Part VI MANUFACTURING

SUPPORT SYSTEMS
Chapters:
23. Product Design and CAD/CAM in the Production System
24. Process Planning and Concurrent Engineering
25. Production Planning and Control Systems
26. Just-In-Time and Lean Production

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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

Manufacturing Support Systems

in the Production System

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1
 Ch 23 Product Design and CAD/CAM
in the Production System

Sections:
1. Product Design and CAD
2. CAD System Hardware
3. CAM, CAD/CAM, and CIM
4. Quality Function Deployment

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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

Manufacturing Support Systems

The procedures and systems used by a firm to manage its

production operations and solve the technical and logistics
problems associated with:
ƒ Designing the products,
ƒ Planning the processes,
ƒ Ordering materials,
ƒ Controlling work-in-process as it moves through the
plant, and
ƒ Delivering quality products to customers

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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

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 The Design Process

The general process of design is characterized as an

iterative process consisting of six phases:
1. Recognition of need - someone recognizes the need that
can be satisfied by a new design,
2. Problem definition - specification of the item,
3. Synthesis - creation and conceptualization,
4. Analysis and optimization - the concept is analyzed and
redesigned,
5. Evaluation - compare design against original
specification,
6. Presentation - documenting the design (e.g., drawings).
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

The Design Process

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3
 Computer-Aided Design (CAD)

Any design activity that involves the effective use of the

computer to create, modify, analyze, or document an
engineering design.
ƒ Commonly associated with the use of an interactive
computer graphics system, referred to as a CAD system.
ƒ The term CAD/CAM is also used if the computer system
supports manufacturing applications as well as design
applications.

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

Reasons for Using a CAD System

ƒ To increase the productivity of the designer,

ƒ To expand the available geometric forms in design - wider
range of mathematically defined shapes possible,
ƒ To improve the quality of the design - more engineering
analysis possible, consideration of more alternatives,
ƒ To improve design documentation - better drawings than
with manual drafting,
ƒ To create a manufacturing database - creation of the
design documentation also creates manufacturing data,
ƒ To promote design standardization - use of design rules to
limit the number of hole sizes, fasteners, etc.
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

4
 1

The Design Process 3

Using CAD
4

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

How a CAD System is Used

in Product Design (Steps 3 - 6)
3. Geometric modeling
ƒ CAD system develops a mathematical description of
the geometry of an object, called a geometric model
4. Engineering analysis
ƒ Mass properties, interference checking for
assemblies, finite element modeling, kinematic
analysis for mechanisms
5. Design evaluation and review
ƒ Automatic dimensioning, error checking, animation
6. Automated drafting
ƒ Preparation of engineering drawings quickly

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
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5
 Geometric Models in CAD

Wire-frame model

Solid model

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

CAD System Hardware

The hardware for a typical CAD system consists of the

following components:
1. One of more design workstations
2. Digital computer
3. Plotters, printers, and other output devices
4. Storage devices

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
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6
 Typical CAD System Configuration

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

Design Workstations

The interface between the computer and the user in the CAD
system
ƒ Functions:
1. Communicate with the CPU,
2. Continuously generate a graphical image,
3. Provide digital descriptions of the image,
4. Translate user commands into operating functions,
5. Facilitate interaction between the user and the
system.

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

7
 CAD System Configurations

1. Host and terminal

ƒ Mainframe serves as host for graphics terminals
ƒ The original configuration in the 1970s and 1980s
when CAD technology was first developing
2. Engineering workstation
ƒ Stand-alone computer system dedicated to one user
ƒ Often networked for sharing data and plotters
3. CAD system based on a personal computer
ƒ PC with high-performance CPU and high resolution
graphics display monitor
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

Host and Terminal Configuration

ƒ Original CAD system configuration in 1970s and 1980s

ƒ Host computer is a mainframe or large mini computer
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
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8
 Engineering Workstation Configuration

ƒ An engineering workstation is a stand-alone computer

system dedicated to one user and capable of executing
graphics software and other programs requiring high-
speed computational power.

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

CAD System based on a PC

ƒ This is a personal computer with a high-performance CPU

and high resolution graphics display screen
ƒ PC-based CAD systems can be networked (as shown) to
share files, output devices, and for other purposes

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
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9
 Computer-Aided Manufacturing

The effective use of computer technology in manufacturing

planning and control
ƒ Most closely associated with functions in manufacturing
engineering, such as process planning and NC part
programming
ƒ CAM applications can be divided into two broad
categories:
1. Manufacturing planning
2. Manufacturing control

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

CAM Applications in
Manufacturing Planning

ƒ Computer-aided process planning (CAPP)

ƒ Computer-assisted NC part programming
ƒ CAD/CAM assisted NC part programming
ƒ Computerized machinability data systems
ƒ Computerized work standards
ƒ Cost estimating
ƒ Production and inventory planning
ƒ Computer-aided assembly line balancing

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

10
 CAM Applications in
Manufacturing Control

ƒ Process monitoring and control

ƒ Quality control
ƒ Shop floor control
ƒ Inventory control
ƒ Just-in-time production systems

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

CAD/CAM

ƒ Concerned with the engineering functions in both design

and manufacturing.
ƒ Denotes an integration of design and manufacturing
activities by means of computer systems.
ƒ Goal is to not only automate certain phases of design
and certain phases of manufacturing, but to also
automate the transition from design to manufacturing.
ƒ In the ideal CAD/CAM system, the product design
specification residing in the CAD data base would be
automatically converted into the process plan for
making the product.
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
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 Computer Integrated Manufacturing

ƒ Includes all of the engineering functions of CAD/CAM,

ƒ Also includes the firm's business functions that are related
to manufacturing,
ƒ Ideal CIM system applies computer and communications
technology to all of the operational functions and
information processing functions in manufacturing.
ƒ From order receipt,
ƒ Through design and production,
ƒ To product shipment.

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

The Scope of CAD/CAM and CIM

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12
 Computerized Elements
of a CIM System

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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

Quality Function Deployment

A systematic procedure for defining customer desires and

requirements and interpreting them in terms of product
features and process characteristics.
ƒ A series of interconnected matrices are established
between customer requirements and the technical
features of a proposed new product.
ƒ The matrices are a progression of phases in which
customer requirements are first translated into product
features, then into manufacturing requirements, and
finally into quality procedures for controlling the
manufacturing operations.
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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

13
 Quality Function Deployment

ƒ Shown as a series of matrices that relate customer

requirements to successive technical requirements in a
typical progression

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Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

The Starting Matrix:

The House of Quality

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 Steps in QFD: The House of Quality

1. Identify customer requirements,

2. Identify product features needed to meet customer
requirements,
3. Determine technical correlations among product features,
4. Develop relationship matrix between customer
requirements and product features,
5. Comparative evaluation of input customer requirements,
6. Comparative evaluation of output technical requirements.

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No portion of this material may be reproduced, in any form or by any means, without permission in writing from the publisher. For the exclusive use of adopters of the book
Automation, Production Systems, and Computer-Integrated Manufacturing, Third Edition, by Mikell P. Groover.

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