom-engineered system
Continuous production of variable mixes of products
Medium production rates
Flexibility to deal with soft product variety
Reasons for Automating 1. To increase labor productivity
2. To reduce labor cost
3. To mitigate the effects of labor shortages
4. To reduce or remove routine manual and clerical tasks
5. To improve worker safety
6. To improve product quality
7. To reduce manufacturing lead time
8. To accomplish what cannot be done manually
9. To avoid the high cost of not automating
Automation Principles
1. Understand the existing process
Input/output analysis
Value chain analysis
Charting techniques and mathematical modeling
2. Simplify the process
Reduce unnecessary steps and moves
3. Automate the process
Ten strategies for automation and production systems
Automation migration strategy
Automation Strategies 1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10.Computer-integrated manufacturing
Automation Migration Strategy
Various areas being covered Definition of Industrial Automation
Mathematical Models for Manufacturing
Industrial Systems
Control Systems
Sensors and Actuators
Automated Machine Tools
Industrial Robotics
Logic Controllers
Handling Systems
Storage Systems
Identification Systems
Manufacturing Cells
Assembly Lines
Flexible Manufacturing Systems
© C.S.Kumar, Mechanical Engineering, IIT Kharagpur
Thank you
End of Introductions.
