9780131134133

The book presents computer integrated manufacturing as an integral element of the entire manufacturing process, describing its relation to product and process design issues; computer-based process control and automation; operations and information systems for manufacturing; quality; and human considerations.This book delves into the manufacturing enterprise, the design elements and production engineering, controlling the enterprise resources, and enabling processes and systems for modern manufacturing.Professionals preparing for the APICS certification exams.

Henry W. Kraebber is a Professor of Mechanical Engineering Technology at Purdue University in West Lafayette, Indiana.

Preface

xiii

PART 1 INTRODUCTION TO CIM AND THE MANUFACTURING ENTERPRISE

1

(68)

The Manufacturing Enterprise

3

(40)

Introduction

3

(4)

External Challenges

7

(3)

Internal Challenges

10

(5)

World-Class Order-Winning Criteria

15

(7)

The Problem and a Solution

22

(4)

Learning CIM Concepts

26

(2)

Going for the Globe

28

(7)

Summary

35

(8)

Bibliography

35

(1)

Questions

36

(1)

Problems

37

(1)

Projects

38

(2)

The Benefits of a CIM Implementation

40

(1)

Technology and the Fundamentals of an Operation---Authors' Commentary

41

(2)

Manufacturing Systems

43

(26)

Manufacturing Classifications

45

(7)

Product Development Cycle

52

(2)

Enterprise Organization

54

(5)

Manual Production Operations

59

(3)

Summary

62

(7)

Bibliography

63

(1)

Questions

63

(1)

Projects

64

(1)

Case Study: Evolution and Progress---One World-Class Company's Measurement System

65

(3)

CIM as a Competitive Weapon

68

(1)

PART 2 THE DESIGN ELEMENTS AND PRODUCTION ENGINEERING

69

(150)

Product Design and Production Engineering

71

(36)

Product Design and Production Engineering

72

(2)

Organizational Model

74

(1)

The Design Process: A Model

75

(11)

Concurrent Engineering

86

(7)

Production Engineering

93

(9)

Summary

102

(5)

Bibliography

102

(1)

Questions

103

(1)

Projects

104

(1)

Case Study: Repetitive Design

105

(2)

Design Automation: CAD and PDM

107

(36)

Introduction to CAD

107

(3)

The Cost of Paper-Based Design Data

110

(1)

CAD Software

111

(10)

CAD: Yesterday, Today, and Tomorrow

121

(8)

Application of CAD to Manufacturing Systems

129

(1)

Selecting CAD Software for an Enterprise

129

(5)

Product Data Management

134

(2)

Summary

136

(7)

Bibliography

137

(1)

Questions

137

(1)

Projects

138

(1)

Web Sites for CAD Vendors

139

(1)

B-Splines to NURBS

140

(2)

Web Sites for Computer Companies

142

(1)

Design Automation: CAE

143

(76)

Design for Manufacturing and Assembly

144

(8)

CAE Analysis

152

(11)

CAE Evaluation

163

(14)

Group Technology

177

(7)

Production Engineering Strategies

184

(20)

Design and Production Engineering Network

204

(6)

Summary

210

(9)

Bibliography

211

(1)

Questions

212

(1)

Problems

213

(1)

Projects

213

(2)

Ten Guidelines for DFA

215

(1)

Web Sites for CAE Vendors

216

(1)

Web Sites for Rapid Prototyping Vendors

217

(2)

PART 3 CONTROLLING THE ENTERPRISE RESOURCES

219

(164)

Introduction to Production and Operations Planning

221

(50)

Operations Management

222

(1)

Planning for Manufacturing

223

(5)

MPC Model---Manufacturing Resource Planning (MRP II)

228

(6)

Production Planning

234

(6)

Master Production Schedule

240

(5)

Inventory Management

245

(3)

Planning for Material and Capacity Resources

248

(4)

Introduction to Production Activity Control

252

(2)

Shop Loading

254

(3)

Input-Output Control

257

(1)

Automating the Planning and Control Functions

258

(1)

Summary

259

(12)

Bibliography

259

(1)

Questions

260

(1)

Problems

261

(3)

Projects

264

(1)

Priority Rule Systems

265

(6)

Detailed Planning and Production-Scheduling Systems

271

(52)

From Reorder-Point Systems to Manufacturing Resource Planning (MRP II)

271

(2)

Material Requirements Planning

273

(12)

Capacity Requirements Planning

285

(3)

Manufacturing Resource Planning

288

(3)

Features of Modern Manufacturing Planning and Control Systems

291

(9)

Summary

300

(23)

Bibliography

302

(1)

Questions

303

(1)

Problems

304

(1)

Projects

305

(1)

Wight's Bicycle Example

306

(2)

ABCD Checklist

308

(10)

An ERP Example Using WinMan

318

(5)

Enterprise Resources Planning, and Beyond

323

(29)

MRP II: A Driver of Effective ERP Systems

326

(1)

Information Technology

327

(3)

The Decision to Implement an ERP System

330

(2)

Identifying ERP System Suppliers

332

(3)

Developing Technologies: Converging and Enabling

335

(6)

Integrating Systems to Manage Design Data

341

(7)

Summary

348

(4)

Bibliography

350

(1)

Questions

351

(1)

Projects

351

(1)

The Revolution in Manufacturing

352

(31)

Just-in-Time Manufacturing

353

(11)

Synchronized Production

364

(2)

The Emergence of Lean Production

366

(3)

Modern Manufacturing Systems in a Lean Environment

369

(5)

Summary

374

(9)

Bibliography

375

(1)

Questions

375

(1)

Projects

376

(1)

Case Study: Production System at New United Motor Manufacturing, Part 1

376

(2)

Case Study: Production System at New United Motor Manufacturing, Part 2

378

(5)

PART 4 ENABLING PROCESSES AND SYSTEMS FOR MODERN MANUFACTURING

383

(188)

Production Process Machines and Systems

385

(40)

Material and Machine Processes

387

(18)

Flexible Manufacturing

405

(8)

Fixed High-Volume Automation

413

(4)

Summary

417

(8)

Bibliography

419

(1)

Questions

420

(1)

Projects

421

(1)

History of Computer-Controlled Machines

422

(3)

Production Support Machines and Systems

425

(61)

Industrial Robots

426

(22)

Program Statements for Servo Robots

448

(6)

Programming a Servo Robot

454

(7)

Automated Material Handling

461

(4)

Automatic Guided Vehicles

465

(11)

Automated Storage and Retrieval

476

(4)

Summary

480

(6)

Bibliography

481

(1)

Questions

481

(2)

Projects

483

(1)

Case Study: AGV Applications at General Motors

484

(2)

Machine and System Control

486

(51)

System Overview

487

(6)

Cell Control

493

(4)

Proprietary Versus Open System Interconnect Software

497

(2)

Device Control

499

(1)

Programmable Logic Controllers

500

(2)

Relay Ladder Logic

502

(4)

PLC System and Components

506

(5)

PLC Types

511

(2)

Relay Logic Versus Ladder Logic

513

(8)

Computer Numerical Control

521

(4)

Automatic Tracking

525

(4)

Network Communications

529

(2)

Summary

531

(6)

Bibliography

532

(1)

Questions

533

(1)

Projects

534

(1)

Turning G Codes

535

(2)

Quality and Human Resource Issues in Manufacturing

537

(34)

Quality Foundations

538

(5)

Total Quality Management

543

(4)

Quality Tools and Processes

547

(10)

Defect-Free Design Philosophy

557

(4)

The Changing Workforce

561

(1)

Self-Directed Work Teams

562

(5)

Summary

567

(4)

Bibliography

569

(1)

Questions

569

(1)

Projects

570

(1)

Index

571

What is included with this book?

The New copy of this book will include any supplemental materials advertised. Please check the title of the book to determine if it should include any access cards, study guides, lab manuals, CDs, etc.

The Used, Rental and eBook copies of this book are not guaranteed to include any supplemental materials. Typically, only the book itself is included. This is true even if the title states it includes any access cards, study guides, lab manuals, CDs, etc.

The global economy and technological innovations bring many new issues and twists to the subject of computer-integrated manufacturing (CINL). It remains as broad as the complex manufacturing enterprises it attempts to model. Some persons would suggest that CIM is too broad for a single course or textbook. However, the essence of CIM is in the integration of the enterprise elements: physical integration through the linking of hardware and software systems, logical integration through shared common enterprise information and data, and philosophical integration based on a new sense of purpose and direction in every entity in the enterprise. Therefore, the integration so critical to a CIM implementation is best introduced in a single course so that links between the enterprise elements can be explored. This book was written to support such an introductory course. Understanding the operation of a comprehensive CIM solution requires some study of traditional manufacturing practice, a look at the current state of CIM, and consideration of how technology and operating procedures may change in the future. The integration of product design techniques and fundamental manufacturing principles, along with a look at changing operations and information systems that support CIM throughout the enterprise, makes this book unique. In the book, we do the following: Describe the different types of manufacturing systems or production strategies used by industries worldwide. This description is important because no two CIM solutions are the same. Go beyond the description of automated machines and software solutions because a successful CIM implementation demands more than technology. In practice, ordering hardware and software is the last step in a CIM implementation; the preliminary work is what guarantees a successful CIM project. Discuss the impact of CIM on all the major elements in an enterprise: product design, shop-floor technology, and manufacturing production and operational control systems. Provide a convincing argument for implementing CIM so that the enterprise will be competitive in the global market. In practice, the technologies available to manufacturers around the globe open every market to world-wide competition. Look at the computer-based systems of the CIM enterprise that support the growing just-in-time and lean production initiatives. In addition, the third edition has the following significant changes: Work-cell design case studies have been added at the end of chapters 1 through 4, 5, 10, and 11, with the work keyed to the concepts presented in the chapters. The chapter on CAD, chapter 4, was changed extensively to an overview of the CAD function in an enterprise and an introduction to product data management (PDM). The enterprise networking concepts were updated and expanded. The finite-element analysis and rapid prototyping sections in chapter 5 were updated and expanded. Numerous new figures have replaced older images, and many new images have been added. Also new to this edition is a CD-ROM containing the demo version of the WinMan software. This software provides its users with an opportunity to work with a fully functional computer-based enterprise resources planning (ERP) system. This tool allows users to see how a modern data-driven system can help companies better manage their operations and the related data. The CD includes a fully functional single-user system that can be installed on a PC. The demonstration takes users through the basics of the system--from the building of item and structure databases to the functions needed to manage customer orders, material management, manufacturing, and accounting information. To provide a complete overview of the computer-integrated enterprise, we divided the book into four parts. In the first part, chapters 1 and 2, we provide an overview of global competition, describe an internal manufacturing strategy, discuss in detail the problem facing manufacturing and the development of an effective solution, and characterize the operation of different types of enterprises. In the characterization, we furnish a classification and description of the manufacturing systems and production strategies used by manufacturing, provide an explanation of the product development and engineering change cycle, and give an overview of the enterprise organization. At the end of part 1, the need for change in manufacturing is made clear and a basic strategy for change in the organization is established. In addition, the description of the enterprise organization in part 1 provides a framework for the CIM concepts introduced in the rest of the text. Part 1 provides the critical introduction to manufacturing and the enterprise that is necessary for a course designed to teach CIM. In part 2, which includes three chapters, we examine the three major design and engineering process segments that take a product from concept to production. Chapter 3 introduces design and production engineering concepts and issues. The use of CIM technology to design and produce world-class products with enhanced enterprise productivity is emphasized. The old design model is compared to a recommended new process that incorporates a concurrent engineering focus to product design. This part of the text concludes with an in-depth description of production engineering functions and the opportunities for productivity gains through integration of technology and data in the enterprise. Computer-aided design (CAD) is the focus of chapter 4. Since design is the starting point for development of the product database, a full chapter is devoted to the integration of CAD into the enterprise operation. To emphasize this integration, we changed the chapter title and the content to include PDM (product data management). The function of CAD technology in the product design process is discussed, and the systems used to develop the product models are described. The importance of PDM and its link to the CAD technology and design department are covered. In chapter 5, we explore the relationships between the concurrent engineering product design model and the computer-aided engineering (CAE) technology available to support every step of the design process and production engineering. We include a complete definition of CAE, design for manufacturing and assembly, finite-element and mass-properties analysis, rapid prototyping, group technology, computer-aided process planning, computer-aided manufacturing, production and process modeling and simulation, maintenance, automation, and product cost analysis. In the final section of chapter 5, we describe the computer network used to tie the design and production engineering functions to the common enterprise database and other business functions. Part 3 of the text shifts the CIM focus to controlling the enterprise resources. CIM is alive and growing in applications that support the management and control of the enterprise. The first chapter in the sequence, chapter 6, describes the concept of manufacturing planning and control (MPC) with a model of a typical MPC system. The function of manufacturing planning and a high-level look at the systems and technologies available for CIM implementations are presented. Attention is given to the high-level system elements of production planning and the master production schedule (MPS). Chapter 6 provides an overview of the critical concepts that are explored in more detail in the following two chapters. In chapter 7, three key elements in the MPC model are discussed in more detail. These include material requirements planning (MRP), capacity requirements planning (CRP), and the production activities that execute the material and capacity plans. Automation software used to implement CIM in this critical part of the enterprise is introduced and explained. Software solutions fo

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Computer Integrated Manufacturing

Computer Integrated Manufacturing

0131134132

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