Preface viii
PART 1 INTRODUCTION TO CIM AND THE MANUFACTURING ENTERPRISE 1
1 The Manufacturing Enterprise 3
1-1 Introduction 3
1-2 External Challenges 7
1-3 Internal Chal!enges 10
1-4 World-Class Order-Winning Criteria 15
1-5 The Problem and a Solution 22
1-6 Learning CIM Concepts 26
1-7 Going for the Globe 28
1-8 Summary 35
Bibliography 35
Questions 36
Problems 37
Projects 38
Appendix 1-1: The Benefits of a CIM Implementation 40
Appendix 1-2: Technology and the Fundamentals of an Operation--Authors'
Commentary 41
2 Manufacturing Systems 43
2-1 Manufacturing Classifications 45
2-2 Product Development Cycle 52
2-3 Enterprise Organization 54
2-4 Manual Production Operations 59
2-5 Summary 62
Bibliography 63
Questions 63
Projects 64
Case Study: Evolution and Progress--One World-Class Company's
Measurement System 65
Appendix 2-1: ClM as a Competitive Weapon 68
PART 2 THE DESIGN ELEMENTS AND PRODUCTION ENGINEERING 69
3 Product Design and Production Engineering 71
3-1 Product Design and Production Engineering 72
3-2 Organizational Model 74
3-3 The Design Process: A Model 75
3-4 Concurrent Engineering 86
3-5 Production Engineering 93
3-6 Summary 102
Bibliography 102
Questions 103
Projects 104
Case Study: Repetitive Design 105
4 Design Automation: CAD and PDM 107
4-1 Introduction to CAD 107
4-2 The Cost of Paper*Based Design Data 110
4-3 CAD Software 111
4-4 CAD: Yesterday, Today, and Tomorrow 121
4-5 Application of CAD to Manufacturing Systems 129
4-6 Selecting CAD Software for an Enterprise 129
4-7 Product Data Management 134
4-8 Summary 136
Bibliography 137
Questions 137
Projects 138
Appendix 4-1: Web Sites for CAD Vendors 139
Appendix 4-2: B-Splines to NURBS 140
Appendix 4-3: Web Sites for Computer Companies 142
5 Design Automation: CAE 143
5-1 Design for Manufacturing and Assembly 144
5-2 CAE Analysis 152
5-3 CAE Evaluation 163
5-4 Group Technology 177
5-5 Production Engineering Strategies 184
5-6 Design and Production Engineering Network 204
5-7 Summary 210
Bibliography 211
Questions 212
Problems 213
Projects 213
Appendix 5-1: Ten Guidelines for DFA 215
Appendix 5-2: Web Sites for CAE Vendors 216
Appendix 5-3: Web Sites for Rapid Prototyping Vendors 217
PART 3 CONTROLLING THE ENTERPRISE RESOURCES 219
6 Introduction to Production and Operations Planning 221
6-1 Operations Management 222
6-2 Planning for Manufacturing 223
6-3 MPC Model--Manufacturing Resource Planning (MRP II) 228
6-4 Production Planning 234
6-5 Master Production Schedule 240
6-6 Inventory Management 245
6-7 Planning for Material and Capacity Resources 248
6-8 Introduction to Production Activity Control 252
6-9 Shop Loading 254
6-10 Input-Output Control 257
6-11 Automating the Planning and Control Functions 258
6-12 Summary 259
Bibliography 259
Questions 260
Problems 261
Projects 264
Appendix 6-1: Priority Rule Systems 265
7 Detailed Planning and Production-Scheduling Systems 271
7-1 From Reorder-Point Systems to Manufacturing Resource
Planning (MRP II) 271
7-2 Material Requirements Planning 273
7-3 Capacity Requirements Planning 285
7-4 Manufacturing Resource Planning 288
7-5 Features of Modern Manufacturing Planning and Control Systems 291
7-6 Summary 300
Bibliography 302
Questions 303
Problems 304
Projects 305
Appendix 7-1: Wight's Bicycle Example 306
Appendix 7-2: ABCD Checklist 308
Appendix 7-3: An ERP Example Using WinMan 318
8 Enterprise Resources Planning, and Beyond 323
8-1 MRP II: A Driver of Effective ERP Systems 326
8-2 information Technology 327
8-3 The Decision to Implement an ERP System 330
8-4 Identifying ERP System Suppliers 332
8-5 Developing Technologies: Converging and Enabling 335
8-6 Integrating Systems to Manage Design Data 341
8-7 Summary 348
Bibliography 350
Questions 351
Projects 351
9 The Revolution in Manufacturing 352
9-1 Just-in-TimeManufacturing 353
9-2 Synchronized Production 364
9-3 The Emergence of Lean Production 366
9-4 Modern Manufacturing Systems in a Lean Environment 369
9-5 Summary 374
Bibliography 375
Questions 375
Projects 376
Case Study: Production System at New United Motor Manufacturing, Part 1 376
Case Study: Production System at New United Motor Manufacturing, Part 2 378
PART 4 ENABLING PROCESSES AND SYSTEMS FOR MODERN
MANUFACTURING 383
10 Production Process Machines and Systems 385
10-1 Material and Machine Processes 387
10-2 Flexible Manufacturing 405
10-3 Fixed High-Volume Automation 413
10-4 Summary 417
Bibliography 419
Questions 420
Projects 421
Appendix 10--1: History of Computer-Controlled Machines 422
11 Production Support Machines and Systems 425
11-1 IndustrialRobots 426
11-2 Program Statements for Servo Robots 448
11-3 Programming a Servo Robot 454
11-4 Automated Material Handling 461
11-5 Automatic Guided Vehicles 465
11-6 Automated Storage and Retrieval 476
11-7 Summary 480
Bibliography 481
Questions 481
Projects 483
Case, Study: AGV Applications at General Motors 484
12 Machine and System Control 486
12-1 System Overview 487
12-2 Cell Control 493
12-3 Proprietary Versus Open System Interconnect Software 497
12-4 Device Control 499
12-5 Programmable Logic Controllers 500
12-6 Relay Ladder Logic 502
12-7 PLC System and Components 506
12-8 PLC Types 511
12-9 Relay Logic Versus Ladder Logic 513
12-10 Computer Numerical Control 521
12-11 Automatic Tracking 525
12-12 Network Communications 529
12-13 Summary 531
Bibliography 532
Questions 533
Projects 534
Appendix 12-1: Turning G Codes 535
13 Quality and Human Resource Issues in Manufacturing 537
13-1 Quality Foundations 538
13-2 Total Quality Management 543
13-3 Quality Tools and Processes 547
13-4 Defect-Free Design Philosophy 557
13-5 The Changing Worldorce 561
13-6 Self-Directed Work Teams 562
13-7 Summary 567
Bibliography 569
Questions 569
Projects 570
Index 571
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