HANOI UNIVERSITY OF SCIENCE AND TECHNOLOGY SCHOOL OF ECONOMICS AND MANAGEMENT REPORT COMPUTER INTERGRATED MANUFATURING – GROUP 1 Lecturer Dr Do Tien Minh NO STUDENT’S NAME STUDENT’S ID CLASS COURSE 1.
HANOI UNIVERSITY OF SCIENCE AND TECHNOLOGY SCHOOL OF ECONOMICS AND MANAGEMENT REPORT COMPUTER INTERGRATED MANUFATURING – GROUP Lecturer : Dr Do Tien Minh N O STUDENT’S NAME Nguyễn Linh Chi Lê Duy Anh Lê Văn Ba Nguyễn Xuân Bách Vũ Ngọc Minh Châu Nguyễn Văn Chiến Nguyễn Thị Hồng Gấm STUDENT’S ID CLASS COURSE 20198007 20198002 20198004 20198005 20198006 20198008 20198011 EM-NU EM-NU EM-NU EM-NU EM-NU EM-NU EM-NU 64 64 64 64 64 64 64 HANOI, July 2022 ACKNOWLEDGEMENT Before embarking on/ culminating in exploring the topic of a Computer Intergrated Manufacturing System essay, We would like to express our sincere thanks to the lecturer of the CIM Course Mr.Do Tien Minh During the research process, he spent hisprecious time answering all questions as well as caring and assisting mein a very wholehearted way so thatie can acquire valuable knowledge, take approaches to the topicquickly and accurately Therefore, thanks to the knowledge that he imparted to methese sources, he was able to search and use the right references selectively to support the completion of the topic on hisschedule In the process of finding/ researching this topic, ihave tried to complete it well, but perhaps due to limited knowledge as well as other objective factors, myarising problems can be inevitable We are expecting the feedback, and further instructions of teachers and readers so that ican draw on experience and solve them in the next topics Best regards! TABLE OF CONTENTS TABLE OF FIGURES PART 1: THEORETICAL BACKGROUND 1.1 CIM concepts CIM = C + I + M = Automation + Information M = Manufacturing System: • System: A system is a group of interacting or interrelated elements that act according to a set of rules to form a unified whole • Manufacturing: The process of converting raw materials, components or parts into finished goods that meet a customer’s expectations or specification I = Integrated: CIM integration includes: • Physical integration o Inter system communication/network o Data exchange - rules o Physical system integration • Business integration o Knowledge-based Decision Support o Business Control o Automated Business Processing o Production and Process Simulation C = Computer: • is an electronic machine that calculates data very quickly, used for storing, writing, organizing, and sharing information electronically or for controlling others Definition of Computer Integrated manufacturing (CIM) • CIM refers to the technology, tool or method used to improve entirely the design and manufacturing process and increase productivity, to help people and machines to communicate It includes CAD (Computer-Aided Design), CAM (ComputerAided Manufacturing), CAPP (Computer-Aided Process Planning, CNC (Computer Numerical Control Machine tools), DNC (Direct Numerical Control Machine tools), FMS (Flexible Manufacturing Systems), ASRS (Automated Storage and Retrieval Systems), AGV (Automated Guided Vehicles), use of robotics and automated conveyance, computerized scheduling and production control, and a business system integrated by a common database (Houston Cole Library) 1.2 CIM structure 1.2.1 Processes involved • Computer-aided designPrototype manufacture • Determining the efficient method for manufacturing by calculating the costs and considering the production methods, volume of products, storage and distribution • Ordering of the necessary materials needed for the manufacturing process • Computer-aided manufacturing of the products with the help of computer numerical controllers: • Quality controls at each phase of the development • Product assembly with the help of robots • Quality check and automated storage • Automatic distribution of products from the storage areas to awaiting lorries/trucks • Automatic updating of logs, financial data and bills in the computer system 1.2.2 Subsystems: Computer-Aided Technique Computer Aided Design (CAD): is the use of computers (or workstations) to aid in the creation, modification, analysis, or optimization of a design CAD Application: • Design • Analysis • Documentation • Manufacturing • Management Computer Aided Manufacturing (CAM): is the use of software and computercontrolled machinery to automate a manufacturing process Basically CAM has following components: • Software that tells a machine how to make a product by generating toolpaths • Machinery that can turn raw material into a finished product Post Processing converts toolpaths into a language machines can understand CAM application: • Manufacturing Planning • Manufacturing Control Computer Aided Engineering (CAE): is the use of computer software to simulate performance in order to improve product designs or assist in the resolution of engineering problems for a wide range of industries CAE Applications: • Stress and dynamics analysis on components and assemblies using finite element analysis (FEA) • Thermal and fluid analysis using computational fluid dynamics (CFD) • Kinematics and dynamic analysis of mechanisms (multi-body dynamics) Computer Aided Quality Assurances (CAQ): is the engineering application of computers and computer controlled machines for inspection of the quality of products CAQ Applications: • Inspection plan management • Statistical process control (SPC) • Supplier quality management • The Computer Aided Manufacturing Planning (CAMP): computers are used indirectly to support the production function CAMP Applications: • Computer Aided Process Planning (CAPP) • Computer assisted NC part programming • Computerized machinability data systems • Development of work standards • Cost estimation • Production and inventory planning • Computer aided line balancing Enterprise Resources Planning (ERP): is a software used to allow automation and integration of business processes in the real time manner ERP modules include: • Basic MRP • Finance • Human resources • Supply chain management (SCM) • Customer relationship management (CRM) o Sustainability Devices and Equipment Required Computer numerical controlled machine tools (CNC): is an electro-mechanical device that uses computer programming inputs to operate machine shop tools Direct numerical control machine tools (DNC): A system connecting a set of numerically controlled machines to a common memory for part program or machine program storage with provision for on-demand distribution of data to machines Programmable logic controllers (PLCs): is a digital computer used for industrial automation to automate different electro-mechanical processes Robots: a machine controlled by a computer that is used to perform jobs automatically Networks: is a collection of computers, servers, mainframes, network devices, peripherals, or other devices connected to allow data sharing Monitoring equipment refers to the equipment installed for assessment of the correct operation of machines or processes Technologies: Flexible manufacturing system (FMS): “a highly automated Group Technologies machine cell, consisting of a group of processing workstations (usually CNC machine tools), interconnected by an automated material handling and storage system, and controlled by a distributed computer system A flexible manufacturing system (FMS) is a manufacturing system that is designed to easily adapt to production changes Typical FMS are: • Machine flexibility • Production flexibility • Process flexibility • Product flexibility • Routing flexibility • Volume (or capacity) flexibility • Expansion flexibility Automated storage and retrieval systems (ASRS): are computer- and robot-aided systems that can retrieve items or store them in specific locations Automated guided vehicle (AGV): is a portable robot that follows along marked long lines or wires on the floor, or uses radio waves, vision cameras, magnets, or lasers for navigation They are most often used in industrial applications to transport heavy materials around a large industrial building, such as a factory or warehouse Automated conveyance systems (ACS): is a fast and efficient mechanical handling apparatus for automatically transporting loads and materials within an area 1.3 CIM functions Computer Integrated Manufacturing (CIM) encompasses the entire range of product development and manufacturing activities with all the functions being carried out with the help of dedicated software packages The data required for various functions are passed from one application software to another in a seamless manner For example, the product data is created during design This data has to be transferred from the modeling software to manufacturing software without any loss of data CIM uses a common database wherever feasible and communication technologies to integrate design, manufacturing and associated business functions that combine the automated segments of a factory or a manufacturing facility CIM reduces the human component of manufacturing and thereby relieves the process of its slow, expensive and error-prone component CIM stands for a holistic and methodological approach to the activities of the manufacturing enterprise in order to achieve vast improvement in its performance In a CIM system functional areas such as design, analysis, planning, purchasing, cost accounting, inventory control, and distribution are linked through the computer with factory floor functions such as materials handling and management, providing direct control and monitoring of all the operations CIM software comprises computer programs to carry out the following functions: • Management Information System • Job Tracking • Sales • Inventory Control • Marketing • Shop Floor Data Collection • Finance • Order Entry • Database Management • Materials Handling • Modeling and Design • Device Drivers • Analysis • Process Planning • Simulation • Manufacturing Facilities Planning • Communications • Workflow Automation 1.4 Factors affecting CIM applications Key factors affecting CIM applications The first factor that is most concerned about the application of CIM is revenue and profit Investors will consider the trade-off between applying CIM or not Does the application of CIM in businesses bring profits to managers or will it cause waste? The second factor affecting the investment of the CIM system is capital The investment in a whole CIM line will cost a lot more than the traditional line However, the payback period will be shorter due to lower operating costs The third factor in the operation process is maintenance The system is operated entirely by computer Besides that is the support of robotic arms Therefore, the maintenance staff must have extremely good expertise to ensure that the system is operating stably and without problems Integration of components from different suppliers • When different machines, such as CNC, conveyors and robots, are using different communications protocols In the case of AGVs, even differing lengths of time for charging the batteries may cause problems Data integrity • The higher the degree of automation, the more critical is the integrity of the data used to control the machines • While the CIM system saves on labor of operating the machines, it requires extra human labor in ensuring that there are proper safeguards for the data signals that are used to control the machines Process control • Computers may be used to assist the human operators of the manufacturing facility, but there must always be a competent engineer on hand to handle circumstances which could not be foreseen by the designers of the control software PART 2: CIM SYSTEM DESIGN 2.1 Identifying the CIM system requirements and functions In the following, we give some fundamentals about shoe components and their different manufacturing phases centimeters Aside from sustaining the body weight, it gives the shoe its particular appearance, and this is the reason why there are so many variants Shoe Design Up to a few decades ago, shoe design and construction could be considered a fruit of engineering, architectural and stylisti experience, surely a great demonstration of manual skills Almost everything was left to shoe designer’s fancy, interpretative ability and experience The dependence on the skills of a single person and the time required by the design (often requiring repeated trial-and-error steps) induced companies to spend energies on the automation and simplification of the whole process This change is still happening, and the current production mixes up technology and handcrafting skills The CAD and Computer Aided Manufacturing (CAM) technologies were introduced in the footwear sector only in the 1980s Developing these new technologies became important when the fashion induced a much wider selection of different shoe models There are two main footwear CADs: o 3D CADs which allow the designer to interact with 3D entities such as the last, heel, upper, and sole in a way similar to the traditional manual process; o 2D CADs which only allow to manage the upper after it has been flattened Manufacturing Phases Manufacturing a shoe requires a great deal of workmanship and personal experience, even though most of the manual work is assisted by more or less sophisticated machines There are three main philosophies on which machines for footwear production are built: manual, semiautomatic, or automatic machines Depending on the amount of automation present in the factory, there can be even the three types of machines all together, spread over the whole manufacturing chain Figure 2 CIM detailed requirments The shoe assembly process (also named lasting or making) can be split in six main steps: • last and upper preparation; • assembling of the upper on the last; • heat treatment; • bottom and sole preparation; • sole fastening; • last removal and finishing 2.2 System architecture design 2.2.1 Developing a flowchart showing material flow and information flow in the production system Process flow for footwear manufacture In order to manufacture a pair of shoes in a shop floor, material is given to two manufacturing areas which are upper and bottom(sole) parts Cutting and stitching processes are implemented in the upper part, and soles are manufactured and stocked from outsole (O/S) press, polyurethane(PU) and phylon(P/L) press in the sole part Components of these two parts are firstly collected in two set places which are upper set place(USP) and bottom set place(BSP), and secondly assembled in an assembly set place(ASP) and sent to a footwear warehouse Fig 2.3 shows a process flow for footwear manufacture Figure Process flow for footwear manufacture An MP module for FPS plays a role of POP system and uses hardware devices for data gathering, conversion, offering and instruction, and its software is composed of three submodules which implements planning, gathering and management Information flow of MP module Information flow of manufacturing processes is like Fig 2.4 In production plan department, a process plan is established, information of daily work sheet is input and labels for shoes are printed according to the input information and handed to manufacturing departments in shop floor Then components of shoes are manufactured according to the output information of production plan and packed by groups, and labels are attached to the packages for management The attached labels are respectively scanned in manufacturing departments Scanned data are input and transferred, a line controller collects and saves delivered data in a manufacturing department, and transferred to the main server The received data are stored at the server, machined and delivered to some necessary departments The software of MP module is composed of three sub-modules The first is a sub-module which implements planning, production and inventory management by using a special label system, the second implements gathering of shop floor data and communication, and the third is used for system manager In the first sub-module, operations that implement data change, data control, planning and warehouse management are programmed Program for real-time monitoring and line control are executed in the second sub-module Real-time monitoring program is for communication with all manufacturing department and line control program is for assembly department, preparing or sewing department, department of assembly set place, uploading to oracle server and information control of products warehouse Stock management and configuration program are implemented in the third sub-module Figure Information flow of MP module Information Flow of Footwear Production System A pair of footwear is produced by implementing many functions from receipt of order information to delivery of a finished product The information flow of the footwear production system(FPS) is shown in Fig In view of manufacturing and management information technology, The software of the footwear production system is composed of modules which are order process(OP), process planning(PP), manufacturing process(MP), material resource planning(MRP) and cost processing (CP) Figure Information Flow of Footwear Production System In Fig 2.5, the system starts from receipt of order information of a new model A new model is designed at the development department and a production planning is set up In production planning department, a master production plan is scheduled, and a material resource planning is established according to production planning information, and materials are ordered and put into a warehouse According to the operation sheet information, materials for footwear products are taken out of a warehouse, delivered and manufactured in manufacturing departments for uppers and soles An upper is composed of many pieces and manufactured by cutting and stitching Outsole, midsole and insole are made by outsole press, injection phylon press and polyurethane, and assembled with an upper at an assembly set place A product assembled is tested through quality control department and the finished footwear product is delivered The developed system is related to software of manufacturing process modules and hardware for shop floor data input in production information flow 2.2.2 Describing functions of each component in the production system Modern production contexts need wider and wider interoperability among software applications with different nature and origin Indeed, this is relevant especially when passing from the design to production, exploiting strong automation and integration among processes and inside them Order information and automatic scheduling through computer Dealing indibviduals orders of various products Control of due dates Preparing Production Planning Inventory control through JIT Minimizing raw material, WIP, inventory Utilizing bar code, RFID Statitical quality control: quality improvement Monitoring facility, process Data collection for facility operating Report for producing defective goods Records & analysis of failing facility Data collection for MIS WIP data Shipment data Direct & Indirect labor data Production control data, defective rate, operation rate, failure rate, production rate Supplier record, quality, acomplishment Defective production data Managing MIS data Reducing indirect cost Rapid decision making using data base Diagnosing failure Minimizing down time Details of failure ( problems) 2.2.3 Indicating technologies and software used in the corresponding components Designing: CAD: is technology for design and technical documentation, which replaces manual drafting with an automated process Figure Designing Adobe Illustrator wrote the book on vector graphics software It sets the standard for professionally designed logos, artwork, infographics, icons, and much more • Affinity Designer: is an excellent choice for personal projects or novice graphic designers with its intuitive user interface o Simulation: Tecnomatix Plant Simulation, Siemens Technomatic, Processing: • Solidification processes, in which the starting material is a heated liquid or semifluid that cools and solidifies to form the part geometry • Particulate processing, in which the starting material is a powder, and the powders are formed and heated into the desired geometry • Figure Processing • Deformation processes, in which the starting material is a ductile solid (commonly metal) that is deformed to shape the part • • • • Material removal processes, in which the starting material is a solid (ductile or brittle), from which material is removed so that the resulting part has the desired geometry Cleaning: includes both chemical and mechanical processes as well as ultrasonic to remove dirt, oil, and other contaminants from the surface Surface treatments: include mechanical working such as shot peening and sand blasting, and physical processes such as diffusion and ion implantation Coating and thin film deposition processes: apply a coating of material to the exterior surface of the work-part Assembling: • • Welding: is the process of heating and welding two pieces of metal together using a powerful electric current Brazing and soldering: is a method of joining without melting the base materials Figure Brazing and soldering • • • • Adhesive bonding: is a manufacturing process in which two or more surfaces are joined using an adhesive Threaded fasteners: are bolts, studs and nuts of different types are widely used for joining parts together Permanent fastening: are single-use fasteners such as rivets and nails, that are designed to permanently join two materials or parts CAE Applications: Stress and dynamics analysis on components and assemblies using finite element analysis (FEA) Inspection (Measuring, Gauging, Observation) • Computer Aided Quality Assurances (CAQ): is the engineering application of computers and computer controlled machines for inspection of the quality of products Figure Computer Aided Quality Assurances Storage Automated storage and retrieval systems (ASRS) are made of a variation of computer-controlled systems that automatically place and retrieve loads from set storage locations in a facility with precision, accuracy and speed Figure 10 Storage Dispatch Dispatch software are systems designed to help automate routing and scheduling processes, provide a simpler and more efficient way to coordinate routes and deliveries while mitigating costly errors 2.3 Developing a database The number and type of processes required to make a shoe depend heavily on several factors such as the type of shoe, the desired quality of the finished product, production time constraints, and final cost Here is a list of the most general manufacturing rules, even though every shoe factory follows its own rules Figure 11 Database Last and Upper Preparation: The last: the shoe assembling phase is done on a last to give the shoe its right shape The upper, initially flat, is forced to assume the last shape with pincers and other grabbing devices, which are part of some machines (such as the toe lasting machine and the seat and side lasting machine) This central role in the production process gives the last a great importance, since errors in the last design or production can lead to problems in later manufacturing phases or in the shoe usage The upper: the initial upper design is performed by a shoe designer directly on the last or on a standard shape (the flattened upper) following the fashion designer drawings This work is done for a single size, it is flattened (if done on the 3D last) and scaled to generate all the shoe sizes usually available A testing phase, during which a small set of shoes is produced, is usually done to detect and fix possible errors The next step is the component (pieces) production The leather cutting can be done manually for small productions, or automatically for medium and large-scale productions Cutting machines can have or not have socket punch, thus actually changing the operations needed to obtain a single piece Cutting with a socket punch is fast but requires the production of templates (a time-consuming process) which are pressed on the leather Cutting without socket punch can be either hand-done (using a cutter and a paperboard reference) or automatically using cutting machines which are somewhat similar to plotters with several cutting heads The pieces to be cut are coded in a file and projected on the leather so that the operator can place them in the best (less space waste) way There are many technologies for this kind of machines (oscillating blade, ultrasonic, laser, water-jet, etc.) Cutting without a socket punch is very economic and flexible and (obviously) removes the time penalty of building the template itself It is the preferred technology for prototyping and, with the most advanced software, even less experienced personnel can obtain good results As usual, several means and materials are available to achieve different cost/quality compromises Once the upper is complete, the outside counter performing is done In this phase, the heel area is thermally shaped and the counter is placed The insole: the next step is to temporarily fasten the insole to the last, through paper tape or a nail, and its trimming These operations are usually either manual or performed with semiautomatic machines Assembling the Upper on the Last: The shoe assembling is usually done with two semiautomatic machines, the tack lasting machine (for the fore part) and the waist lasting machine (for the lateral and back parts) The upper is fastened with glue and/or nails A peening phase ensures good coupling between glued components Heat Treatment: The assembled shoe must remain on the last for some time to permanently assume the proper shape To shorten this time, the shoe is subjected to relatively strong thermal shocks Bottom and Insole Preparation: The next steps are roughing (used to remove the leather superficial layer whose finishing treatments are somewhat glue repellent) and gluing of the bottom preparing it to the sole fastening These phases are usually performed through semiautomatic machines, and sometimes the same machine performs both operations Sole Fastening: In this phase, the sole and the upper-ins a sole-press is used Doing this operation with great care is extremely important for the quality of the finished product Last Removal and Finishing: Once the shoe is completed the last is removed It is now possible to fasten the heel and the final operations (like polishing) are performed After some quality checks, the finished shoe is confectioned PART 3: CONCLUSIONS 3.1 Strengths and weakness of the CIM system that your group has designed Strengths: • Less error-prone • Creates an automated manufacturing process • System is constantly monitored so if there is a breakdown: the type and location of breakdown is easily identified making maintenance easier • Reduces cost of maintenance • After the high initial greater profits will be achieved Weaknesses: • Full dependent on computer data This can be a problem if the data can only be interpreted on one brand of software company, and if some machinery requires software for another software brand then this can be an issue • High initial capital costs/investments due to computers, robots, training of personnel • Maintenance is complex, requires highly skilled employees 3.2 What should be taken into consideration in running the your CIM system Expensive and time-consuming tasks such as maintenance and reliability become critical aspects Thus the equipment must then be designed for maintenance Modularity and reconfigurability in manufacturing systems and system components must also be considered The characteristics of a company in terms of capital, knowledge workers, complexity of the material flow, layout types, etc should be considered while designing and implementing CIM Human factors : should be considered at the earliest stages of the planning and implementation of CIM systems If not, a CIM project may fail as workers struggle to operate and maintain the system Human factors are important in areas such as installation, operation, maintenance, and safety Installation requires workers well trained in automation principles Knowledge workers such as computer operators and software engineers, and a multi-functional workforce are essential to improve integration and adaptation in the implementation of CIM CIM is not just a hardware/software solution It also affects the way people work and the way they interrelate Most people resist changes and the changes can make workers feel threatened The introduction of any new technology must be handled carefully and sensitively CIM can help break down the (communication) barriers • • • between specialist areas (design, production, accounts, etc.) since they start to share common pools of data Although linking of the different parts of a production system is an integral part of CIM, the various parts of the system should not be so tightly coupled that failure in any one part brings down the entire system - the system should include some redundancy, back-up and decoupling mechanism Location decisions, for example, may be affected by the shift in relative costs associated with a CIM system Establish clear business KPIs as well as calculate ROI (return in investment) It is critical to set clear KPIs and evaluate ROI Based on calculations for different scenarios, we can understand the advantages of implementing CIM Analyzing your manufacturing problems It is critical to get more visibility into the manufacturing issues and requirements We need to analyze your final product's quality and how it can be enhanced Then, we have to consider all the benefits and drawbacks of CIM Also, we should understand how the quality improvement process can be boosted by CIM technology • Ensuring an efficient CIM engineering process: You have to keep in mind that the success of any computer integrated manufacturing (CIM) project heavily depends on the following aspects: o finding top-notch specialists that will assist you on this path; o choosing the suitable sources of data; o allocating IoT sensors that collect data from different devices; o developing an ecosystem of platforms that collect data from different sources; o cleaning, aggregating, and preprocessing the data; o applying machine learning/AI or data science models; o visualizing the insights • Develop production and process management techniques or systems o These footwear manufacturing circumstances of disharmony make production management difficult o In order to implement CIM system in a shop floor, real-time information of shop floor should be collected, analyzed, delivered and used to other departments effectively o Computer Aided Process Planning (CAPP), CNC machine, CAD/CAM integration can add to improve productivity and reduce waste o Due to the nature of the shoe manufacturing industry and the complex operations that have to be performed in order to construct a shoe, we have to examine a selection of operations for processing single flat component parts as well as more complex three-dimensional operations encountered when lasting and soling a shoe 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Inform Technol., vol 15, no 4, pp 243–244, 2000, Palgrave-Macmillan eds [8] A S Bharadwaj, “A resource-based perspective on information technology capability and firm performance: An empirical investigation,” MIS Quarterly, vol 24, no 1, pp 169–196, 2000 [9] M S Threlkel and B Kavan, “From traditional EDI to internet-based EDI: Managerial considerations,” J Inf Manage., vol 14, pp 347–360, 1999 [10] C L Iacovou et al., “Electronic data interchange and small organizations: Adoption and impact of technology,” MIS Quarterly, vol 19, no 4, pp 465–485, 1995 ... and machines to communicate It includes CAD (Computer- Aided Design), CAM (ComputerAided Manufacturing) , CAPP (Computer- Aided Process Planning, CNC (Computer Numerical Control Machine tools), DNC... • Analysis • Documentation • Manufacturing • Management Computer Aided Manufacturing (CAM): is the use of software and computercontrolled machinery to automate a manufacturing process Basically... management • The Computer Aided Manufacturing Planning (CAMP): computers are used indirectly to support the production function CAMP Applications: • Computer Aided Process Planning (CAPP) • Computer