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3. Operational level. Day-to-day tasks, such as scheduling, are performed at the operational level. The primary responsibility at this level is the effective utilization of the resources made available through the decisions made on the strategic and tactical levels. Because of the variability in demand or machine downtime, the planning horizon at this level must be relatively short, normally 1 to 15 days. While each of these levels has certain responsibilities in a manufacturing plant, the objectives are often conflicting. This can be attributed to inherent differences between departments (e.g., sales and marketing may require a large variety of products to serve every customer s needs, while the production department finds its job easier if there is little product variation). One of the main causes of conflicting decisions is a lack of communication due to ineffective sensors and control systems between levels and departments. CIM with adequate sensors and control systems provides the ability to link together technological advances, eliminate much of the communication gap between levels, and bring all elements into a coherent production system.
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CIM with Sensors and Control Systems at the Plant Level
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Some of the important emerging concepts related to CIM with effective sensors and control systems are flexible manufacturing systems, material handling systems, automated storage and retrieval systems (AS/RS), computer-aided design (CAD), computer-aided engineering (CAE), computer-aided manufacturing (CAM), and microcomputers. These components of CIM can be classified into three major groups (Fig. 5.8).
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5.4.2.1 Flexible Manufacturing Systems Incorporating Sensors and Control Systems
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An FMS can link several elements on the shop floor through sensors in order to coordinate those elements. While CIM can be applied to any manufacturing industry, FMSs find their niche in the realm of discrete production systems such as job shops. The most important FMS elements are numerical control machines and an automated material handling network to transport the product from raw material inventory, through the NC operations, and finally to the finished goods inventory. Numerical control technology has made major advances with the advent of computer numerical control and direct numerical control (CNC/DNC). Microprocessors and sensors located on the machine itself can now provide the codes necessary for the parts to be operated on.
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Strategic Computer-aided management
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Tactical Computer-aided engineering (CAE)
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Operational Computer-aided manufacturing (CAM)
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Decision support system
AI: artificial intelligence DSS: decision support systems DBMS: database management systems
Mfg. Info. System
MIS: management information systems MRP: materials resource planning BOM: bill of materials file
Shop floor control Design
CAD: computer-aided design GT: group technology
Analysis
FEA: finite element analysis FEM: finite element modeling
Quality assurance
CAQA: computer-aided quality assurance SPC: statistical process control
Mfg. Engr.
CAPP: computer-aided process planning GT: group technology NC: numerical control
CNC: computer numerical control DNC: direct numerical control FMS: flexible manufacturing system WIP: work-in-process inventory AS/RS automated storage and retrieval system
FIGURE 5.8
Components within CIM.
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Material Handling
Material handling is the means of loading, unloading, and transporting workpieces among different machines and departments. It is accomplished in several ways: Transfer lines consist of fixed automation machinery such as conveyer belts. Their advantages are high speed and low cost. Their major disadvantage is their lack of flexibility. Dedicated transfer lines can handle only a limited number of parts and cannot be easily changed once in place, thus defeating the goals of an FMS. Robots provide another alternative for moving workpieces. Generally, robots can be made very flexible because of their programmability, but they are limited to their region of access. Automated guided vehicles can move workpieces a great distance, but they lack the speed found in both robot and transfer lines. Yet because of their ability to be programmed to different routes, they are more flexible than transfer lines.
5.4.2.3 Automated Storage and Retrieval Systems
By means of AGVs, raw materials can be taken from the loading dock and placed in a designated place in inventory. Using an AS/RS, inventory can be tracked throughout the manufacturing process and optimized for strategically locating items in storage. Because the process is computerized, data on what exactly is in inventory assist planners in determining order and production schedules. Inventories consist of raw materials, work in process, and finished goods. Inventories should be controlled by keeping track of inventory locations and amounts. An AS/RS can accomplish this task.
5.4.2.4 Computer-Aided Engineering/Design/Manufacturing (CAE/CAD/CAM)
Computer-aided design helps the engineer in many ways during the design stage. Simply drawing the part on a computer increases the productivity of designers, but CAD is more than just automated drafting. It can facilitate group technology and the construction of a bill of materials (BOM) file. Computer-aided engineering consists of the many computerized facets of engineering that go into a particular product. When a part has been designed, the CAE subgroup is responsible for generating the NC code that can be used by the NC machines on the floor. By using GT, similar parts can be classified by similar attributes and placed in part families. By grouping parts this way, much redundancy in design and manufacturing is eliminated.
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