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Slide1

Introduction to Computer Integrated Manufacturing

(CIM)

Slide2

Learning Objectives• Modern manufacturing process and its

various components, highlighting the different systems (e.g., CAD, CAE, MRP/ERP, CAM, CNC, CMM and PDM), showing:– different types of information – what happens in each system– integration challenges

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Slide3

Basic Flow of InformationCustomerRequirements

DesignRequirements

EngineeringDesign

ProductCharacteristics

Manufacturing / SupplierProcesses

ProductionQualityControls

Slide4

Manufacturing Systems• Computer Aided Design (CAD)• Computer Aided Engineering (CAE)

– Finite Element Analysis (FEA)– Computational Fluid Dynamics (CFD)

• Manufacturing Resource Planning (MRP)• Enterprise Resource Planning (ERP)• Computer Aided Manufacturing (CAM)• Product Data Management (PDM)• Co-ordinate Measuring Machine (CMM)• Computer Numerical Control (CNC)

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Slide5

Manufacturing Data• Request for Quote (RFQ)• Process Plan• Bill of Material (BOM)• Customer order• Supplier and component

data• Product design• Analysis & simulation data• NC program• Tooling and fixture design

• Engineering Change data• Purchase Order (PO)• Assembly instructions• Operating, maintenance and

user manual• Design specification• Inspection & verification data• Test plan, test instruction,

test cases and test results• QC & QA data

Slide7

Typical Design to Production Flow

Concept PreliminaryDesign

EngineeringAnalysis

DetailedDesign

Engineering

ManufacturingPrelim Production Planning

Prelim Tool Design

Production Planning

Final Tool Design NC Programming

CAD Systems

CAE Systems

ERP or MRP Systems

CAM Systems

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Slide9

Typical Design to Production Flow

Concept PreliminaryDesign

DetailedDesign

Engineering

Manufacturing

CAD Systems

Slide10

What is CAD?• Computer-Aided Design

– I-DEAS, CATIA, Unigraphics, ProE• Use of computers in the product design

process; can be used for sketching, schematics, analysis, and prototyping

• CAD systems can be used for Geometric Modeling (parametric, features); and Automatic Drafting (sectional views, projections, etc.)

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Slide11

I-DEAS CAD Systems

Slide12

Unigraphics CAD System

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Slide14

Typical Design to Production Flow

Concept PreliminaryDesign

EngineeringAnalysis

DetailedDesign

Engineering

Manufacturing

CAD Systems

CAE Systems

Slide15

What is CAE?

• Computer-Aided Engineering– StarCD, Ansys, and Abaqus

• Use of computer simulation as a tool for Engineering Analysis :– Minimize part weight, – increase part robustness, etc.

• Integrate with CAD and CAM

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Slide16

Types Of CAE

Thermal Analysis

Stress AnalysisFEA (Finite Element Analysis)

Flow AnalysisCFD (Computational

Fluid Dynamics)

Dynamic Analysis

Slide17

Typical Design to Production Flow

Concept PreliminaryDesign

EngineeringAnalysis

DetailedDesign

Engineering

ManufacturingPrelim Production Planning

Prelim Tool Design

Production Planning

Final Tool Design NC Programming

CAD Systems

CAE Systems

ERP or MRP Systems

CAM Systems

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Slide19

What is CAM?• Computer-Aided Manufacturing• Determine the accuracy of designs prior to

manufacture• Uses CAD drawings to produce the machine

code needed to make the actual part• Eliminates unnecessary production cost as

well as reducing time needed to produce part

Slide21

CAM Systems

Automatic Lathe CNC

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Slide22

CAM Systems

CMMcoordinate measuring machine

Slide27

Typical Design to Production Flow

Concept PreliminaryDesign

EngineeringAnalysis

DetailedDesign

Engineering

ManufacturingPrelim Production Planning Production Planning

CAD Systems

CAE Systems

MRP or ERP Systems

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PDM Systems

(Product Data Management)

Slide37

What is PDM?

• Product Data Management• Giving people the right information to do

their job at the right time• On average people spend 40% of time

looking finding right data only 20% of the time

• Used mainly for concurrent engineering

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Slide38

Detailed Example of the Engineering Process at Wescast Industries

Slide39

Wescast Industries• World’s largest supplier of exhaust manifolds for

passenger cars and light trucks• Work with customers globally• Manufacturing facilities in Ontario (5), as well as

the USA and Hungary • Sales and design locations in Canada, Germany,

the USA and the UK • Use I-DEAS, CATIA, Unigraphics and ProE

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Slide40

Engineering Process

Rapid ToolingVerification Validation

RapidPrototyping

ProcessSimulation

StressSimulation

FlowSimulation 3-D CAD

Design

Production

PartApproval

Slide41

Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerificationRapid ToolingValidationPart ApprovalProduction

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Slide42

Wescast Engineering Process FlowConcept Design

Slide43

Concept Design

3-D CAD Design StageThis is where the customer & manufacturingrequirements are captured and modeled into a 3-D Computer Aided Virtual Design. This data is used in all subsequent stages.

Outputs• 3-D CAD model ready for translation to other formats

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Slide44

Concept Design

3-D CAD Design StageThis is where the customer & manufacturing requirements are captured and modeled into a 3-D Computer Aided Virtual Design. This data is used in all subsequent stages.

Challenges• lack of information• incompatiblegeometry

• tight time-line• lack of resources

Workarounds• chair initial design review meetings.• use outside resources to create or improve geometry.• work shifts or take advantage of Global time difference.

Potential Errors• miscommunication• incomplete design• incorrect data

Outputs• 3-D CAD model ready for translation to other formats

Slide45

Wescast Engineering Process FlowConcept DesignFlow Simulation

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Slide46

FlowSimulation

Flow Simulation StageComputational Fluid Dynamics is used to virtually simulate the exhaust gas flow thru the manifold. Gas elements are checked such as; velocity, temperature, pressure and dispersement across the exit opening. This information is used to optimize the manifolds flow rate and improve emissions.

Outputs• Analysis data report• Interactive 3-D visual flow image

Flow Simulation

Slide47

Challenges• lack of information• incompatiblegeometry

• tight time-line• lack of resources

Workarounds• use outside resources to create or improve geometry.• work shifts or take advantage of Global time difference.• make assumptions

Potential Errors• miscommunication• incorrect assumption• incorrect data

FlowSimulation

Flow Simulation StageComputational Fluid Dynamics is used to virtually simulate the exhaust gas flow thru the manifold. Gas elements are checked such as; velocity, temperature, pressure and dispersement across the exit opening. This information is used to optimize the manifolds flow rate and improve emissions.

Outputs• Analysis data report• Interactive 3-D visual flow image

Flow Simulation

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Slide48

Wescast Engineering Process FlowConcept DesignFlow SimulationStress Simulation

Slide49

StressSimulation

Stress Simulation StageFinite Element Analysis is used to virtually apply stress forces to the manifolds exterior design. In a virtual environment the manifold is mounted onto the cylinder head of the engine. Next, virtual forces are applied bringing the weak areas to the surface, which are highlighted in a colour map. This information is used to increase robustness and eliminate redundancy. Outputs

• Analysis data report• Multiple colour images

Stress Simulation

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Slide50

StressSimulation

Challenges• lack of information• incompatiblegeometry

• tight time-line• lack of resources

Workarounds• use outside resources to create or improve geometry.• work shifts or take advantage of Global time difference.• make assumptions

Stress Simulation StageFinite Element Analysis is used to virtually apply stress forces to the manifolds exterior design. In a virtual environment the manifold is mounted onto the cylinder head of the engine. Next, virtual forces are applied bringing the weak areas to the surface, which are highlighted in a colour map. This information is used to increase robustness and eliminate redundancy.

Outputs• Analysis data report• Multiple colour images

Potential Errors• miscommunication• incorrect assumption• incorrect data

Stress Simulation

Slide51

Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess Simulation

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Slide52

Process Simulation StageThis is where the manufacturing process is simulated using computer aided technologies. During this stage process related defects are projected. This virtual information is used to help refine the process design in order to reduce scrap rates and improve yield.

Outputs• Interactive 3-D visual images showing solidification results.

Process Simulation

Slide53

Potential Errors• incorrect data• incorrect material parameters.

Process Simulation StageThis is where the manufacturing process is simulated using computer aided technologies. During this stage process related defects are projected. This virtual information is used to help refine the process design in order to reduce scrap rates and improve yield.

Outputs• Interactive 3-D visual images showing solidification results.

Workarounds• use outside resources for computing power, or to create or improve geometry.

Challenges• incompatible

geometry• tight time-line• lack of resources• slow computer process speeds• obtaining material parameters.

Process Simulation

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Slide54

Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid Prototyping

Slide55

Rapid Prototyping StageIn this stage the 3-D Computer Aided Virtual Design is transformed into a physical replication. This hand held replica is used by all team members to better visualize the design intent. It can be mounted to an engine to check for interference issues, and it can also be used to perform physical testing.

Outputs• Full size physical representation of the final product.

Rapid Prototyping

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Slide56

Potential Errors• incorrect data• poor assembly and build.

Workarounds• use outside resources to create or improve geometry, or to create the physical prototype.

Challenges• incompatible

geometry• tight time-line• lack of resources

Rapid Prototyping StageIn this stage the 3-D Computer Aided Virtual Design is transformed into a physical replication. This hand held replica is used by all team members to better visualize the design intent. It can be mounted to an engine to check for interference issues, and it can also be used to perform physical testing.

Outputs• Full size physical representation of the final product.

Rapid Prototyping

Slide57

Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerification

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Slide58

Verification StageUsing a Rapid Prototype, air is pressurizedthru the manifold design. Elements that are checked range from: air velocity, volumetric flow, and dispersment across the exit opening. The resulting information here is used to substantiate data that is derived from the CFD results. This test is also used when computational resources are limited.

Outputs• Analysis data report with volumetric flow results. Results compare inlet ports for balance.

Verification

Slide59

Challenges• lack of information• tight time-line• lack of resources

Workarounds• use outside resources to create or improve geometry.• work shifts or take advantage of Global time difference.• make assumptions

Verification StageUsing a Rapid Prototype, air is pressurized thru the manifold design. Elements that are checked range from: air velocity, volumetric flow, and dispersment across the exit opening. The resulting information here is used to substantiate data that is derived from the CFD results. This test is also used when computational resources are limited.

Potential Errors• incorrect set-up• machine out of calibration

Outputs• Analysis data report with volumetric flow results. Results compare inlet ports for balance.

Verification

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Slide60

Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerificationRapid Tooling

Slide61

Rapid Tooling StageThis stage is where rapid tooling is created using the 3-D Computer Aided Virtual Design CAD data.

Outputs• Rapid tooling designed to support low volume production runs.

Rapid Tooling

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Slide62

Workarounds• use outside resources to create or improve geometry.• use outside resources to create tooling.• use outside resource overseas.

Rapid Tooling StageThis stage is where rapid tooling is created using the 3-D Computer Aided Virtual Design CAD data.

Outputs• Rapid tooling designed to support low volume production runs.

Challenges• incompatible geometry• tight time-line• lack of resources• Overseas deliveries

Potential Errors• incorrect CAD data• incorrect tool designRapid Tooling

Slide63

Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerificationRapid ToolingValidation

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Slide64

Validation StageThe Engine Exhaust Simulator is used to validate the manifold design. It replicates the engine testing that is used by the customer (better known as the Dynamometer test). The information gathered here will be used to help validate the manifold design.

Inferred Images

Outputs• Analysis report on durability, failures, warping, cracking, breakage & meltdown.

Validation

Slide65

Workarounds• make assumptions to customers dyno set-up.

Potential Errors• incorrect manifold• incorrect set-up

Validation StageThe Engine Exhaust Simulator is used to validate the manifold design. It replicates the engine testing that is used by the customer (better known as the Dynamometer test). The information gathered here will be used to help validate the manifold design.

Challenges• tight time-line• lack of resources• matching the customers Dyno set-up

Inferred Images

Outputs• Analysis report on durability, failures, warping, cracking, breakage & meld down.

Validation

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Slide66

Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerificationRapid ToolingValidationPart Approval

Slide67

Part Approval StageThe Dyno test is performed by the customer on a prototype engine. The engine cycles hot (900C) & cold (200C) for 200 hours.

Outputs• Observation comments pertaining to crack, warp, breakage, leak and melt down

Part Approval

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Slide68

Workarounds• use a mock-up of a similar production part

Potential Errors• incorrect manifold design• late delivery

Challenges• tight time-line• capturing all design changes

Part Approval StageThe Dyno test is performed by the customer on a prototype engine. The engine cycles hot (900C) & cold (200C) for 200 hours.

Outputs• Observation comments pertaining to crack, warp, breakage, leak and melt down

Part Approval

Slide69

Wescast Engineering Process FlowConcept DesignFlow SimulationStress SimulationProcess SimulationRapid PrototypingVerificationRapid ToolingValidationPart ApprovalProduction

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Slide70

Production StageOnce the manifold design has been validated by the Dyno test, the customer will give the approval to begin the production tooling.

Outputs• A production part that meets and/or exceeds the customer expectations.

Production

Slide71

Production StageOnce the manifold design has been validated by the Dyno test, the customer will give the approval to begin the production tooling.

Workarounds

• NONE

Potential Errors• manifold design is not production intent

Challenges• tight time-line• capturing design intent from prototype designs to production designs• meeting quoted target ratesOutputs

• A production part that meets and/or exceeds the customer expectations.

Production

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Slide72

Summary• CAD systems generate the product design

– Can be expensive and some designers struggle to make the 2-D to 3-D paradigm shift

• CAE systems support design improvements through virtual simulations– Not widely accepted yet and expensive to operate

• CAM systems used to manufacture tooling from CAD designs– Compatibility with CAD systems is still a problem

• ERP/MRP systems used to monitor and manage entire business

• PDM systems used to tie design management with manufacturing management– Need company-wide buy-in, may be a high cost

Slide73

“Islands of Automation”Systems evolution

2D drafting1960’s 1970’s 1980’s 1990’s 2000’s

GT

NC

Robotics

CAM

FMS CNC

DNC

CAPPCAD

MRP

JITQC QA

FMC

OPTTPM

TQM

CAECIM

PDM

VM

CAPM MRPII

LMWCM

AMERP

SCM

B2BB2C

6σ

OO

GUI

WWW

Deming’s 14 rules

PDM

IBM vs SAP: Evolution of complex system: open / data driven