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online 00 (2017) 000–000
atatwww.sciencedirect.com
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Procedia Manufacturing 13 (2017) 1159–1166
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Manufacturing Engineering Society International Conference 2017, MESIC 2017, 28-30 June
Manufacturing Engineering Society
2017, International Conference
Vigo (Pontevedra), Spain2017, MESIC 2017, 28-30 June
2017, Vigo (Pontevedra), Spain
ERP-machining centre integration: a modular kitchen production
ERP-machining
Manufacturing centre
Engineering integration:
Society a modular
International Conference kitchen
2017, production
MESIC 2017, 28-30 June
case
2017, Vigo study Spain
(Pontevedra),
case study
Costing modelsM. Doiro , F.J. Fernández , M. Félix inb,, Industry
G. Santosb 4.0: Trade-off
a a b b
for
M. capacity
Doiro a optimization
, F.J. Fernández a
, M. Félix G. Santos
between usedIndustrial,
capacity and operational efficiency
E.Ingeniería Industrial, Universidad de Vigo, C/Maxwell 9, Vigo 36310, Spain
a

E.Ingeniería a
Universidad
ESD Polyt. Institutebde Vigo,
Cávado eC/Maxwell 9, Vigo 36310,
Ave, Portugal Spain
b
ESD Polyt. Institute Cávado e Ave, Portugal
A. Santana , P. Afonsoa,*, A. Zaninb, R. Wernkeb
a

Abstract a
University of Minho, 4800-058 Guimarães, Portugal
Abstract b
Unochapecó, 89809-000 Chapecó, SC, Brazil
This document presents an ERP system connection with a CNC machining center application in a kitchen furniture
This documentfacility.
manufacturing presentsThis
an has
ERP system connection
contributed with a CNC
to allow individually machining
designed product center application
to every customerinthrough
a kitchen
highfurniture
process
manufacturing
flexibility and facility. ThisAhas
integration. contributed
Dynamic to allow
Structure individually
Parametric designed
Bill Of product
Materials to every
is used customer
as basic elementthrough
in the high process
management
flexibility
informationand
Abstract integration. A Dynamic Structure Parametric Bill Of Materials is used as basic element in the management
system.
information
The machining system.
center used to perform the preassembly machining with different drilling, milling and sawing modules provides a
The
Under machining
process the center
that used
concept
versatility of to not
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would the preassembly
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using single processes
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basedof thewould
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© 2017 The
Indeed, material and
leanAuthors. labor costs
Publishedand
management and an
by Elsevier improvement in the quality of the final product.
B.V. improvement approaches suggest capacity optimization instead of
continuous
© 2017 The Authors.
Peer-review under Published by
responsibility of Elsevier B.V. committee of the Manufacturing Engineering Society International Conference
the scientific
maximization.
© 2017 The Authors.The study of capacity
Published by optimization and costing models is an important research topic that deserves
Peer-review
2017. under responsibility of Elsevier B.V. committee
the scientific of the Manufacturing Engineering Society International Conference
contributions
Peer-review under
2017.
from both the
responsibility practical and
of the scientifictheoretical
committee ofperspectives. This Engineering
the Manufacturing paper presents andInternational
Society discusses aConference
mathematical
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model for capacity management based on different costing models (ABC and TDABC). A generic model has been
Keywords: dynamic structure parametric BOM; kitchen furniture; modularization
developed and it was
Keywords: dynamic used
structure to analyze
parametric BOM;idle capacity
kitchen andmodularization
furniture; to design strategies towards the maximization of organization’s
value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity
optimization
1. Introductionmight hide operational inefficiency.
©1.2017
Introduction
The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference
Modularization of product structures can serve as a means to provide the variety needed from a customer point of
2017.Modularization of product structures can serveacrossas a means to provide thetovariety needed from a customer point of
view and at the same time reuse sub-solutions different products improve time-to-market and maintain
view and
predictable at the same time reuse sub-solutions across different products to improve time-to-market and maintain
Keywords: Costproduct quality
Models; ABC; [1]. Capacity Management; Idle Capacity; Operational Efficiency
TDABC;
predictable product quality
Computer-aided design[1]. and manufacturing (CAD/CAM) systems are key when attempting any Mass
Computer-aided
Customization (MC)design
strategy and[2].manufacturing
This is expected (CAD/CAM)
since, insystems
essence,areMCkeyrelieswhenon attempting
flexibility any Mass
and quick
Customization
responsiveness. (MC) strategy [2]. This is expected since, in essence,
1. IntroductionCAD systems allow customer-driven design changes to be implemented and deployed intoMC relies on flexibility and quick
responsiveness. CAD in
production instructions systems
due time;allowCAM customer-driven
systems handledesign changes
the diversity to beordering
of parts implemented and deployed
while maximizing into
machine
production instructions in due time; CAM systems handle the diversity of parts ordering while
The cost of idle capacity is a fundamental information for companies and their management of extreme importance maximizing machine
in
2351-9789 ©production
modern systems.
2017 The Authors. In general,
Published it isB.V.
by Elsevier defined as unused capacity or production potential and can be measured
in several©under
2351-9789
Peer-review ways: tons of production,
2017responsibility
The Authors. Published
of available
by Elsevier
the scientific B.V.hours
committee of manufacturing,
of the Manufacturing etc.Society
Engineering The International
management of the 2017.
Conference idle capacity
Peer-review underTel.:
* Paulo Afonso. responsibility
+351 253 of the761;
510 scientific committee
fax: +351 253 604of741
the Manufacturing Engineering Society International Conference 2017.
E-mail address: psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017.
2351-9789 © 2017 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017.
10.1016/j.promfg.2017.09.178
1160 M. Doiro et al. / Procedia Manufacturing 13 (2017) 1159–1166
2 M. Doiro / Procedia Manufacturing 00 (2017) 000–000

use. Also Bill of Materials (BOM) has come to play an important role in CAD and computer-aided production
management (CAPM) [3]. Some studies in scientific literature about BOMs [4], CAD/CAM data design [5] and
BOM and CAD/CAM integration (proposing a generic BOM structure) [6] deal with the dynamic environment of
manufacturing. Integrating manufacturing software makes it easier to manage manufacturing data. The integration
enhances value in an economic and time perspective. Shih [7] noted how manufacturing software can be integrated
to increase earnings.
This paper presents the results obtained from an Enterprise Resources Planning (ERP) connection with a CNC -
machining center (Bre.Ma VEKTOR25-13) application in a kitchen furniture manufacturing company (HH. Sánchez
Blanco, S.A. - HERSAN). The information about the necessary components and their machining programs is
automatically generated regarding from the customers orders, which include the modules to be manufactured and the
corresponding options of model, color, material, handle, etc. This achieves two of the five levels of modularization
according to Pines [8]: providing quick response to the customer and standard components can be configured in a
wide variety of products.
The antecedent of this project is a logistical improvement project carried out in the company in 2010. In that
project the architecture of a customized ERP system was designed. The production module obtained from the
customers' orders, among other things, the cutting of the product together with the production orders in the primary
area of the production process (cutting, gluing, sanding and coating). In this primary phase, the pieces that are to be
assembled in the secondary phase or final assembly of the furniture are obtained.
The objectives of this project are:

 improvement of flexibility and speed in the generation of machining programs

 decrease of measurement and operator errors
 improvement of processing times including setups

2. Production process analysis

The production process is divided into two distinct parts according to the layout: a job shop for preparation of
materials (primary phase) and a flow shop in which the final assembly is done (secondary phase). Fig. 1 shows the
diagram illustrating the modular production process and its correspondence with the layout.

Fig. 1. Modular production system and B.O.M basic levels.

 M. Doiro et al. / Procedia Manufacturing 13 (2017) 1159–1166 1161
M. Doiro / Procedia Manufacturing 00 (2017) 000–000 3

The production management process begins with the receipt of customer orders. A semi-automatic MRP software
(based on an database management system) determines the net requirements for raw materials and component parts
for each period on the planning horizon. A Dynamic Structure Parametric Bill Of Materials (DSP BOM) [9] is used
in this ERP information system module. This generic BOM enables the management of all product variations by
designing a single BOM pattern [10]. A new Bill of Materials (BOM) is created for each order line. Due to the
uniqueness of the kitchen furniture, 210 parameters were established and they determine all the functional
possibilities included in the technical catalog of the company up to the present moment. If new furniture designs do
not adapt to the current parametric structure, then it would be sufficient to increase the number of parameters.
Once the necessary basic components (glasses, fittings and wood and / or laminate parts) are determined, the
ordering supplies and manufacturing orders for the primary process are proposed: cutting, gluing, edging, varnishing
and lacquering. It´s noteworthy that the preparation of cutting orders and the corresponding programs for obtaining
parts is done with the help of a board surface optimization software (BSO) and a cutting programs generation
software according to the type of part and material (CPG). The corresponding cutting operation is performed on a
Biesse Excel 4832 Router.
Natural wood and agglomerates with melamine or laminates pieces are obtained at the end of the primary phase.
These pieces will form part of the assembly kit of the furniture and they are at level 2 in the BOM (Type A in Fig.
1). This is due to the fact that these parts still lack a machining process which is intended to prepare them so that
they can be assembled together later in the assembly process. This process is based on the Preassembly
Mechanization Programs Generation (PMPG in Fig. 1) and consists of different drilling, milling and sawing
instructions (for example, to obtain the holes in the sides of the furniture necessary to establish the joining with the
shelves or the milling of a door to incorporate the handle). It should be noted that the technical catalog of the
company is composed of more than 6000 different references of cabinets only considering the variants that arise
according to the type of furniture and the standard dimensions (in Fig. 2 the levels 0 and 1 in a BOM of the generic
reference ALTO 50I H45 FMA is shown).

Módule
04MA50I

SIDE FIX SHELVE MOVIL SHELVE BACK DOOR

450 x 320 467 x 316 466 x 290 497 x 447 496 x 446
(2 u.) (2 u.) (1 u.) (1 u.) (1 u.)

Fig. 2. Example of furniture module BOM detail (levels 0 and 1).

There is a very high furniture final references, depending on the model, color of doors or drawers, interior color,
handle, etc.,. Also, each piece of furniture has its own machining depending on the dimensions, colors, handles, etc.
For this the number of machining programs is also extremely large. It is at this point that there is a need to establish
a system capable of establishing specific machining programs for each of the level 1 components of the BOM. For
this, a procedure has been designed with the objective of establishing the PMPG using the same parameterization of
the product used in the primary phase (MRP - BSO – CPG).

3. Preassembly machining management process design

Fig. 3 shows a flowchart with the process of assigning the machining programs and the interaction between the
manufacturing primary and secondary phases. In the following subsections this process is detailed
1162 M. Doiro et al. / Procedia Manufacturing 13 (2017) 1159–1166
4 M. Doiro / Procedia Manufacturing 00 (2017) 000–000

START PMPG
(SOFT . APP. 1)

Yes PARAMETRIZED No
MODULE Yes STANDARD No (10%)
MODULE

PARAMETR_A
Yes SPECIAL No (1%)
MODULE

PARAMETR_B

EXECUTION LIST (E.L.)

Yes WIFI No
OK

SERVER
Bre.Ma pendrive

MANUFACTURING (PRIMARY PHASE)

START PM EDGE
RECOVERING CUTTING
(SOFT.APP. 2) BANDING
PROCESS PROCESS
PROCESS
LABEL

REGISTRAR
Label PICKING INCIDENCIA
Module Yes MATERIAL No
Printing OK

MANUFACTURING (SECONDARY PHASE ) Yes

REPAIR
PREASSEMBLY
MACHINING PROCESS Yes No No
OK
FURNITURE ASSEMBLY
PROCESS

CUSTOM PREASS. M. PROCESS

Fig. 3. Procedure for the execution of the preassembly machining.

3.1. End items parameterization system

These premises have been considered to establish the programs of mechanized to obtain pieces Type B
(preassembly):

 All furniture modules share 5 basic types of generic parts: sides, fixed shelves, fronts, backs and interior shelves.
 M. Doiro et al. / Procedia Manufacturing 13 (2017) 1159–1166 1163
M. Doiro / Procedia Manufacturing 00 (2017) 000–000 5

 The machining of a generic part may depend on other generic part (s) of the same piece of furniture, or other
variables of the furniture itself: width, height, depth, model, handle, material, hand...
 All furniture belongs to a basic category: high, low, sink / oven plate, refrigerator column... The number of
categories is expandable in case of new designs that do not fit the current categories. These categories define
each of the preassembly machining programs.
 The preassembly machining programs share the parameterization system with the cutting programs in the
manufacturing primary phase.

It is necessary to clarify that, although in 90% of the cases (according to sales of the last 3 years) the furniture is
standard, there is also the possibility of modification according to the customer's needs (for example if a module of
furniture has 3 interior shelves because its height defines it, the customer has the possibility to modify that number,
as well as its dimensions, position in height, etc.). The latter type of furniture called "special modules" can be
parameterized again in most cases. This means that only a small number of references (1%) cannot be machined
under the general procedure (in this case, the machining of some piece of furniture would have to be performed in a
semi-automatic way called custom preassembly machining*)
At the present time there are 10 basic categories of furniture for which 10 machining programs are used. These
have been created with the EDICAD design tool. An example of side machining incorporating all the drills and
milling holes before setting parameters shown in Fig. 4a. Depending on the values that take the different parameters
the drills and milling holes will be defined for every concrete piece (Fig. 4b shows a single customization for a
cabinet with drawer’s side).
a b

Fig. 4. Preassembly machining program example: (a) no setting parameters and (b) a single customization.

It is noteworthy that the number of programs is very small considering the variety of furniture. This has been
tried to balance the number of lines of code with the number of basic categories. In addition, each program consists
of basic subprograms (for example, the drilling line subprogram for fixed shelving). This feature does not have to
change the programs if there is a modification in the design of the products, but only the subprogram corresponding
to the modified option.

3.2. Preassembly machining procedure

The execution of the preassembly machining programs is performed by the launch of an Execution List. The List
is an enumeration of individual machining programs [11]. The programs are generated by a CAD-CAM system

* In the supervisor PC machining programs would be allocated between a small number of flexible programs already created or the program being specifically
designed from EDICAD
1164 M. Doiro et al. / Procedia Manufacturing 13 (2017) 1159–1166
6 M. Doiro / Procedia Manufacturing 00 (2017) 000–000

(EDICAD). The list defines the sequence of operations that allows to produce several components (for example two
sides, a door and three shelves)
The procedure for the preassembly machining execution consists of two stages: preparation and launching of the
lists of execution. For the first stage a specific computer application (Soft.App.1 in Fig. 3) has been designed. Fig. 5
shows the main screen of the application in which the preassembly machining programs and the specific parameters
according to the category of the furniture are assigned to each order line (note the differentiation according to
standard or special). In addition to the parameter used to specify the category of furniture, only 10 other parameters
are necessary to indicate all the machining possibilities of each category.
The execution list is transmitted via wifi or manually to the numeric control (Albatros) of the machining center.
This control consists of a supervisor PC that represents the Operator-Machine interface, and a variable number of
modules, for the handling and control of all the operating resources of the machining center.

Fig. 5. Software for execution lists generation (Soft.App.1).

On the other hand, a specific production control software application generates the main module label when all of
its type A parts are available. With the printed physical label a barcode is scanning from the machining system
supervisor pc. The code calls the previously generated execution list. This reading process is the only operation in
the internal setup of the machining center (logically only will be done when the type A pieces are physically
available to feed the train of entry of the machining center). The label is also used as a production order for final
assembly.
Fig. 6 shows different aspects of the machining center: detail of the feeding train with a type A piece (a), detail of
revolver and drilling groups (b) and supervisor PC with the main screen for launching the execution lists (c).
 M. Doiro et al. / Procedia Manufacturing 13 (2017) 1159–1166 1165
M. Doiro / Procedia Manufacturing 00 (2017) 000–000 7

a b c

Fig. 6. Machining Centre Bre.Ma Vektor25-13.

4. Results

All the objectives set out at the beginning of the project have been achieved.
The proposed procedure for the preassembly machining execution has replaced a manual system of assignment of
machining programs. To date a horizontal pantograph and other singles machines have been machining pieces. A
skilled operator with extensive knowledge of the products made for each piece a selection of subprograms between a
discrete and fixed number of them.
This change has improved the flexibility of the process in two different ways. Flexibility of the workforce on the
one hand since process is now carried out by any operator of the company as it does not require specific knowledge
of programming or the product. This implies reaching a polyvalence of workers index of 100% in this productive
system section. On the other hand, the parametric system allows a greater adaptation to the special furniture (99% of
the furniture adapts well to a parameterization type A or type B).
The speed of the preassembly process has also been increased. This has meant an increase in capacity in the
section. Although an in-depth time study has not been done, this increase is estimated at about 500%. The main
cause of this increase has been the conversion of internal activities to external during the setup. Now the machining
center is running all the time if necessary (it has a preload area of material). In fact the bottleneck constituted by the
process of machining preassembly that was done in different machines has been eliminated. This has also allowed
incorporating a new line of products that do not require final assembly (furniture kit).
The procedure for the generation of the execution lists ensures uniformity in the elaboration of the machining
programs. It plays as a poka-yoke because in case of an error, once corrected it is impossible to happen again. This
has eliminated program selection errors and also homogenized the final product.
And finally, the fact that all the pieces of the same module are machined at the same time ensures an intangible
benefit in organizational and order terms.

5. Conclusions

The presented project is based on the use of dynamic structure parametric bills of materials. These BOMs are not
only used in material requirement planning but are basic in the generation of machining programs.
The system of parameterization based on the modularization of pieces and categories of furniture allows the
different CAD/CAM systems used it in the primary and secondary phases of manufacturing.
The machining center used to perform the preassembly machining with different drilling, milling and sawing
modules provides a process versatility that would not be possible using single machines.
It´s allowed a standardization of the preassembly machining process for about 99% of the furniture. This means a
very significant saving in material and labor costs and an improvement in the quality of the final product.
1166 M. Doiro et al. / Procedia Manufacturing 13 (2017) 1159–1166
8 M. Doiro / Procedia Manufacturing 00 (2017) 000–000

Acknowledgements

We thank to Francisco Sánchez for sharing his pearls of wisdom with us during the course of the R&D project.
We are also immensely grateful to HH. Sánchez Blanco, S.A. workforce for provided insight and expertise about
kitchen furniture industry.

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[8] J. Pine. Plann. Rev. 21 (4) (1993) 6-55.
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[10] O. Torkul, R. Yılmaz, I.H. Selvi, M.R. Ras. Comp. & Ind. Eng. 86 (2015) 22-28.
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