hakan gultekin1 a synthesis of decision models for tool management in automated manufacturing
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Hakan Gultekin 1
A Synthesis of Decision Models for Tool Management in Automated Manufacturing
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Scope of the Paper
Evaluates tool management approaches Identifies operational tradeoffs Analyzes models developed to address
management decisions involving tooling Accounts for 25% to 30% of both fixed and variable costs of production in automated manufacturing
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Management Decisions Involve
Selecting optimal machining parameters Most economic processing rate for a
particular operation Loading of tools and jobs on machines Determination of optimal tool-mix
inventories needed for a particular production schedule
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Tool Management Requires
A tool monitoring strategy:
To coordinate tooling inventory, tool tracking, tool loading/unloadingTo ensure that the appropriate tools are available in the right time in the right quantitiesTo account for tool availability and tool changesTo coordinate tool transfers between machines and tool cribsTo identify and react to unexpected tool wear and breakage
A control strategy:
A scheduling strategy:
A planning strategy:
A design strategy:
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Classification
Tool management can be classified into: Tool-level Machine-level System-level issues
Decisions at one level constrain those at lower levels, information from lower levels feeds back to higher level decisions
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Integration of Tool Management and Other Basic Production Functions
Better tracking and cost accountability of tooling
Due to minimizing number and types of required toolsDue to reduced tools’ stockoutsand setup delays
Increase in productivity
Reduction in production costs
Improvements in part and routing flexibility
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Order Delivery Schedule
Process Planning andPart Programming
Machine Sequencing
Scheduling
Machine Grouping
Capacity Requirements Planning
Tool Requirements Planning
Master Production Planning
Process MonitoringIndividual Tool Monitoring
Tool Placement in Magazine
Tool Allocation to Machines
Machine Loading
Tool Inventory Control
Tool Replacement
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Tool Specific Issues
Number and types of tools Tool speed rates Tool feed rates Technology used to monitor and control
machining and tooling conditions
TOOL LEVEL MACHINE LEVEL SYSTEM LEVEL
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Level of integration necessary between the various production functions
Greater capital and time involved in developing hardware, software and technical support for automated manufacturing
Tool Specific Issues
More critical in automated manufacturingthan manual operations because of:
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Tool Specific Issues
TOOL LEVEL MACHINE LEVEL SYSTEM LEVEL
Spindle speed Depth of cut
Feed rate
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Major tool management concerns: Tool life Cutting tool economics Tool standardization Information requirements
Tool Specific Issues
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1-Tool Life
Useful life depends on: Machining environment (speed, feed
rate…) Material composition of the part and the
tool Depth of the cut
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1-Tool Life
Taylor:
VTn = k
Extended tool life equation:
Vt=C/dxfy
Expected tool life
Cutting speed Emprical constants (depends on m/c conditions andmaterial composition)
Cutting speed fora given tool life
Depth of cut
Feed rate
Empirical constants
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2-Cutting Tool Economics
Economic tool life: optimal time interval between planned tool replacements.
Tradeoff:As machine speed increases, tooling
expenses rise exponentiallyvs
Throughput rates increases Machine speed should be controlled
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2-Cutting Tool Economics
Cook’s formula:
Y=(Yo+nG)/(n+1)
Y: mean tool usage costYo=initial cost of the tooln: number of times a tool is regroundG: cost of a single regrind
Economic tool life is found where Y is minimized
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2-Cutting Tool Economics
Objectives include: Production rate, profit rate, variable cost, surface roughness.
Decision variables: Speed, feed rate, spindle revolution rate.
Multiple shallow cuts vs fewer deeper cuts More realistic cases: tool life is treated as
a random variable
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2-Cutting Tool Economics
Using same tool for a mixture of part
types: Minimizes the # of tool changes Minimizes the # of tools required Increases part routing flexibility
However, existing tool life models are unable to provide reliable predictions of tool life under these conditions
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3-Tool Standardization
Hundreds of tool types and thousands of tools in inventory
Done either by redesigning the part or process, or assigning more operations to similar tool types
Substantial savings in tool inventories, data management and improved system reliability
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4-Information requirements
Common tool management database Data record should be linked to vendors,
part types, machines… Extensive information requirements both
for planning and monitoring tooling
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4-Information requirements
Tools must be monitored for wear to permit planning for replacement and regrinding.
Continuous monitoring: Adaptive control to adjust m/c speed and feed rates appropriately
Off-line monitoring: Increase non-productive m/c times and may result in workpiece damage.
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4-Information requirements
Sophisticated information systems to: coordinate delivery of the proper tools to
specific m/c’s in time provide location information correlate the # of tools needed for the
quantity of parts to be produced offer acceptable substitutes when needed
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4-Information requirements
Bar-code labelling of tools or tool cabinets or memory chips are used to track tools and collect real time data
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Tool Management at the Machine Level
Loading and placing a set of tools in the machines’ magazine
Determining the part input sequences to meet certain magazine constraints
Establishing tool replacement strategies
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Tool Management at the Machine Level
ToolMagazine
Work table
Part
Stored Tools
Empty Storage Slot
Active Tool
Tool Change Arm
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1-Equipment Selection
Specifications of a tool magazine and an automatic tool changer include: Tool storage capacity Type of accessing system Whether tool loading is manual or
automatic Tool standards used Maximum tool diameter, length, weight
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2-Sequencing on a Flexible Machine
Total number of tools required is usually larger than the available magazine storage capacity
Required tool may be absent and a toolchange must occur before that operation can begin
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2-Sequencing on a Flexible Machine
Objectives include: Min # of group tool change instances Min # of individual tool changes Min tool setup, tool replacement and
m/c times
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3-Tool Placement in a Magazine
Many tools of various sizes Placement of individual tools determine
magazine capacity (large tools) Weight balancing Tool search time
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3-Tool Placement in a Magazine
One copy of each tool to save magazine capacity or multiple copies because of short life or often use
Open research question: Determination of the optimal # of copies of each tool
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4-Tool Replacement
Tool replacement strategy is two-fold: When to replace a particular tool due to
wear or failure Which additional tools to change early,
given a tool change must take place.
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4-Tool Replacement
Non-bottleneck machines: Tool change may not result in lost system throughput
Bottleneck machines: Change several tools early when one tool fails.
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System Management
Tooling issues arise in: Production planning Scheduling Spare tool management Tool inventory management
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1-Master Production Planning
Effective planning models must take into
account: Tool magazine sizes Tool commonalities Tool changing times Tool lives
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1-Master Production Planning
Tool management issues are particularly
visible in: Part type selection Machine grouping Loading problems
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1- Part-Type Selection
Two approaches: Batching approach: Partition the part
types into batches, machine each batch individually, change all the tools
Flexible approach: Select the part type to be produced next, machine according to ratios that balance the workload
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1-Master Production Planning
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Flexible approach: More frequent tool changes but the time to
change tools is much less More uniform utilization of machines and setup
personnel Decreased order leadtime and increased
productivity More duplicate tooling and more sophisticated
tool transport system
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1-Master Production Planning
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2- Machine Grouping and Loading Machine grouping problem: Partition
machines into groups so that each machine in a group is tooled to be able to perform same set of operations
Loading problem: Allocate the operations and required tools among the machine groups subject to technological and capacity constraints
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1-Master Production Planning
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2- Machine Grouping and Loading Can be considered jointly, separately or
iteratively Many studies in the literature
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1-Master Production Planning
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3- Manual vs Automatic Tool Handling Tool transporters requires large
investment in tools, magazines, setup and delivery system, causes additional scheduling problems
Some setup time on the magazines is reduced
No formal characterization of operational tradeoffs.
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1-Master Production Planning
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2-Machine Sequencing and Process Monitoring
Tools are resources that must be scheduled and controlled along with parts.
Few scheduling models fully consider the implications of tooling constraints
Machine, operation and routing flexibilities increases complexity of scheduling
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3-Process Planning for Economic Production Rates
Improved scheduling performance can be based on a production rate/tool wear tradeoff
Once a throughput target is set processing times can be manipulated to reduce cost and increase tool lives
Slow down noncritical machines
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4- Spares Management
Tool handling system Ability to substitute non-identical tools Need to provide alternate part routes # of identical tools required Tool magazine capacities Tool life distributions Tool costs
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5- Tooling Inventory Management
Operational flexibility requires many tool types
At least 3 duplicate tools: one in tool magazine, one as backup, one in preparation
# of types in storage increases over time Determination of the appropriate # of tools
to be purchased
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Custom tools are more expensive but can shorten processing times
Optimal reorder points and safety stock levels are not studied
The tradeoff between tool availability, manufacturing capacity, tool reorder points and the overall investment in tooling stocks
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5- Tooling Inventory Management
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TOOL LEVELDESIGN PLANNING CONTROL
-Standardization of Tool Types (3)
-Tool Tracking Technology (3)
-Tool Information Requirements (5)
- Assignment of Tool Types to Operations (2)
- Economic Process Planning (21)
-Tool Life (13)
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SINGLE MACHINE LEVELDESIGN PLANNING CONTROL
-Monitoring and Control Technology (0)
-Tool Magazine Capacity (0)
-Tool Changing Technology (0)
-Tool Replacement Strategy Due to Expected Tool Wear (5)
-Sequencing Parts/ Scheduling Tools (8)
-Sequencing Operations/ Assigning Tools to Slots (4)
-Tool Replacement Strategy Due to Actual Wear (2)
-Adaptive Control at One Machine (1)
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SYSTEM LEVELDESIGN PLANNING CONTROL
-Number and Type of Machines (0)
-Tool Loading & Handling Technology (0)
-Loading Duplicate Tools (0)
-Production Planning (2)-Part Type Selection (7)-Cell Grouping & Facility Loading (14)-Tool Change Times and Detailed Scheduling (6)-Processing Rate Determination & Bottleneck Control (6)-Spares Levels (0)-Allocation of Spares (7)-Tool Inventory Control (4)
-Adaptive Control Strategies (2)
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Questions?