From manufacturing
events to an integrated
process-
Integration as a
competitive advantage
David E. Suica, PE/ President / Fastems LLC
The basic premise is that every time someone needs to touch a part the cost
of that part increases.
Also each time there is human intervention an error can occur.
Wrong data entered
Poor measurements
A delay in part processing
This is true not only in manufacturing but in all industries. And cited in a
Cornell paper by Prof, Baker, Potter, Schroder and with lean principals as
sighted in LeanCor Supply chain Group.
The Challenge Setting and TrendsYour Customer
Competitiveness
Delivery
TimePrice
Delivery
Performance
Success Factors
You
Lead
Time Cost
Quality
Competition
Lack of talented
workforce
Smaller batch sizes
Shorter delivery times
Traceability demands
Safety
Globalization
Environment
Energy
Shorter product
life cycles
Market fluctuation
First time right
The Roots of Lean, Three M:s
External: market
demand fluctuations
Internal: missing
production resources,
machinery breakdowns,
sick leaves, etc.
Unevenness leads
to overburden of the
production machinery
and people.
Among the others unevenness and overburden leads to non-value-added work.
Which again leads to unevenness and overburden –
vicious circle aka. daily hassle at production is ready
UnevennessMura
OverburdenMuri
WasteMuda
From Challenge to Solution
UnevennessMura
OverburdenMuri
WasteMuda
How modern Manufacturing Management Software and Integrated
Automation can help you to create the flow:
1. managing unevenness
2. avoiding overburden
3. reducing non-value-adding work
Leading to:
1. shorter delivery times
2. reduced cost
3. improved delivery performance (quality)
Thus providing the ultimate goal of customer satisfaction
Why Creating Flow is Then so Hard?
Process, Machinery, Inspection Setups • Presetting • Measuring
Material • Cutting • Deburring
Washing
MES • PDM
CAM • QMS • TDM
ERP
KPI
Production system pyramid
Because team-play of many data system
and production assets are required,
but they are not connected!
ERP
MES
production simulation
Modern Manufacturing Environment
Modern Manufacturing
Environment creates
seamless production
team-play by integrating
production data systems and
production machinery to
work together Flow
Situational awareness
& transparency
Production Planning
and Simulation
Manufacturing Automation
(Production Execution)Setups • Presetting • Measuring
Material • Cutting • Deburring • Washing
QMS
TDM
ERP
PDM
CAM
KPI
MMSManufacturing
Management
Software
Manufacturing Automation
Setups • Presetting • Measuring
Material • Cutting • Deburring
Machine Pallets
Manufacturing Automation
(Production Execution)
Horizontal Machine Tools
Machine pallet
loading stationMMS operating panel
Total Integration
Page 8
ERP/MES-> Orders, part data
<- Production
feedback
TDM-> Tool base data
-> Tool offsets
<- Tool need
QUALITY
SYSTEMS<- Uptime data
<- Scrap data
<- Output data
PDM-> Production documents
TOOL PRESETTING-> Measured Tool offsets
CAD/CAM-> NC programs
MACHINE
TOOLS<-> NC programs, tool
data, program
selection/start/status,
hand shaking, machine
status
Trending – WIP eliminated from production chain
Page 9
• Conventional manufacturing routings have parts completed sequentially in different fixtures or work holding.
• This causes excess WIP and long lead times.
• In modern FMS technology it is possible to do all process steps with one setup.• One setup/clamping and part is ready for assembly!
MeasuringWashingDeburringMachiningPreparing
$ $$ $$$ $$$$
Manufacturing Automation
Setups • Presetting • Measuring
Material • Cutting • Deburring • Washing
Central tool storage (CTS) Automatic Storage for Machine
Pallets and Material Pallets
Horizontal Machine Tools
Machine pallet
station
Integrated material
management
Deburring Cell
Washing machine
CMM
Autoloading
Setups • Presetting • Measuring
Material • Cutting • Deburring • Washing
QMS
TDM
ERP
PDM
CAM
KPI
MMSManufacturing
Management
Software
Your Success Factors
Your Customer
CompetitivenessDelivery
TimePrice
Delivery
Performance
Thank you Fastems - 4000 systems worldwide
1982 24/7 8,200
First system
installed and
still in use
Teleservice support
world wide
Fastems record:
spindle hours
per year
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