Human-computer interaction in manufacturing

The introduction of computers into the manufacturing environment has resulted in a significant impact on productivity and quality of manufactured products. Computers in manufacturing can be used to perform information processing, to control and monitor the manufacturing process, and to support the production operations in the plant. The use of computers does not, by itself, improve or degrade the skill levels required by operators. This is, in fact, a management function. Managers, product designers, and manufacturing personnel make choices to determine how machines and people will interact. When applied in the proper environment, computer-integrated manufacturing systems will increase machine utilization, reduce production cost, and improve productivity. The effective use of computers in manufacturing can be achieved by defining three major needs: manufacturing education, training, and research and development. This paper will study the elements of human-computer interactive systems and define requirements for proper use of computers in manufacturing.     

QEX: An in-process quality control expert system

True computer-integrated manufacturing requires that many links between factory processes become more automated, more computerized, and more intelligent. Many links between processes, however, are based on human judgement, experience, and intuition. These are naturally difficult tasks to automate, but the advent of artificial intelligence, and specifically expert system programming, has made such links possible. This paper presents a research effort toward one of these links, that of quality control judgements of ongoing processes. The use of expert system programming, combined with in-process metrology and system integration, allows the factory to be more fully automated and computer-integrated, resulting in higher precess precision and lower production errors. This paper will discuss how the expert system approach is used to integrate the quality judgement process into the production process, and bring the factory one step further toward total CIM.     

Implementing a Manufacturing Information System

The adoption of a computer-driven technology should lead to cost reduction, improved control, and increased profitability. However, it should not be adopted just because it has worked well in other organizations. The corporate staff groups, in their zeal to please management, often lose objectivity and plunge into the new system adoption process to the detriment of the organizational welt-being. This article discusses the advantages of implementing a manufacturing information system to help MIS managers coordinate a strategy for CIM - computer-integrated manufacturing.     

Group technology applications for computer-integrated manufacturing

Traditionally, group technology has dealt primarily with batch-type manufacturing which is engaged with small lot sizes and a variety of products. Recently, however, due to the development and implementation of computer- integrated manufacturing, group technology has been recognized as an essential element of the foundation for the successful development and implementation of computer-integrated manufacturing through the application of the part-family concept and also a common database for CAD/CAM integration. The optimum design and effective operation of a fully automated manufacturing cell system and/ or factory systems for factories of the future require a careful analysis of all the requirements which the system must satisfy under a group technology environment.     

Impact of product configuration systems on product profitability and costing accuracy

This article aims at analyzing the impact of implementing a product configuration system (PCS) on the increased accuracy of the cost calculations and the increased profitability of the products. Companies that have implemented PCSs have achieved substantial benefits in terms of being more in control of their product assortment, making the right decisions in the sales phase and increasing sales of optimal products. These benefits should have an impact on the company’s ability to make more accurate cost estimations in the sales phase, which can positively affect the products’ profitability. However, previous studies have not addressed this relationship to a great extent. For that reason, a configure-to-order (CTO) manufacturing company was analyzed. A longitudinal field study was performed in which the accuracy of the cost calculations and the products’ profitability were analyzed before and after a PCS was implemented. The comparison in the case study revealed that increased accuracy of the cost calculations in the sales phase and consequently increased profitability can be achieved by implementing a PCS.     

The advent of “green” computer design

Computer manufacturing and consumption are becoming a significant environmental concern. Some fundamental changes are beginning to take place in the computer industry. These changes aren't about MIPS or megabytes. They're about manufacturers in the computer industry beginning to look for ways to reduce the resources they consume and the waste they generate, and for ways to make their products more recyclable. This process is known as “green” computer design. One factor driving green design is the fact that computer manufacturing and consumption is growing rapidly and is becoming a significant cause for environmental concern. For example, semiconductor manufacturing is very resource-intensive: making just one wafer requires substantial amounts of energy, photochemicals, acids, hydrocarbon based solvents, and other materials. Meanwhile, computers are also creating a waste disposal problem. Based on current consumption pattern, IBM estimates that discarded computers will occupy 2 million tons of US landfill space by 2000. Making components, etching circuit boards, and other manufacturing processes generate additional tons of waste. Green computer design addresses four primary issues: reducing the resources consumed and the waste generated when producing computers or components; developing cleaner manufacturing processes; minimizing the energy and other resources that computers consume; and enabling computers and components to be used (and thereby stay out of the waste stream) longer     

A methodology for the automation of medium or small manufacturing companies

Many products are produced by discrete manufacturing plants in lots of 100 items or fewer. Currently, most small and medium-sized manufacturing companies are far from computer-integrated automation. New computer-integrated manufacturing systems with their associated hardwares require tremendous initial investments that are beyond the means of most small and medium-sized companies. In this paper we investigate how these companies can upgrade and automate their existing facilities at a minimal and viable cost. In Section 2 we discuss main references (books and trade journals) that contain detailed information on software packages for automation. In Section 3 we discuss the criteria for selecting software packages. In Section 4 we discuss how to use the obtained information to create a data base of different alternatives. In Section 5 we outline different areas of manufacturing. For illustrations, we discuss manufacturing planning, intelligent systems, and computer areas. In Section 6 we discuss a new method for the selection of the best alternative using the data base. The method is a simple interactive paired comparison method based on a computer package developed on a personal computer.     

A modular and integratable approach to CIM

The factory of the future holds the promise of improved productivity and efficiency through the computerization of manufacturing applications. To fulfill this promise, computer technologies must provide superior results for each targeted manufacturing application. One approach to providing those superior results takes advantage of the natural evolution of manufacturing operations, a modular set of computeraided applications that can be integrated. Each module provides a “pocket of excellence” that can be integrated through networking as and when such communication becomes advantageous. Graphics workstation technology has provided dramatic improvements in performance, at price levels attractive to more segments of the industry than ever thought possible. Modular systems already exist that take advantage of this technological explosion through application software tailored to specific manufacturing functions. Communications between these modular applications can be achieved by networking but only at the discretion of the user, not at the discretion of the vendor. This paper will discuss how industry can increase productivity and efficiency by adopting a modular computer-integrated manufacturing (CIM) approach that is practical.     

CIM—the integration of manufacturing and information systems

The integration of computers within the manufacturing environment has long been a method of enhancing productivity. Their use in many facets of a manufacturing enterprise has given industries the ability to deliver low-cost, high-quality competitive products. As computer technology advances, we find more and more uses for new hardware and software in the enterprise. Over a period of time, we have seen many “islands” of computer integration. Distinct, fully functional hardware and software installations are a common base for many industries. Unfortunately, these islands are just that, separate, distinct and functional but non-integrated. The lack of integration within these information systems make it difficult for end users to see the same manufacturing data. We are finding the need for a “single image” real-time information system to provide the enterprise with the data that is required to plan, justify, design, manufacture and deliver products to the customer. Unfortunately, many industries have a large installed base of hardware and software. Replacement of current systems is not a cost-justified business decision. An alternative would be the migration of current systems to a more integrated solution. The migration to a computer-integrated manufacturing (CIM)-based architecture would provide that single image real-time information system.

The effort and skills necessary for the implementation of a CIM-based architecture would require active participation from two key organizations: Manufacturing and information systems (I/S). The manufacturing engineers, process engineers and other manufacturing resource would be the cornerstone for obtaining requirements. The ability to effectively use I/S is a critical success factor in the implementation of CIM. I/S has to be viewed as an equal partner, not just as a service organization. Manufacturing management needs to understand the justification process of integrating computer systems and the “real” cost of integration versus the cost of non-integrated manufacturing systems. The active participation of both organizations during all phases of CIM implementation will result in a effective and useful integrated information system.     

An expanded SEMATECH CIM framework for heterogeneous applications integration

A significant effort in recent computer-integrated manufacturing (CIM) development was carried out by SEMATECH who had laid out and created an open framework for the integration of manufacturing execution system applications running in semiconductor industries at the factory operation level. This paper presents the feasibility to incorporate basic manufacturing applications at the factory engineering level, which include product design, process planning, and material requirement planning, into the SEMATECH CIM framework to form a generic framework across both factory operation level and factory engineering level. The CIM framework established in this paper was aimed to provide a reusable integrated system framework that clearly specifies the functional interface boundaries and standard information model of the required components, in general, manufacturing systems at both factory operation and factory engineering levels. Standard unified modeling language (UML) diagrams and Petri nets have been utilized to model and analyze the specifications and dynamic behaviors of this generic CIM framework. The goal is to build a framework by creating a common, modular, flexible, and integrated object model that unifies an advanced object-oriented architecture concept and heterogeneous manufacturing application development in an open and multisupplier CIM system environment.     

Recent developments in computer-integrated manufacturing in Japan

This paper reviews recent progress in the field of computer-integrated manufacturing in Japan. In addition to the introduction of many turnkey CAD/CAM systems in mechanical industries, various VAD/CAE/CAM systems have been successfully developed in the automobile and electrical appliance industries. These systems drastically reduce the time required for the manufacturing of new products and improve their quality. Productivity of batch production has been increased through installment of unattended flexible manufacturing systems. Similar systems have been applied to medium-size lot and medium-size volume production. The operations of spot welding, arc welding, painting and assembling have been automated by the use of industrial robots. Very recently, much effort is being devoted to the construction of computer network systems for the coordination of all the production activities. This will allow for reduction in production lead times and decrease in stock items in factory inventory.     

Distributed CAD/CAM: Myth and Reality

The technologies needed to implement distributed design and computer-integrated manufacturing already exist. Vendors must now develop the products required by this new level of automation.     

Smart manufacturing process and system automation – A critical review of the standards and envisioned scenarios

Smart manufacturing is arriving. It promises a future of mass-producing highly personalized products via responsive autonomous manufacturing operations at a competitive cost. Of utmost importance, smart manufacturing requires end-to-end integration of intra-business and inter-business manufacturing processes and systems. Such end-to-end integration relies on standards-compliant and interoperable interfaces between different manufacturing stages and systems. In this paper, we present a comprehensive review of the current landscape of manufacturing automation standards, with a focus on end-to-end integrated manufacturing processes and systems towards mass personalization and responsive factory automation. First, we present an authentic vision of smart manufacturing and the unique needs for next-generation manufacturing automation. A comprehensive review of existing standards for enabling manufacturing process automation and manufacturing system automation is presented. Subsequently, focusing on meeting changing demands of efficient production of highly personalized products, we detail several future-proofing manufacturing automation scenarios via integrating various existing standards. We believe that existing automation standards have provided a solid foundation for developing smart manufacturing solutions. Faster, broader and deeper implementation of smart manufacturing automation can be anticipated via the dissemination, adoption, and improvement of relevant standards in a need-driven approach.     

A versatile virtual prototyping system for rapid product development

This paper presents a versatile virtual prototyping (VP) system for digital fabrication of multi-material prototypes to facilitate rapid product development. The VP system comprises a suite of software packages for multi-material layered manufacturing (MMLM) processes, including multi-toolpath planning, build-time estimation and accuracy analysis, integrated with semi-immersive desktop-based and full-immersive CAVE-based virtual reality (VR) technology. Such versatility makes the VP system adaptable to suit specific cost and functionality requirements of various applications.

The desktop-based VR system creates a semi-immersive environment for stereoscopic visualisation and quality analysis of a product design. It is relatively cost-effective and easy to operate, but its users may be distracted by environmental disturbances that could possibly diminish their efficiency of product design evaluation and improvement. To alleviate disturbance problems, the CAVE-based VR system provides an enclosed room-like environment that blocks out most disturbances, making it possible for a design team to fully concentrate and collaborate on their product design work.

The VP system enhances collaboration and communication of a design team working on product development. It provides simulation techniques to analyse and improve the design of a product and its fabrication processes. Through simulations, assessment and modification of a product design can be iterated without much worry about the manufacturing and material costs of prototypes. Hence, key factors such as product shape, manufacturability, and durability that affect the profitability of manufactured products are optimised quickly. Moreover, the resulting product design can be sent via the Internet to customers for comments or marketing purposes. The VP system therefore facilitates advanced product design and helps reduce development time and cost considerably.     

Whole Life Cost: The Future Trend in Software Development

Whole life costing refers to the cost of ownership of a product from initial concept until eventual retirement with all cost categories taken into consideration. Traditionally software engineers have only been interested in the software development life cycle. This paper surveys research into whole life cost research in industry and finds that interest is greatest where the market is most competitive. In recent years the falling cost of computers has lead to increasing use of whole life cost in the marketing and advertising of IT products though there is very little published case study data available. Trends in other industries have shown that research will increase until more data is available and whole life costing is considered part of the normal design methodology. It will also be included in university computer science courses to train the professionals of the future in whole life cost techniques. This revised version was published online in August 2006 with corrections to the Cover Date.     

Achieving CIM Through Mastery of the Basics

Many manufacturers are considering computer-integrated manufacturing in their search for a competitive edge. However, before automating inefficient processes, companies should first examine and streamline their current methods of operation.     

Computer instruction for scholars in the humanities

Conclusion The common theme running through our discussion of both modes of adaptation to computer technology and problem areas in effective computer-assisted research is the relationship between computer expertise and scholarly research. Knowledge about computers is currently gained by social scientists and humanists in a wide variety of fashions. There are very few formal instructional programs, and most computer skills are obtained on the job. Although it is impossible at this stage to specify in detail either the content or the prerequisites for computer instructional programs for scholars in the social sciences and the humanities, I would recommend for consideration on the following general points. Investigators should have a basic understanding of the design and logic of computers. This knowledge will enable them to have a clearer concept of computers as symbol manipulating devices capable of both arithmetic and logical operations. However, very few investigators will ever use a computer at the level of its basic machine language. Therefore, investigators should learn to solve problems in higher level languages. I consider it essential that they learn at least two such languages, including both numerical and character manipulations. This kind of comprehensive instructional program will assist investigators in exercising greater control over the computer-assisted phases of research; it should allow them wider flexibility in selecting computer techniques appropriate for the research design; and finally, it will allow greater ease in adapting to future advances in computers.     

Integrated product and process designenvironment tool for manufacturing T/R modules

We present a decision-making assistant tool for an integrated product and process design environment for manufacturing applications. Specifically, we target microwave modules that use electro-mechanical components and require optimal solutions to reduce cost, improve quality, and gain leverage in time to market the product. This tool will assist the product and process designer to improve their productivity and enable them to cooperate and coordinate their designs through a common design interface. We consider a multiobjective optimization model that determines components and processes for a given conceptual design for microwave modules. This model outputs a set of solutions that the Pareto optimal concerning cost, quality, and other metrics. In addition, we identify system integration issues for manufacturing applications, and propose an architecture that will serve as a building block to our continuing research in virtual manufacturing applications.     

Method for analysis and dynamism of factory structure in automotive manufacturing

A turbulent environment characterized by unsteady economic cycles, customized products, a growing bandwidth of products, an exploding number of variants and shorter product life cycles force manufacturers to permanent adaptation of their factories. Flexible and changeable structures will be required to enable factories dealing with the technological challenges and economic pressure of the future competitively. In order to achieve changeability objectives in manufacturing, a detailed analysis of existing structures and its representative attributes is essential. It is the basis for systematic structure planning of factories. In this paper a method for analyzing the capacitive and technological structure of a factory embedded in a network of manufacturing and its network of suppliers is presented. The synchronization of product and production development under the influence of change is intended. Therefore, the structural views of product and production are specifically in focus of the method. Based on the results of the analysis models an approach of a tool for giving product and production structure dynamism is suggested to investigate the effects and dependencies of change drivers in manufacturing.     

A knowledge-based approach to design for manufacturability

In the light of growing global competition, organizations around the world today are constantly under pressure to produce high-quality products at an economical price. The integration of design and manufacturing activities into one common engineering effort has been recognized as a key strategy for survival and growth. Design for manufacturability (DFM) is an approach to design that fosters the simultaneous involvement of product design and process design. The implementation of the DFM approach requires the collaboration of both the design and manufacturing functions within an organization. Many reasons can be cited for the inability to implement the DFM approach effectively, including: lack of interdisciplinary expertise of designers; inflexibility in organizational structure, which hinders interaction between design and manufacturing functions; lack of manufacturing cost information at the design phase; and absence of integrated engineering effort intended to maximize functional and manufacturability objectives. The purpose of this research is to show how expert systems methodology could be used to provide manufacturability expertise during the design phase of a product. An object- and rule-based expert system has been developed that has the capability: (1) to make process selection decisions based on a set of design and production parameters to achieve cost-effective manufacture; and (2) to estimate manufacturing cost based on the identified processes. The expertise for primary process selection is developed for casting and forging processes. The specialized processes considered are die casting, investment casting, sand casting, precision forging, open die forging and conventional die forging. The processes considered for secondary process selection are end milling and drilling. The cost estimation expertise is developed for the die casting process, the milling and drilling operations, and the manual assembly operations. The results obtained from the application of the expert system suggest that the use of expert systems methodology is a feasible method for implementing the DFM approach.