Pretace
PART 1 INTRODUCTION TO ClM AND THE MANUFACTURING ENTERPRISE
1 The Manufacturing Enterprise
1-1 lntroduction 2
1-2 External ChaIlenges 5
1-3 lnternal Challenges 8
1-4 World-CIass Order-Winning Criteria 14
1-5 The Prohlem and a SoIution 21
1-6 Learning CIM Concepts 24
1-7 Going for the Glohe 26
1-8 Summary 33
Reterences 33
Questions 34
ProhIems 35
Projects 36
Appendix 1-1: The Benefits of a ClM Implementation 37
Appendix 1-2: The Parable of the TWo Farmers 38
2 Manufacturing Systems
2-1 Manufacturing Classifications 45
2-2 Product Development Cycle 52
2-3 Enterprise Organization 53
2-4 Manual Production Operations 60
2-5 Summary 62
References 63
Questions 63
Projects 64
Appendix 2-1: ClM as a Competitive Weapon 64
Case Study : Evolution and Progress-0ne WorId-Class
Company's Measurement System 65
PART 2 THE DESIGN ELEMENTS AND PRDDUCTION ENGINEERING
3 Product Design and Production Engineering
3-1 Product Design and Production Engineering 70
3-2 Or Organization Model 71
3-3 The Design Process: A Model 74
3-4 Concurrent Engineering 82
3-5 Production Engineering 88
3-6 Summary 98
References 98
Questions 99
Projects 99
Case Study: Repetitive Design 100
4 Design Automation: CAD
4-1 lntroduction to CAD Systems 101
4-2 General System Operation 108
4-3 CAD Classification: Hardware Platforms 110
4-4 CAD Classification: Software 115
4-5 Application of CAD to Manufacturing Systems 125
4-6 Summary 129
References 131
Questions 132
ProhIems 132
Projects 133
Appendix 4-1: B-Splines to Nurhs 133
Appendix 4-2t Web Sites for CAD Vendors 135
Appendix 4-3t Web Sites for Computer Systems 136
5 Design Automation : Computer-Aided Engineering
5-1 Design for Manufacturing and Assembly 139
5-2 Computer-Aided Engineering Analysjs 144
5-3 Computer-Aided Engineering Evaluation 154
5-4 Group Technology 160
5-5 Production Engineering Strategies 165
5-6 Design and Production Engineering Network 185
5-7 Summary 188
Reterences 189
Questions 189
Problems 190
ProJects 191
Appendix 5-1: Ten Guidelines for Design for Assembly 192
Appendix 5-2: Weh Sites for CAE Vendors 193
Appendix 5-3: Weh Sites for Rapid Prototyping Vendors 194
PART 3 MANAGING THE ENTERPRISE RESOURCES
6 Introduction to Production/Operations Planning
6-1 Operations Management 199
6-2 Manufacturing Planning and Control 200
6-3 Manufacturing Planning and ControI ModeI-
Manutacturing Resource PIanning (MRP2) 205
6-4 Material Requirements PIanning 207
6-5 lntroduction to Production Activity ControI 211
6-6 Gantt Charts and Schedule Boards 212
6-7 Priority Control and Dispatching Techniques 213
6-8 Shop Loading 219
6-9 Input/Output ControI 221
6-10 Automating the MPC Function 221
6-11 Summary 223
References 224
Questjons 225
Prohlems 225
Projects 226
7 Introduction to Manufacturing Planning and ControI 228
7-1 PIanning in the MPC System 228
7-2 Production Planning 232
7-3 Master Production ScheduIe 238
7-4 lnventory Management 243
7-5 Product Data Management 247
7-6 Summary 249
References 251
Questions 251
Prohlems 252
Projects 255
Case Study 7-1: Production System at New United Motor Manufacturing, Part 1 256
8 Material PIanning, Production Scheduling,
and Operating Systems 258
8-1 MateriaI Requirements Planning 258
8-2 Capacity Reguirements Planning 268
8-3 From Reorder-Point Systems to Manufacturing Resource PIanning (MRP ll) 270
8-4 Just-in-Time Manufacturing 281
8-5 Synchronized Production 293
8-6 The Emergence ot Lean Froduction 295
8-7 Summary 298
References 299
Questions 300
ProhIems 301
Projects 302
Case Studyt Production System at New United Motor Manufacturing, Part 2 303
Appendix 8-1: Wight's BicycIe ExampIe 307
Appendix 8-2: ABCD Checklist 309
9 Enterprise Resource Planning, and Beyond
9-1 MRP ll: A Driver of Effective ERP Systems 321
9-2 lnformation TechnoIogy 322
9-3 The Decision to Implement an ERP System 325
9-4 Features of Modern MP&C Systems 326
9-5 Developing TechnoIogies; Converging and Enahling 330
9-6 Identitying ERP System SuppIiers 335
9-7 Summary 337
References 338
Projects 338
Appendix 9-1: Identifying the Ahhreviations lncIuded in Figure 9-1 339
Appendix 9-2: lmportant ERP-Related Sites on the lnternet 339
Appendix 9-3: An ERP Example Using WinMan 340
PART 4 ENABLlNG PR0CESSES AND SYSTEMS F0R MODERN
MANUFACTURlNG
10 Production Process Machines and Systems
10-1 MateriaI and Machine Processes 347
10-2 FIexible Manufacturing 367
10-3 Fixed High-Volume Automation 376
10-4 Summary 379
References 381
Questions 382
Projects 383
APPendix 10-1: History of Computer-Controlled Machines 383
11 Production Support Machines and Systems
11-1 lndustrial Rohots 386
11-2 Automated MateriaI Handling 403
11-3 Automatic Guided VehicIes 409
11-4 Automated Storage and Retrieval 419
11-5 Summary 423
References 424
Questions 424
Projects 425
Case Study: AGV Applications at GeneraI Motors 426
12 Machine and System ControI
12-1 System Overview 427
12-2 CelI ControI 430
12-3 Proprietary Versus Open System lnterconnect Software 434
12-4 Device Control 437
12-5 Programmahle Logic Controllers 438
12-6 Computer Numerical Control 449
12-7 Automatic Tracking 453
12-8 Network Communications 458
12-9 Summary 459
References 460
Questions 461
Projects 462
Appendix 12-1: Turning G Codes 462
13 QuaIity and Human Resource Issues in Manufacturing
13-1 Quality 464
13-2 TotaI QuaIity Management 465
13-3 Quality Tools and Processes 469
13-4 Defect-Free Design Philosophy 479
13-5 The Changing Workforce 483
13-6 SeIf-Directed Work Teams 484
13-7 Summary 489
References 490
Questions 491
Projects 492
Appendix 13-1: Deming's Fourteen Points 492
Index
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