computer Integrated manufacturing

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computer Integrated manufacturing
Larry Whitman whitman_at_imfge.twsu.edu (316)
691-5907 [phone]
Industrial Manufacturing Enterprise
Department The Wichita State University http//www
.mrc.twsu.edu/whitman/classes/ie775
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IE775

• Text
• Computer Integrated Manufacturing
• from concepts to realisation,
• Roger Hannam 1996,
• Addison-Wesley, New York, NY
• Also, other books will be needed (dont have to
  buy)
• Rajan Suri, Quick Response Manufacturing A
  Companywide Approach To Reducing Lead Times,
  Productivity Press Inc., 1998.
• H. T. Goranson, The Agile Virtual Enterprise
  Cases, Metrics, Tools, 1999.
• Shigeo Shingo, A Study of the Toyota Production
  System from an Industrial Engineering Viewpoint
• James P. Womack, Daniel T. Jones, Lean Thinking
  Banish Waste and Create Wealth in Your
  Corporation
• James P. Womack, Daniel Roos, Daniel Jones The
  Machine That Changed the World Based on the
  Massachusetts Institute of Technology
  5-Million-Dollar 5-Year Study on the Future of
  the Automobile
• Christopher Meyer, Fast Cycle Time How to Align
  Purpose, Strategy, and Structure for Speed

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Opportunities for Improvement

• Writing Center - LAS Building 6th Floor 601
• Talk with a student assistant about drafts of
  your paper.
• Also use computer assistance to develop skills
• Free
• Conversation Class for non-native speakers
• Informal practice group to gain confidence in
  speaking
• Thursdays 130-220pm (you can start any week)
• Learning Resource Center Grace Wilkie East
• Free

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Paper

• Library review and critique
• papers 1-3 you must use 3 papers
• from lit
• to be kind I have a prelim list
• of papers on the web site
• To be kind, I will review an outline
• of your paper once and a final version of your
  paper once. I promise a 48 hr (working days)
  turnaround. Requirements - at least two papers I
  have not seen and turn in copies of those papers.
• Save on z/share/imfge/ie775/papern directory and
  turn in a paper copy. Save in the format
  lastnamen, where n is the paper number
• Register book topic on the website (must be
  approved first).
• Use the writing lab prior to talking with me.

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Paper

• Order
• Title page, abstract, intro, body, conclusion,
  bib/ref, and copies of papers.
• Figure captions and numbers below figure (if
  needed)
• Explain figure in text
• Requirements - at least two papers I have not
  seen and turn in copies of those papers. (be sure
  they are in endnote)
• Save on class directory and give paper copy.
• Turn in borrowed materials - (or no grade!!)

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Paper

• Use page numbers - 1,2,3,etc.
• Abstract lt150 words - whats the big idea???
• Format bib/ref consistently
• Bib/Ref - use journal first, then conf, then web.
• Look at other papers (SJET paper)
• No lists (few) WRITE!!!
• Spelling/grammar
• If you dont understand something - dont write
  about it!!!!!

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Paper suggestions

• Give it to a friend and they ask what does this
  mean? If they cant answer, then rewrite!!!
• Do not impress me! Make it so your friend
  understands it. If they dont understand it,
  remove it!!!
• Do I understand what the paper says?
• 10 minute review - 48 hour turnaround
• Dont kill yourself!!!

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Plagiarism

• If it is not your words (if you copy word for
  word) must be in quotes with ref at the end.
• If it is mostly from one or two papers, you need
  to put the ref at the end.
• If I find ONE place of plagiarism, the paper gets
  a zero
• You have one week to fix it, if I find another
  place with plagiarism, you still get a zero, if
  not your score is half what it would have been.

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Reaction Paper

• First, choose 2-4 papers on the topic
• Before reading the paper/book, look it over,
  reading the chapter titles, subheadings, opening
  lines of chapters--not really reading, but
  skimming--to get a flavor for what the readings
  are all about. Then write a short paragraph which
  explains your specific goals and expectations
  (what you hope to gain by studying this
  material). Some things to think about when
  writing the paragraph could be your reasons for
  selecting the course, the types of changes you
  might consider making in your use in your work
  upon learning more about the topic, or any way
  the topic might help you in your job. 33 points
• After reading the complete paper(s)/book, write
  the main section of your Reaction Paper, which
  should be based on your own responses to the
  ideas and resources presented in the book. This
  section should run from 2 to 3 pages, and should
  give the reader not only your reaction to the
  material presented, but also a sense of your
  particular professional background/work
  situation. In other words, the Reaction Paper is
  not simply a summary of the content of the book
  it is a synthesis of the significant ideas in the
  book and your own professional knowledge and
  experience. 33 points.
• Describe how you might incorporate these ideas
  into your daily work. These initial thoughts you
  have on possible professional applications might
  be the seed for your Internet-based Project.
  Discuss how the ideas in the book might need to
  be modified to meet your particular work
  situation. Also, discuss any ways in which these
  materials are not suitable for your particular
  professional application and critique them
  accordingly. 33 points

Adapted from course documentation created
byChristopher Essex, Instructional Systems
Technology, Indiana UniversityEmail
cessex_at_indiana.edu Website http//php.indiana.ed
u/cessex/
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Steps to do the papers

• Review the topic
• do I have a basic idea?
• do I know of seminal articles?
• Review standard literature.
• Look in endnote library
• Acquire additional literature.
• At least article I am unaware of.
• Follow the format from the IU website (except
  of pages)
• Write Draft
• Read Draft
• Revise Paper
• Give to friend for review
• Revise
• Submit for Professor Review
• Revise
• Turn in

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Manufacturing Enterprise

• Why do you care?
• To get the big picture

Local Optimums
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Systems Approach
Environment
System
Enterprise Goals
input
output
External Suppliers
External Customers
Your Supplier
Your Customer
Your Process
feedback
feedback
People Tools Machines
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Enterprise Analysis

• The Enterprise can be analyzed using process
  analysis, simulation, activity based analysis,
  and other tools.

input
output
input
output
External Suppliers
External Customers
Your Supplier
Your Process
Your Supplier
Your Process
Your Customer
feedback
feedback
feedback
feedback
People Tools Machines
People Tools Machines
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Enterprise Representation

• The Enterprise is a system that has certain
  fundamental processes.

Enterprise

• Set direction

• Acquire customers
• Develop product and process
• Fulfill orders
• Support customerand product

• Acquire resources
• Manage financialassets

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Implementation
Enterprise Transformation must be planned.
Internal and External Environment
Constrains and Enables
Enterprise Vision
Desired Future
To-Be
Technology Strategy
Process Improvement Strategy
Current Enterprise
Cultural Change Strategy
PlannedTransformation
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Systems Approach

• Emphasizes the whole systeminstead of component
  systems
• Optimizes whole systeminstead of improving the
  efficiencyof nearby components

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Systems Approach

• Systems exist within the environment
• The environment affects the system
• The environment cannot be controlled
• The environment has knowns and unknowns
• The system is controlled by the decision maker
• Interactions with the environment must be
  considered

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Systems Approach

• All processes have relationshipswith other
  processes.

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Systems Approach
All processes are made up of smaller activities.
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Systems Approach
Business Environment
Enterprise
A systems approach allows us to see opportunities
for improvement atall levels.
Processes
Activities
Tasks
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Systems Approach
Design Road
BuildRoadbed
Apply Lime
Pave Road
Use Road
Quarry
Crushing
Calcining
Shipping
1st crushing
screening
2nd crushing
screening
sizing
storing
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Systems Approach
Each employee/department/enterprise interfaces
with many systems!
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Process vs. Results
Emphasis
Problem Solving
Managers Role
ACTIVITY
OUTPUT
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Viewpoints

• Western companies generally implement
  improvements as a step change by the application
  of technology
• Japanese change incrementally and continually and
  involve people
• Shingo Shingeo

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Operation of Companies and their data
Customer
Possible Orders or Forecasts
Design
Sales
BOM
Master Production Schedule
Production Planning (MRP)
Capacity (MRPII)
Inventory
Purchasing
MfgEng
Shop Schedules
Receiving
Route Cards Inst/Tapes
Mfg Operations
Materials Allocations
FGI
Assy/Test
Painting
Packing/Dispatch
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Marketing

• Marketing - (new customers)
• Sales - (existing customers)

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Engineering
Marketing
External Data
Product Development
Research
Eng Rels
Mfg Dev
Design
Facilities Engineering
Mfg Eng
Production Planning
Plant Ops
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Production Planning

• Master production scheduling
• Material planning and resource planning
• Procurement
• Production control

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Plant Operations

• Production Management and control
• Receiving
• Materiel
• Manufacturing Processes
• Test and Inspection
• Material Transfer
• Shipping
• Plant Maintenance

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Physical Distribution

• Physical distribution planning
• Physical distribution operations
• Warranties, servicing, and spares

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Business and Financial Management

• Human Resources
• Payroll
• Accounts Payable, billing, accounts receivable
• Cost accounting
• Financial planning and management
• Strategic planning

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Food Flow Chart
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PCB Sample Flow
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PCB Detailed Flow
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PCB Detailed Flow (continued)
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PCB Detailed Flow (continued)
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IDEF

• Integration DEFinition
• U.S. Air Forces Integrated Computer Aided
  Manufacturing (ICAM) (late 1980s)
• Many different IDEF methods
• Each method is useful for describing a particular
  perspective
• (IDEF0), functional or activity modeling
• (IDEF1), information modeling
• (IDEF1x), data modeling
• (IDEF3), process description capture
• (IDEF4), object oriented design
• (IDEF5), ontology capture

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IDEF is top down (decompositional)
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IDEF0

• activity (or function) is represented by the
  boxes
• inputs are represented by the arrows flowing into
  the left hand
• outputs are represented by arrows flowing out the
  right hand
• arrows flowing into the top portion of the box
  represent constraints or controls
• arrows flowing into the bottom of the activity
  box are the mechanisms

• Order of boxes do not imply sequence!
• Top Down

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Enterprise Models

• Not included in slides available on internet
• but several examples will be presented in class

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Next Class

• Chapter 3-5!