Computer Integrated Manufacturing and Robotics (IPPC-307) PDF

Computer Integrated Manufacturing and Robotics (IPPC-307) Instructor: Dr. Bikash Kumar Assistant Professor, IPE Department National Institute of Technology Jalandhar Email: [email protected] DR. B. R. AMBEDKAR...

Computer Integrated Manufacturing and Robotics (IPPC-307) Instructor: Dr. Bikash Kumar Assistant Professor, IPE Department National Institute of Technology Jalandhar Email: [email protected] DR. B. R. AMBEDKAR NATIONAL INSTITUTE OF TECHNOLOGY JALANDHAR (An Institute of National Importance, established by MHRD) DETAILED SYLLABUS Introduction: Scope, islands of automation, architecture of CIM, information flow in CIM, elements of CIM, benefits, limitations, obstacles in implementation. Product Design and CAD, application of computers in design, CAM - manufacturing planning and control, concurrent engineering, design for manufacturing and assembly. Group Technology: Concept, design and manufacturing attributes, part families, composite part, methods of grouping, PFA, classification and coding system- OPITZ, MICLASS, Relevance of GT in CIM, GT and CAD, benefits and limitations of GT. Flexible Manufacturing Systems: Concept, flexible & rigid manufacturing, manufacturing cell and FMS structure, types, components of FMS, Distributed Numerical Control (DNC), Building Blocks of FMS, Flexible Assembly System. Computer Aided Production Planning and Control: Computer integrated production management system, Variant & Generative methods of CAPP, aggregate planning, master production schedule, shop floor control, materials requirement planning, capacity planning, manufacturing resource planning and enterprise resource planning. Computer Aided Quality Control: Objectives, non-contact inspection methods, equipment; contact type inspection: Co-ordinate Measuring Machines (CMM), construction, working principle and applications, Inspection robots. Production Support Machines and Systems in CIM: Industrial robots for load/unload, automated material handling, automatic guided vehicles, automated storage and retrieval system. Kinematics, dynamics and control of robotic manipulators. Data Acquisition and Database Management Systems: (a) Data acquisition system, type of data, automatic data identification methods, bar code technology, machine vision.(b) Data and database management system, database design requirements, types of DBMS models- hierarchical, network and relational models and their applications. Communication in CIMS: Role of communication in CIMS, requirements of shop floor communication, types and components of communication systems in CIM, Networking concepts, network topology, access methods, ISO-OSI reference model for protocols, MAP/TOP, TCP/IP. Planning and Implementation of CIMS: Planning for CIMS, need for planning, Phases of CIM implementation, incremental implementation and one-time implementation, CIM benchmarking, Economic and social justification of CIM., CIM case studies Dr. Bikash Kumar 2 Reference Books Ibrahim Z. and Sivasubramanian, R., “CAD/CAM Theory and Practice”, Tata McGraw Hill Publications, New Delhi, 2009. Paul R., “Computer Integrated Manufacturing”, Prentice Hall, 2005. Groover M. P., “Automation, Production Systems and Computer Integrated Manufacturing”, Prentice Hall, 2007. Rao P.N., “CAD / CAM Principles and Applications”, McGraw Hill Publishers, New Delhi, 2010. Yoram K., “Computer Control of Manufacturing Systems”, McGraw Hill Publications, 2005. Dr. Bikash Kumar 3 Course objectives ✓ At the end of the course you shall be able to acquire knowledge of engineering product specifications in respect of CAD/CAM integration. ✓ You shall be able to generate and manage the data in FMS and CIM systems. ✓ You shall be able to generate and manage the part programming using G-/M-code. Dr. Bikash Kumar 4 Course Outcomes 1. Understand the elements of an automated manufacturing environment. 2. Design flexible manufacturing cell after carrying out group technology study and finally creating FMS. 3. Apply data management and its importance for decision making in CIMS environment. 4. Apply knowledge about various methods of communication in CIMS. 5. Apply knowledge about Computer Aided Quality control and Process Planning Control. 6. Understand and apply the kinematics, dynamics and control for industrial robots Dr. Bikash Kumar 5 Evaluation Scheme ▪ Continuous Assessment (I, II, III) ▪ Continuous Assessment I: (A, B, C, D) A, B, C and D Objective Filling Short Quiz test blank test duration test ▪ Continuous Assessment II: Group assignment, Presentation, Group project ▪ Continuous Assessment III: Class participation, other.. ▪ End Semester Examination ▪ Attendance/Project Dr. Bikash Kumar 6  INTRODUCTION Introduction: Scope, islands of automation, architecture of CIM, information flow in CIM, elements of CIM, benefits, limitations, obstacles in implementation. Product Design and CAD, application of computers in design, CAM - manufacturing planning and control, concurrent engineering, design for manufacturing and assembly. Dr. Bikash Kumar 7 Learning Objectives Production Systems Understand the various spheres of manufacturing activity where computers are used What is meant by product cycle with the differences between the conventional and computer-based manufacturing systems Definitions of various computer-based applications Discuss various facets of the design process Computer Aided Design and its applications Various types of manufacturing organisations Computer Aided Manufacturing and its applications Meaning of Computer Integrated Manufacturing Dr. Bikash Kumar 8 Introduction The word manufacturing derives from two Latin words, ✓manus (hand) and ✓factus (make) Combination means made by hand. First appeared in the English language around 1567. Commercial goods of those times were made by hand. The methods were handicraft, accomplished in small shops, and the goods were relatively simple, at least as compared with today’s standards. Factories came into existence, with many workers at a single site. The work had to be organized using machines rather than handicraft techniques. Dr. Bikash Kumar 9 Contd… The products became more complex, and so the processing had been done to fabricate them. Workers had to have expertise in their tasks. Rather than overseeing the fabrication of the entire product, they were responsible for only a small unit of the total work. More up-front planning was required, and more coordination of the operations were needed to keep track of the work flow in the factories. Slowly but surely, the systems of production were being developed. The systems of production are essential in modern manufacturing. Dr. Bikash Kumar 10 Production System Defined A collection of people, equipment, and procedures organized to accomplish the manufacturing operations of a company Dr. Bikash Kumar 11 Facilities… Production System Facilities include the factory, production machines and tooling, material handling equipment, inspection equipment, and computer systems that control the manufacturing operations. Plant layout – the way the equipment is physically arranged in the factory Manufacturing systems – logical groupings of equipment and workers in the factory The manufacturing systems come in direct physical contact with the parts and/or assemblies being made. They “touch” the product. Dr. Bikash Kumar 12 Manufacturing Systems Three categories in terms of the human participation in the processes performed by the manufacturing system: 1. Manual work systems - a worker performing one or more tasks without the aid of powered tools, but sometimes using hand tools 2. Worker-machine systems - a worker operating powered equipment 3. Automated systems - a process performed by a machine without direct participation of a human Dr. Bikash Kumar 13 Manual Work System Examples A machinist using a file to round the edges of a rectangular part that has just been milled A quality control inspector using a micrometer to measure the diameter of a shaft A material handling worker using a trolley to move cartons in a warehouse A team of assembly workers putting together a piece of machinery using hand tools. Dr. Bikash Kumar 15 Worker-Machine System Examples A machinist operating on lathe to fabricate a part for a product A fitter and an industrial robot working together in an arc–welding work cell A crew of workers operating a rolling mill that converts hot steel slabs into flat plates A production line in which the products are moved by mechanized conveyor and the workers at some of the stations use power tools to accomplish their processing or assembly tasks. Dr. Bikash Kumar 16 Automated System Examples Chemical processes, oil Refineries, and Nuclear power plants. Dr. Bikash Kumar 17 Manufacturing Support Systems Involves a cycle of information-processing activities that consists of four functions: 1. Business functions - sales and marketing, order entry, cost accounting, customer billing 2. Product design - research and development, design engineering, prototype shop 3. Manufacturing planning - process planning, production planning, MRP, capacity planning 4. Manufacturing control - shop floor control, inventory control, quality control Dr. Bikash Kumar 18 Information Processing Cycle in Manufacturing Support Systems Dr. Bikash Kumar 19 COMPUTERS IN INDUSTRIAL MANUFACTURING The role of computers in manufacturing may be broadly classified into two groups: 1. Computer monitoring and control of the manufacturing process 2. Manufacturing support applications, which deal essentially with the preparations for actual manufacturing and post-manufacture operations In the first category: such applications where the computer is directly interfaced with the manufacturing apparatus for monitoring and control functions in the manufacturing process. Dr. Bikash Kumar 20 Contd… In the second category: all the support functions that computers can provide for the successful completion of manufacturing operations. The types of support that can be envisaged are the following: CAD— Computer Aided Design The use of computer methods to develop the geometric model of the product in three-dimensional form, such that the geometric and manufacturing requirements can be examined. CADD— Computer Aided Design and Drafting Combining the CAD function with drafting to generate the production drawings of the part for the purpose of downstream processing. Dr. Bikash Kumar 21 Contd… CAE— Computer Aided Engineering The use of computer methods to support basic error checking, analysis, optimisation, manufacturability, etc., of a product design. CAM— Computer Aided Manufacturing Generally refers to the computer software used for machining and other processing applications. develop the Computer Numerical Control part programs. CNC simulator CAPP— Computer Aided Process Planning The use of computers to generate the process plans for the complete manufacture of products and parts. KAM soft CATD— Computer Aided Tool Design Computer assistance to be used for developing the tools for manufacture such as jigs and fixtures, dies, and moulds. Dr. Bikash Kumar 22 Contd… CAP— Computer Aided Planning The use of computers for many of the planning functions such as material requirement planning, scheduling, etc. ERP, PLM CAQ— Computer Aided Quality Assurance The use of computers and computer-controlled equipment for assessing the inspection methods and developing the quality control and assurance functions. APQP (advance product quality planning) CAT— Computer Aided Testing Refers to the software tools that can take a system through its various phases of operations and examine the response against the expected results. CACSD, CADMAT Checking the part whether it is within the specified tolerance or not. Dr. Bikash Kumar 23 Why computer integration is needed? 1. To increase labor productivity 2. To reduce labor cost 3. To minimize the effects of labor shortages 4. To reduce or remove routine manual and clerical tasks 5. To improve worker safety 6. To improve product quality 7. To reduce manufacturing lead time 8. To accomplish what cannot be done manually 9. To decrease work-in-process inventory 10.To improve scheduling performance Dr. Bikash Kumar 25 Definition Integration Total manufacturing enterprises using Integrated systems +data communications Coupled with New managerial philosophies Dr. Bikash Kumar 26 Scope of CIM PRODUCT DESIGN INFORMATION MARKETING FINANCE PLANNING CIM WAREHOUSING PURCHASING AUTOMATED WORK MANUFACTURING CENTRE Dr. Bikash Kumar 27 Island of automation Automation: process in which a machine follows a predetermined sequence of operations with little or no human intervention. IoA: refers to a situation in which individual systems or processes within an organization are automated independently, resulting in disconnected & isolated islands of automated functionalities. Ineffective communication or integration leading to inefficient or limited overall automation benefit. Ex: one dept opted automated system to manage customers, and inventory tracking is also automated, hence automation may be successful on its own, however, overall they fail to create a comprehensive end-to-end automation ecosystem. Dr. Bikash Kumar 28 Challenges resulting from IoA Lack of coordination Inefficiency Limited visibility Scaling difficulties Dr. Bikash Kumar 29 DESIGN PROCESS Design is an activity that needs to be well organised and should take all influences that are likely to be responsible for the success of the product under development, into account. A product can range from a single component, which is functional in itself like a wrench (spanner) to the assembly of a large number of components all of which will contribute to the functioning of the part, such as an automobile engine. The complexity of the design process increases with the number and diversity of components present in the final part. Dr. Bikash Kumar 30 Contd… The various faculties that are responsible for a successful product can be classified under two headings as follows: Product Engineering Manufacturing Engineering Product functions Process Planning Product specifications Tooling Conceptual design Manufacturing Information Ergonomics and Aesthetics Generation Standards Production Organisation Detailed design Marketing and Distribution Prototype development Testing Simulation Analysis Drafting Dr. Bikash Kumar 31 Contd… Ideally, the designer should consider all these factors while finalising the design. It is impossible for a single individual to carry out all these functions, except in the case of simple parts. For complex systems, the product design function needs to be carried out by a team of specialists who have specified knowledge and experience in the individual areas as mentioned earlier. The design process goes through well-structured stages to reach the stage of actual part production. Dr. Bikash Kumar 32 Why PD is important before Manufacturing Well designed product: Can be manufactured using few resources, less time & with minimal waste Can influence cost of tooling & equip. needed for production Ensures that product can be consistently manuf. to meet quality standard, reducing defect & improving reliability Can enhance durability & life span of product, leading to better customer satisfaction Can be easily scaled up for mass production Addressing potential manuf. Issue during design phase can prevent delay later in production process, ultimately speeding up time-to-market Dr. Bikash Kumar 33 Contd… Can be quickly prototyped and tested, allowing for rapid iteraton & refinement Ensures product meet all necessary safety standard, reducing the risk Can affect environmental footprint of manuf. Process, influencing material waste, energy consumption & recyclability Dr. Bikash Kumar 34 Stages in the design process Problem identification and need recognition Problem definition and conceptualization Geometric modeling and spatial analysis Engineering analysis and optimization Prototype development Manufacturing process development Manufacturing Implementation Dr. Bikash Kumar 35 Problem Identification At this stage, it is possible to identify some of the basic questions related to the product such as who, what, where, when, why and how many should be answered with fair accuracy. In order to provide answers, the design team may have to explore a number of sources and methods. Dr. Bikash Kumar 36 Contd… Historical Information: Already existing information collected through the literature, marketing surveys, etc. This should be able to answer questions like ✓The current technology ✓Existing solutions (even competitor’s product details) Requirement Specification: A clear definition of the requirements is specified at this stage. Market Forces: Consider the various market forces that will affect the product. General Solutions: By resorting to past designs, engineering standards, technical reports, catalogues, handbooks, patents, etc. Dr. Bikash Kumar 37 Problem Definition The next stage is the clear definition of the problem and coming up with all possible ideas for solutions. May be carried out in various forms of components Processes involved in the problem-definition stage Dr. Bikash Kumar 38 Geometric Modelling Provides a means of representing part geometry in graphical form At this stage, it is necessary to employ computers at the various phases. Dr. Bikash Kumar 39 Engineering Analysis A thorough analysis of the product is carried out to get as much of information as possible before committing to final manufacturing. For this purpose, a large number of computer aids are available. The analysis stage is basically an iterative one with modification to the geometric model being carried out until the desired end result is achieved. Dr. Bikash Kumar 40 Strength Analysis It is necessary to obtain the stresses and strains in the component when it is in service. Analytical methods are feasible for simple shapes and configurations. However, for complex shapes, it is necessary to use finite element analysis methods. Finite Element Analysis (FEA) breaks down a model into small uniform elements and applies the loading and boundary conditions for each of the elements. The stresses and strains thus derived are more representative of the final values. Dr. Bikash Kumar 41 Kinematic Analysis Many of the parts developed will have a number of components, some of which will also have relative motion requirements under service. Kinematic-analysis systems allow the user to optimize the product performance by providing a fundamental understanding of how a design will perform in its real- world environment. This understanding, such as how an assembly will behave in motion and how the individual parts move under extreme conditions, provides the necessary insight for creating the best possible product design. Dr. Bikash Kumar 42 Dynamic Analysis For certain equipment that is likely to be operating under high speeds, it is necessary to extend the above system for dynamic conditions. Using this, engineers can evaluate the designs for vibration requirements by performing dynamic time, frequency, random, and shock-response simulations. Dr. Bikash Kumar 43 Design for Manufacture and Assembly Design for Manufacture and Assembly (DfMA) is a design approach that focuses on ease of manufacture and efficiency of assembly. By simplifying the design of a product it is possible to manufacture and assemble it more efficiently, in the minimum time and at a lower cost. DfMA combines two related concepts: 1. Design for Manufacture (DFM) 2. Design for Assembly (DFA) Dr. Bikash Kumar 44 Design for Manufacture (DFM) DFM involves designing for the ease of manufacture of a product’s constituent parts. concerned with selecting the most cost-effective materials and processes to be used in production, and minimising the complexity of the manufacturing operations. Design for Assembly (DFA) DFA involves design for a product’s ease of assembly. It is concerned with reducing the product assembly cost and minimising the number of assembly operations. Both DFM and DFA seek to reduce material, and labour costs. Dr. Bikash Kumar 45 DfMA principles Guidelines Minimise the number of components Tolerances of parts within process capability Clarity: can only be assembled one way Minimise the use of flexible components Design for ease of assembly Eliminate or reduce required adjustments Use standard processes and methods. Limit the manufacturing processes to those already available and that the plant has expertise in. Reduce the variety of manufacturing processes used. Use standard components in the design. Provide liberal tolerances such that overall manufacturing cost could be lowered. Use materials that have better manufacturability. Since many of the secondary operations require additional cost, they should be minimised or avoided. Use modular design Dr. Bikash Kumar 46 Cont. DFMA is a systematic procedure that aims to help companies make the fullest use of the manufacturing processes that exist and keep the number of parts in an assembly to the minimum. Can be achieved by enabling the analysis of design ideas. It is not a design system, and any innovation must come from the design team But it does provide quantification to help decision- making at the early stages of design. Dr. Bikash Kumar 47 Methodology of design for manufacture and assembly Design concept Suggestions for simplification of Design for assembly product structure Selection of materials and process for Suggestions for more economic early cost estimates materials and processes Best design concept Details design for minimum Design for manufacture (DFM) manufacturing costs Prototype Boothroyd and Dewhurst Boothroyd, G. (1996). Design for Manufacture and Assembly: The Boothroyd-Dewhurst Experience. Design for Production X, 19–40. doi:10.1007/978-94-011-3985-4_2 Dr. Bikash Kumar 49 Prototype Development Before committing the design to manufacture An additional physical tests on the part: the need to develop a physical model for such purpose. Rapid prototyping (RP) – A means through which the product geometry as modelled in the earlier stages is utilized to get the physical shape of the component. Rapid Prototyping Test and Design Working evaluation refinement drawings It may be necessary/desirable to A careful evaluation of each Final hard copies of the carry out actual testing on feature and capability components and assemblies → actual parts to verify computer embedded in the design to be to provide information for the simulation. carried out but only involves downstream application in the minor modifications and manufacturing. enhancements. Dr. Bikash Kumar 50 Rapid Prototyping Dr. Bikash Kumar 51 Manufacturing Process Development After finalizing the product design, it is important to move the product to the manufacturing stage. Already the geometric models of the individual components as well as the assemblies are available both in electronic form as well as hard-copy form from the earlier stages. They are utilized for developing the necessary manufacturing processes again utilizing computers to their fullest extent. The typical components present are shown in Fig. Dr. Bikash Kumar 52 Contd… Manufacturing Process Development Process Product planning plant design Tool design Time & motion study Manufacturing Information information requirement generation design Manufacturing simulation Dr. Bikash Kumar 53 Components in Manufacturing Process Development ▪ Process Planning Determine exactly how a product will be made to meet the requirements specified at the most economical cost. ▪ Tool Design Develop tooling design such as fixture, injection mould cavities, mould cores, mould bases, and other tooling. ▪ Manufacturing Information Generation Refers to the various part programs required during the manufacturing such as CNC part programs, robot programs, and inspection programs. ▪ Manufacturing Simulation Carry out the actual simulation of machining on the computer screen → cost and time saving. ▪ Information Requirement Design Refers to the information pertinent to the manufacturing of the part that could be generated using the part model data such as BOM, material requirement planning, production planning, shop-floor control, and plant simulation. ▪ Time and Motion study Optimize the product’s manufacturing cycle such as time for material handling, manufacturing, set-up the component and machine tool. ▪ Production Plant Design The actual plant to produce the design for the production volumes. Dr. Bikash Kumar 54 COMPUTER AIDED DESIGN ( CAD) Computer aided design thus utilizes the computer as a tool for all functions that are involved in the design process. The main functions that would utilize the computer are ✓Layout design for the overall assembly ✓Individual component modelling ✓Assembly modelling ✓Interference and tolerance stack checking ✓Engineering drawings Dr. Bikash Kumar 55 Computer Aided Manufacturing (CAM) Use of computer in manufacturing process. Siemens says: “Computer aided manufacturing (CAM) commonly refers to the use of numerical control (NC) computer software applications to create detailed instructions (G-code) that drive computer numerical control (CNC) machine tools for manufacturing parts. Manufacturers in a variety of industries depend on the capabilities of CAM to produce high-quality parts.” A broader and simpler definition would be: any manufacturing process that uses computer software to facilitate, assist or automate parts of the manufacturing process. Dr. Bikash Kumar 56 Advantages of Using CAM Greater Design Freedom Increased Productivity Greater Operating Flexibility Shorter Lead Time Improved Reliability Reduced Maintenance Reduced Scrap and Rework Better Management Control Dr. Bikash Kumar 58 CAD/CAM CAD/CAM denotes the integration of design and manufacturing activities by means of computer systems. The method of manufacturing a product is a direct function of its design. CAD/CAM establishes a direct link between product design and manufacturing engineering. It is the goal of CAD/CAM not only to automate certain phases of design and certain phases of manufacturing, but also to automate the transition from design to manufacturing. In the ideal CAD/CAM system, it is possible to take the design specification of the product as it resides in the CAD database and convert it automatically into a process plan for making the product. Dr. Bikash Kumar 59 Computer Integrated Manufacturing (CIM) 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. Dr. Bikash Kumar 60 Contd… There are a number of advantages to be gained by employing computer applications in individual domains It is possible to utilize computers in all aspects of the product cycle Dr. Bikash Kumar 61 Scope of CIM Includes all of the engineering functions of CAD/CAM But it also includes the firm’s business functions that are related to manufacturing. Dr. Bikash Kumar 62 Challenges before the manufacturing engineers Required to achieve the following objectives to be competitive in a global context. Reduction in inventory Lower the cost of the product Reduce waste Improve quality Increase flexibility in manufacturing To achieve immediate and rapid response to: ✓ Product changes ✓ Production changes ✓ Process change ✓ Equipment change ✓ Change of personnel CIM technology is an enabling technology to meet the above challenges to the manufacturing. Dr. Bikash Kumar 63 TYPES OF MANUFACTURING The term “manufacturing” covers a broad spectrum of activities. Manufacturing industries can be grouped into following categories: i. Continuous Process Industries ii. Mass Production Industries iii. Batch Production Industries Dr. Bikash Kumar 64 Continuous Process Industries In this type of industry, the production process generally follows a specific sequence. These industries can be easily automated and computers are widely used for process monitoring, control and optimization. Oil refineries, chemical plants, food processing industries, etc. are examples of continuous process industries. Dr. Bikash Kumar 65 Job Production Industries Job production, where items are made individually and each item is finished before the next one is started. Dr. Bikash Kumar 66 Batch Production Industries The largest percentage of manufacturing industries can be classified as batch production industries. The distinguishing features of this type of manufacture are the small to medium size of the batch, and varieties of such products to be taken up in a single shop. Batch production is a method of manufacturing where identical or similar items are produced together for different sized production runs. identical, standardised items are produced Dr. Bikash Kumar 67 CIM HARDWARE Comprises the following: i. Manufacturing equipment such as CNC machines or computerized work centres, robotic work cells, DNC/FMS systems, work handling and tool handling devices, storage devices, sensors, shop floor data collection devices, inspection machines etc. ii. Computers, controllers, CAD/CAM systems, workstations /terminals, data entry terminals, bar code readers, tags, printers, plotters and other peripheral devices, modems, cables, connectors etc. Dr. Bikash Kumar 68 CIM SOFTWARE Comprises computer programmes to carry out the following functions: Management Information Job Tracking System Inventory Control Sales Shop Floor Data Collection Marketing Order Entry Finance Materials Handling Database Management Device Drivers Modeling and Design Process Planning Analysis Manufacturing Facilities Simulation Planning Communications Work Flow Automation Monitoring Business Process Engineering Production Control Network Management Manufacturing Area Control Quality Management Dr. Bikash Kumar 69 PRODUCT DEVELOPMENT THROUGH CIM The expectations of today’s customer include ✓Superior quality and performance, ✓Higher technological capabilities and ✓On time delivery All these are to be provided at reduced costs because of global competition faced by the manufacturing industries. Dr. Bikash Kumar 70 SEQUENTIAL ENGINEERING The traditional product development process It includes product design, development of manufacturing process and supporting quality and testing activities, all carried out one after another. This situation assumes that there is no interaction among the major departments involved in product manufacturing during the initial development process. Often the need for engineering changes is discovered during planning or manufacturing or assembly. Design department in a typical sequential product development process finalizes the design without consulting the manufacturing, quality or purchase departments. Dr. Bikash Kumar 71 Contd… Planning might feel it necessary to request design changes based on several reasons like procurement or facility limitations. Changes in design may be called for when the manufacturing department is unable to meet design specifications or there are problems in assembly. These changes are however to be incorporated in design. The design documents are therefore sent back to the design department for incorporating the changes. The design/redesign path is shown in Fig. Dr. Bikash Kumar 72 Contd… Dr. Bikash Kumar 73 Contd… This will lead to inevitable conflicts, each department sticking to their own decisions and may often require intervention of senior management to resolve conflicts or differences in opinion. Design changes will involve both material and time wastages. In such a situation, time taken to product development is usually more In current age, the time delay between market demand and introduction of product in the market has to be as short as possible. Sequential product development process, therefore, may not suit the present global scenario. Dr. Bikash Kumar 74 Contd… Sequential Engineering is often called “across the wall” method. Each department may function in the insulated way Dr. Bikash Kumar 75 Contd… Each segment of the product development team (Design, Planning, Manufacturing etc.) completes its task in isolation and passes over the documents to the next segment. There is no interaction among the groups before the design is finalized. If a serious mistake in the product is detected during testing, the revision process has to start from design, resulting in materials wastage and loss of time. Dr. Bikash Kumar 76 CONCURRENT ENGINEERING Also known as Simultaneous Engineering The product development is done using a cross functional team approach. Technique adopted to improve the efficiency of product design and reduce the product development cycle time. Sometimes referred to as Parallel Engineering. It brings together a wide spectrum of people from several functional areas in the design and manufacture of a product. Representatives from R & D, engineering, manufacturing, materials management, quality assurance, marketing etc. develop the product as a team. Dr. Bikash Kumar 77 Contd… Everyone interacts with each other from the start, and they perform their tasks in parallel. CE gives the opportunity to marketing and other groups to review the design during the modeling, prototyping and soft tooling phases of development. CAD systems especially 3D modelers can play an important role in early product development phases. In fact, they can become the core of the CE. They offer a visual check when design changes cost the least. Dr. Bikash Kumar 78 COMPARISON OF CE and SE The distribution of the product development cost during the product development cycle This figure shows that though only about 15% of the budget is spent at the time of design completion, whereas the remaining 85% is already committed. The decisions taken during the design stage have an important bearing on the cost of the development of the product. Therefore the development cost and product cost can be reduced by proper and careful design. Dr. Bikash Kumar 79 REDUCTION IN THE NUMBER OF DESIGN CHANGES In CE, large number of design changes are identified and implemented at the beginning or in the early phase of product development cycle. This number goes on decreasing for the remaining period. The reduction in design change requests with CE is substantially less at the later stages of the product development process. Compared to this, defects are detected often during the sequential engineering process. Dr. Bikash Kumar 80 CONTD… Distribution of Design Changes Across the Life Cycle of a Product Concurrent Engineering Sequential Engineering Dr. Bikash Kumar 81 COST OF CHANGES IN DESIGN Cost of Design Change Dr. Bikash Kumar 82 HOLISTIC APPROACH TO PRODUCT DEVELOPMENT Concurrent engineering approach introduces a new philosophy in product development. No longer is product development considered the exclusive activity of the design department. Participation of planning, manufacturing, quality, service, vendor development and marketing personnel in the development process enables the cross functional team to view the development as a total responsibility and this results in better communication among the various departments. Dr. Bikash Kumar 83 ROBUST PRODUCTS Concurrent approach to product design results in products with fewer errors and therefore avoids the loss of goodwill of the customers due to poorly engineered products. The entire product development team looks at each and every aspect of products – cost, specifications, aesthetics, ergonomics, performance and maintainability. The resulting product will naturally satisfy the customer. Dr. Bikash Kumar 84 REDUCTION IN LEAD TIME FOR PRODUCT DEVELOPMENT Time compression in product development is an important issue today. Concurrent engineering reduces the product development time significantly as the preparatory work in all downstream functions can take place concurrently with design. Elimination of the errors in design appreciably reduces the possibility of time overrun, enabling the development schedule to be maintained. Dr. Bikash Kumar 85 Contd… Dr. Bikash Kumar 86 IMPLEMENTATION OF CONCURRENT ENGINEERING The cycle of engineering design and manufacturing planning involves interrelated activities in different engineering disciplines simultaneously, than sequentially Dr. Bikash Kumar 87 CHARACTERISTICS OF CE The concurrent engineering approach can be characterized by the following factors: ✓ Integration of product and process development and logistics support ✓ Closer attention to the needs of customers ✓ Adoption of new technologies ✓ Continuous review of design and development process ✓ Rapid and automated information exchange ✓ Cross functional teams ✓ Rapid prototyping Dr. Bikash Kumar 89 KEY FACTORS INFLUENCING THE SUCCESS OF CE Requires consideration of several important factors. Directives, training programs, reorganizations and pep talks, have been ineffective given the magnitude of change needed to implement CE. CE can succeed if it comes from bottom up in the organization. If those at the bottom share the concerns and agree that a problem exists, they are more likely to work together to solve it. In addition several problems are to be considered before introducing CE. Dr. Bikash Kumar 90 Contd…. Despite the challenges, a manufacturing company may meet, CE will result in considerable reduction in product development time. It should be realized that it may take some time to make the members of the team to work together. Dr. Bikash Kumar 91 Case Study There are several examples of successful implementation of CE. Hewlett Packard is one such example. Its joint venture in Japan, Yokogawa Hewlett-Packard, reported amazing improvements after implementing CE. Over a five year period, R & D’s cycle time decreased by 35%, manufacturing costs declined 42%, inventory dropped 64%. Meanwhile its market share tripled and profits doubled. Dr. Bikash Kumar 92 EXAMPLE OF CONCURRENT ENGINEERING The development of Scooty moped and other products by TVS Motors Ltd. in India. Before taking up the design, cross functional teams were formed to design and engineer the product. This reduced not only the product development time but also helped the manufacturer to introduce the quality product in the market. Dr. Bikash Kumar 93