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CIM Technology 1 OpenCIM
Student Activities Book Catalog No. 100384 Rev. A May 2003
CIM Technology 1 – OpenCIM Student Activities Book Every effort has been made to make this book as complete and accurate as possible. However, no warranty of suitability, purpose, or fitness is made or implied. Intelitek is not liable or responsible to any person or entity for loss or damage in connection with or stemming from the use of the software, equipment and/or the information contained in this publication. Intelitek bears no responsibility for errors which may appear in this publication and retains the right to change specifications without prior notice.
Intelitek Inc. 444 East Industrial Park Drive Manchester, NH 03109-5317 USA Tel: (603) 625-8600 Fax: (603) 625-2137 website: http://www.intelitek.com email:
[email protected]
Table of Contents Table of Contents......................................................................................................................... i Introduction About This Activities Book................................................................................. v SAFETY ............................................................................................................................VI Activity 1
Getting Started .................................................................................................1-1 Objectives ...................................................................................................................1-1 Skills ...........................................................................................................................1-1 Materials .....................................................................................................................1-1 Overview ....................................................................................................................1-2 Procedures ................................................................................................................1-10 Task 1-1: Determining the Advantages of CIM ..................................................1-10 Task 1-2: Review Main Components of CIM .....................................................1-10 Task 1-3: Review of Basic CIM System Components ........................................1-11 Task 1-4: Team Discussion and Review .............................................................1-11
Activity 2
Introducing OpenCIM Software.......................................................................2-1 Objectives ...................................................................................................................2-1 Skills ...........................................................................................................................2-1 Materials .....................................................................................................................2-1 Overview ....................................................................................................................2-2 Procedures ..................................................................................................................2-7 Task 2-1: Accessing Working Cells from the Project Manager ............................2-7 Task 2-2: Identifying Components of OpenCIM Software. ..................................2-9 Task 2-3: Rotating and Zooming in the Graphic Display Window.....................2-10 Task 2-4: Redirecting the Camera .......................................................................2-11 Task 2-5: Observing a CIM Production Cycle ....................................................2-13 Task 2-6: Team Discussion and Review .............................................................2-16
Activity 3
Parts and Production Flow ..............................................................................3-1 Objectives ...................................................................................................................3-1 Skills ...........................................................................................................................3-1 Materials .....................................................................................................................3-1 Overview ....................................................................................................................3-2 Procedures ..................................................................................................................3-7 Task 3-1: Identifying Parts of a Template .............................................................3-7 Task 3-2: Review of Production Components.......................................................3-8 Task 3-3: Running a Basic CIM Production .........................................................3-9 Task 3-4: Team Discussion and Review .............................................................3-10
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Activity 4
Storage Setup ...................................................................................................4-1 Objectives ...................................................................................................................4-1 Skills ...........................................................................................................................4-1 Materials .....................................................................................................................4-1 Overview ....................................................................................................................4-2 Procedures ..................................................................................................................4-6 Task 4-1: Identifying the Location of a Part in Storage ........................................4-6 Task 4-2: Setting the Storage Stock ......................................................................4-8 Task 4-3: Setting the Storage Stock and Part Location .......................................4-10 Task 4-4: Observing the ASRS Contents after Production .................................4-13 Task 4-5: Setting Default Storage .......................................................................4-15 Task 4-6: Team Discussion and Review .............................................................4-16
Activity 5
Production Planning ........................................................................................5-1 Objectives ...................................................................................................................5-1 Skills ...........................................................................................................................5-1 Materials .....................................................................................................................5-1 Overview ....................................................................................................................5-2 Procedures ..................................................................................................................5-7 Task 5-1: Editing a Customer Order .....................................................................5-7 Task 5-2: Updating a Manufacturing Order ........................................................5-11 Task 5-3: Tracking Production Following MRP Modification ...........................5-13 Task 5-4: Editing the Customers List ..................................................................5-14 Task 5-5: Ordering Parts for the New Customer.................................................5-15 Task 5-6: Team Discussion and Review .............................................................5-17
Activity 6
Processes and Machine Definition .................................................................6-1 Objectives ...................................................................................................................6-1 Skills ...........................................................................................................................6-1 Materials .....................................................................................................................6-1 Overview ....................................................................................................................6-2 Procedures ..................................................................................................................6-8 Task 6-1: Process Types in OpenCIM...................................................................6-8 Task 6-2: Adding a New Process to an Existing Machine ....................................6-8 Task 6-3: Team Discussion and Review .............................................................6-11
Activity 7
Part Definition ...................................................................................................7-1 Objectives ...................................................................................................................7-1 Skills ...........................................................................................................................7-1 Materials .....................................................................................................................7-1 Overview ....................................................................................................................7-2 Procedures ..................................................................................................................7-7 Task 7-1: Viewing Supplied Part Information ......................................................7-7 Task 7-2: Viewing Product Part Information ........................................................7-8 Task 7-3: Team Discussion and Review ...............................................................7-9
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Activity 8
Defining a Product Part....................................................................................8-1 Objectives ...................................................................................................................8-1 Skills ...........................................................................................................................8-1 Materials .....................................................................................................................8-1 Overview ....................................................................................................................8-2 Procedures ..................................................................................................................8-5 Task 8-1: Adding a New Supplied Part to the Basic CIM Cell .............................8-5 Task 8-2: Adding and Defining a Product Part .....................................................8-9 Task 8-3: Team Discussion and Review .............................................................8-17
Activity 9
Producing a New Part ......................................................................................9-1 Objectives ...................................................................................................................9-1 Skills ...........................................................................................................................9-1 Materials .....................................................................................................................9-1 Overview ....................................................................................................................9-2 Procedures ..................................................................................................................9-3 Task 9-1: Updating Storage...................................................................................9-3 Task 9-2: Placing an Order for the New Product Part...........................................9-6 Task 9-3: Tracking Production of WOOD PROD in the CIM cell .....................9-10 Task 9-4: Team Discussion and Review .............................................................9-11
Activity 10
Timing and Optimization................................................................................10-1 Objectives .................................................................................................................10-1 Skills .........................................................................................................................10-1 Materials ...................................................................................................................10-1 Overview ..................................................................................................................10-2 Procedures ................................................................................................................10-7 Task 10-1: Preparing to Observe Production Timing..........................................10-7 Task 10-2: Observing Production Timing with the Scheduler Gantt ................10-11 Task 10-3: Team Discussion and Review .........................................................10-15
Activity 11
Viewing Production Details in the Device View...........................................11-1 Objectives .................................................................................................................11-1 Skills .........................................................................................................................11-1 Materials ...................................................................................................................11-1 Overview ..................................................................................................................11-2 Procedures ................................................................................................................11-4 Task 11-1: Viewing Device Activity at Station 1................................................11-4 Task 11-2: Viewing Device Activity at the CNC Station .................................11-10 Task 11-3: Team Discussion and Review .........................................................11-15
Activity 12
Viewing Production Details in the Storage View ........................................12-1 Objectives .................................................................................................................12-1 Skills .........................................................................................................................12-1 Materials ...................................................................................................................12-1 Overview ..................................................................................................................12-2 Procedures ................................................................................................................12-3 Task 12-1: Viewing Production Details in the Storage View..............................12-3 Task 12-2: Team Discussion and Review .........................................................12-13
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Activity 13
Adding a CNC Machine ..................................................................................13-1 Objectives .................................................................................................................13-1 Skills .........................................................................................................................13-1 Materials ...................................................................................................................13-1 Overview ..................................................................................................................13-2 Procedures ................................................................................................................13-4 Task 13-1: Inserting a New Object into the Basic CIM Cell...............................13-4 Task 13-2: Configuring the Connectivity Settings ............................................13-15 Task 13-3: Team Discussion and Review .........................................................13-17
Activity 14
Defining Part Production in the Lathe ..........................................................14-1 Objectives .................................................................................................................14-1 Skills .........................................................................................................................14-1 Materials ...................................................................................................................14-1 Overview ..................................................................................................................14-2 Procedures ................................................................................................................14-2 Task 14-1: Defining a New Process for the Lathe...............................................14-2 Task 14-2: Adding a New Part ............................................................................14-7 Task 14-3: Team Discussion and Review .........................................................14-17
Activity 15
Integrated Production ....................................................................................15-1 Objectives .................................................................................................................15-1 Skills .........................................................................................................................15-1 Materials ...................................................................................................................15-1 Overview ..................................................................................................................15-2 Procedures ................................................................................................................15-2 Task 15-1: Setting the MRP Manufacturing Order .............................................15-2 Task 15-2: Updating Storage...............................................................................15-8 Task 15-3: Team Discussion and Review .........................................................15-10
Activity 16
Tracking Integrated Production ....................................................................16-1 Objectives .................................................................................................................16-1 Skills .........................................................................................................................16-1 Materials ...................................................................................................................16-1 Overview ..................................................................................................................16-2 Procedures ................................................................................................................16-3 Task 16-1: Tracking the Sequence of Production ...............................................16-3 Task 16-2: Tracking the Sequence of Production with Updated Process Durations..................................................................................16-8 Task16-3: Team Discussion and Review ..........................................................16-11
Activity 17
Improving System Performance ...................................................................17-1 Objectives .................................................................................................................17-1 Skills .........................................................................................................................17-1 Materials ...................................................................................................................17-1 Overview ..................................................................................................................17-2 Procedures ................................................................................................................17-3 Task 17-1: Enlarging the Buffer Capacity...........................................................17-3 Task 17-2: Observing System Performance with the Additional Buffer...........17-10 Task 17-3: Team Discussion and Review .........................................................17-14
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Introduction
About This Activities Book This manual contains 17 activities, each of which can be completed in one 45-minute lab session. For each of the activities you will require a PC with OpenCIM Version 3.0 software installed. At the beginning of each activity you will encounter several lists: ♦ Objectives are the goals you will achieve. ♦ Skills are the competencies you will develop. ♦ Materials are the specific items you will need for each activity.
The Overview introduces you to the subjects you will explore in each activity. The Procedures contain a series of Tasks, or operations. The first time an operation is to be performed, instructions are given in a tutorial manner. In subsequent tasks you should be able to perform these operations without guidance. Many tasks are best performed when each team member takes on a different role. One student may, for example, handle the hardware while another student manages the software. The activities are designed so that team members can switch roles and repeat tasks, thereby allowing everyone more hands-on time. Questions and tables for entering results and observations appear throughout the tasks. Questions for discussion and review conclude each activity. All questions and tables are printed on a set of Worksheets supplied with this book. Record your answers in the worksheets, or as directed by your instructor. Do not write in this book. You will be directed to perform inventory and safety checks at the beginning of every working session, and to shut down the system properly at the end of each activity. It is assumed you are familiar with the PC and are comfortable working in the Windows/DOS operating environment. However, instructions are explicit enough to allow novices to use the tekLINK's specific software.
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Safety Safety precautions in the workplace serve to protect both the human operators and the equipment. You will be working offline in the CIM Technology 1 tekLINK so safety should not be an issue. However, it is important to remember these safety issues. ♦ Make sure that the CIM system is offline before beginning the tekLINK. Previous users may
have left the system online which could cause a potentially dangerous environment for both the human operators and CIM equipment.
♦ Read the instructions and ensure you understand them clearly. ♦ Ensure that the computer is turned on and shut down properly when working on the
activities.
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Activity 1
Getting Started Before you begin this activity, take the pre-test according to your teacher’s instructions. The purpose of the pretest is to measure your knowledge and skills in the field of Computer Integrated Manufacturing (CIM). This test will not affect your tekLINK grade. When you finish the pre-test, please hand it in to your teacher. OBJECTIVES In this activity you will accomplish the following: ♦ Understand the concept of Computer Integrated Manufacturing (CIM) ♦ Identify the main components and devices in a basic CIM cell ♦ Identify the various phases of CIM production
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Understand how CIM cells are used to simulate the production cycle from planning through the production stages.
Determine the advantages of CIM manufacturing.
Describe the role of robotics in CIM.
♦ Occupational and Technical:
Describe the main CIM components of the CIM cell.
Operate the OpenCIM software.
MATERIALS In this activity you will need the following materials: ♦ Pre-test and Pre-test Answer Sheet ♦ A PC with the OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
What is Automation? Automation is a system of manufacture designed to enable machines to perform specific tasks formerly done by humans, and to control sequences of operations without human intervention. The term automation has also been used to describe non-manufacturing systems in which programmed or automatic devices can operate independently or nearly independently of human control. In the fields of communications, aviation, and astronautics, for example, automated devices are used to perform various operations much faster or better than could be accomplished by humans. These include automatic telephone switching equipment, automatic pilots, and automated guidance and control systems.
What is Computer Integrated Manufacturing (CIM)? To stay competitive, factories are increasingly automating their production lines with Computer Integrated Manufacturing (CIM) systems. A CIM cell is an automated assembly line that uses a network of computers to control robots, production machines and quality control devices. The CIM cell can be easily programmed to produce custom parts and products. Educational CIM cells are used to simulate the production cycle and enable control and analysis of various aspects of the cycle, from the planning through production. Figure 1-1 shows a variety of CIM cells used in educational settings
Figure 1-1: Examples of CIM cells for educational use
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Advantages of CIM CIM systems offer the following advantages: ♦ Computer integration of information provides all departments of a
factory rapid access to the same production data.
♦ Accessibility of production data results in faster response to change.
This in turn shortens lead times, increases the company's responsiveness to customer demands and competition, and improves due-date reliability.
♦ Computer-aided scheduling optimizes use of the shop floor. This
improves the utilization of machine tools, and reduces work-inprogress and lead times.
♦ Real-time production data can improve quality by using techniques
such as statistical process control to optimize the production processes.
♦ Computer analysis and prediction of material requirements for
production can reduce inventory levels and lead times. The integration between suppliers and customers are also benefits.
♦ Downloading machining instructions, including tool changes, from
CAM (Computer Aided Manufacturing) systems to CNC (Computer Numerically Controlled) machines reduces machine setup time and increases machine utilization.
The trend among manufacturers today is to produce smaller batches of more varied products. Without CIM automation, this trend would result in higher costs because of increased setup time and additional labor.
CIM Training Industry today is experiencing a shortage of qualified CIM technicians and engineers. Manufacturers demand graduates whom understand the integration between all elements of a CIM. This CIM training module aims to address this need by providing an industrial-level training system for the educational environment. This CIM training module is the first in a series of three modules that will introduce you to the principles and practice of CIM production. In this module, you will work entirely in an “off-line” mode, meaning that you will use solely OpenCIM simulation software to simulate a working CIM environment. In future modules, you will also practice your CIM skills in an “online” environment, using actual CIM hardware. In the following activities, you will simulate the manufacture of several unique parts using CIM simulation software (OpenCIM). In doing so, you will gain a more complete understanding of the overall operation of a CIM system.
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Main Components of CIM All CIM systems generally share the following components, which are necessary for most production processes: ♦ Robotic Arms: CIM systems are fully automated, and robotic arms
are critical components in these automated systems. In CIM, robotic arms perform tasks that would otherwise require human intervention, thus enabling the system to be fully automated. Examples of tasks performed by robotic arms include the picking and placing of parts in/from machines, removing of parts from storage, assembling of parts and handling of parts for quality control. In later activities, you will be introduced to some of the robot types and robot tasks used in CIM.
Figure 1-2: Robotic arm units working with CNC Machines
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♦ Storage: A storage station is used to store raw materials prior to
production, as well as finished products following the production process. Such stations are fully automatic and controlled by robotic arms. A typical CIM storage station includes a machine known as an ASRS or Automated Storage and Retrieval System. The ASRS is a robotic storage device used to store and retrieve parts in a CIM cell. The ASRS is used as the main source of raw material for the cell, and can also serve as a warehouse for parts in various stages of production. Storage cells in the ASRS contain templates, either empty or containing parts. A CIM cell may contain any number of ASRS stations.
Figure 1-3: ASRS Photos ♦ Machines: “Machine” is a
generic term used to describe a wide variety of production devices, such as CNC machines and laser engravers. Such machines require that parts be inserted or placed into them, usually by a robotic arm. The inserted parts are predefined in size and nature. The machine is programmed in advance to process a particular part, ensuring precise and exact part production. Figure 1-4: CNC Mill
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♦ Quality Control (QC): This group of equipment includes measuring
devices, such as optical systems, laser scan meters and CMMs (Coordinate Measuring Machines). The purpose of these devices is to determine whether a product meets the quality control specifications defined prior to the production process. QC components include high precision measuring tools that the system uses to determine whether the product should advance to shipment or be rejected. Following the rejection of a product, the system must be capable of adjusting itself so that it does not automatically reject subsequent parts.
Figure 1-5: QC using Laser Scan Meter ♦ Closed Loop Conveyor: By
nature, CIM components tend to be located in multiple production stations that are physically distant from one another. This requires a system that moves parts from one robotic station to another (for Figure 1-6: Conveyor Photo example from an ASRS to a CNC machine). A closed loop conveyer with stop stations controlled by PLC is typically used for this purpose. Stop and release units (i.e. stop stations) are located on the conveyor in front of each production station. The stop stations are controlled by the PLC and enable the robot to pick a part from the conveyor and place the part on it.
CIM systems can also include a wide variety of components in addition to the equipment previously mentioned. Many of the equipment types will be discussed in future activities, after you have become more familiar with basic CIM operation and production.
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A Basic CIM System This module focuses on a basic CIM cell with the following components: ♦ ASRS (with 36 storage cells) ♦ Machine (mill) tended by a robot ♦ Conveyor (with 2 stop stations)
This basic simulated CIM cell will be used for all of the activities in this module. As your knowledge of CIM increases, you will be introduced to increasingly complex CIM configurations.
Machine (CNC mill)
Conveyor (2 stop stations)
ASRS (36 cells)
Figure 1-7: Example of a basic CIM system
Storage In this module, you will work with an automatic storage device known as an ASRS (Automatic Storage and Retrieval System). The ASRS (36) is used to store either empty templates or templates that contain parts. The parts can be supplied parts or finished products. The ASRS you will use is built like a bookcase with special compartments designed for the templates. This “bookcase” is tended by a robot that removes parts from the device and places finished products into the device for storage.
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This “bookcase” type ASRS represents only one configuration and type of ASRS (Automatic Storage and Retrieval Systems). These ASRS storage devices can be found in many types of configurations (i.e., varying number of cells, varying sizes, varying cell dimensions) and types (i.e., round, rectangular).
Figure 1-8: Graphic representation of ASRS
CNC Machine The machine used in this cell is a CNC mill, which is frequently used for the processing of many types of materials. CNC mills are used to shape raw materials, such as wood, plastic, or metal, into parts of predefined dimensions. Generally, the CNC machine needs to be fed a part, either manually or by a robotic arm. To achieve fully automated functionality in the CIM system, the parts are fed to the CNC machine by a robotic arm.
Figure 1-9: Graphic representation of CNC mill machine
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Conveyor The basic CIM cell described in this module includes two separate robotic stations, an ASRS and a machine. The conveyor is the mechanism responsible for transferring parts from one station to another. The conveyor has predefined stop locations, where the part is loaded on the conveyor and unloaded from it. Figure 1-10: Conveyor
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PROCEDURES Task 1-1: Determining the Advantages of CIM Answer the following true or false questions. Q Do CIM systems use computer-aided scheduling and CAM systems to
increase machine utilization? Q Does computer analysis and planning increase lead-time and
inventory levels? Task 1-2: Review Main Components of CIM Q CIM uses computers to do which of the following three tasks?
Provide access to production data.
Produce raw materials.
Control robots and quality control devices.
Produce parts.
Q Determine which of the following three items can be stored using an
ASRS:
Raw materials.
Finished products.
Templates.
Partially processed parts.
Q Does the PLC control the stop stations of the conveyor? Q Is the conveyor used to move the robot from one place to another? Q Determine which of the following devices may be integrated into a
CIM cell:
Storage
Machine
Quality control devices
Q Can parts be fed to CNC machines manually or automatically? Q Can a CIM cell include more than one storage station? Q Is it the ASRS, the conveyor, or the robotic arm that is responsible for
transferring parts from station to station?
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Task 1-3: Review of Basic CIM System Components Q Are robotic arms used in the ASRS? Q Is a conveyor used to move parts between predefined stations in the
CIM cell? Task 1-4: Team Discussion and Review Q Discuss whether or not automation increases or reduces human
intervention in the manufacturing process.
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Activity 2
Introducing OpenCIM Software OBJECTIVES In this activity you will accomplish the following: ♦ Learn basic operation of CIM simulation software ♦ Use CIM simulation software to run a simulated production cell ♦ Identify the main components of the OpenCIM software
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Observe a CIM production cycle using the CNC milling machine. Learn how the OpenCIM software can be used to represent an actual virtual production cycle.
♦ Occupational and Technical:
Select your working cell from the CIM Project Manager and then access the CIM Manager and Virtual CIM applications for the selected cell.
Identify the OpenCIM Manager components.
Define the viewing options of the Graphics Display window.
Initiate and then observe production cycle, by following the route of one part.
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
OpenCIM© Software In this activity you will use CIM simulation software, known as OpenCIM, to learn the basics of CIM operation and management. OpenCIM is designed to teach students the principles of automated production using integrated robotics, computers and CNC machines. It also allows advanced users to search for optimal production techniques through off-line and on-line experimentation. The following features characterize the software: ♦ OpenCIM software enables users to create and modify CIM cells and
components. The CIM cell setup may represent an actual installation or it may be a virtual cell.
♦ OpenCIM allows for targeted training at a given station or device. ♦ OpenCIM includes a 3D solid model graphic display that dynamically
and accurately simulates the CIM components and features. It provides both online tracking of the production process and off-line simulation.
♦ OpenCIM provides the opportunity to observe how a set of diverse
hardware components works together in a real-world environment. Its ability to use equipment found in actual industrial CIMs enables realistic simulation
♦ OpenCIM resembles industrial CIMs in its ability to expand by using
distributed processing at each production station. Distributed processing also makes for a more robust system.
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OpenCIM Project Manager The CIM Project Manager window provides access to the functionality of different cells in the OpenCIM software. After selecting the required project in the CIM Project Manager window, you can then activate the following OpenCIM applications, as required: ♦ CIM Manager
: Enables the user to centrally control all the activities of the selected CIM Cell.
♦ CIM Setup
: Enables the user to create and modify the Virtual CIM setup of the selected CIM Cell.
Figure 2-1: CIM Project Manager Window
The CIM Project manager includes the following components: ♦ Menu Bar: Consists of four menus that enable the functionality of the
project manager described briefly below.
♦ Toolbar: Provides shortcuts to frequently used options of the project
manager.
♦ User Projects Tab: Contains the list of projects that were added to the
list by the logged in user.
♦ Archive Tab: Contains the list of predefined projects that were
automatically installed with the software.
♦ Status Bar: Contains information regarding the functionality of the
selected toolbar option.
The CIM project manager enables the user to: ♦ Select different CIM cells and then activate the CIM Manager or CIM
Setup applications, for the selected cell.
♦ Copy cells from the project manager archive and save them in the user
projects list.
♦ Add new CIM cells to the user projects list.
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♦ Import existing CIM cells from a specified directory. ♦ Export CIM cells from the user projects list to a specified directory for
backup purposes.
♦ Remove CIM cells from the user projects list.
OpenCIM Manager Components The OpenCIM Manager window provides access to the functionality of the OpenCIM software of the selected cell.
Figure 2-2: OpenCIM Manager window
The OpenCIM Manager window includes the following components: ♦ Menu bar: The menu bar, located at the top of the OpenCIM Manager
window, consists of five menus, each of which enables access to OpenCIM functionality. The menu options will be introduced in the activities you will perform in this module.
♦ Toolbar: The toolbar, located directly below the menu bar, consists of
buttons that provide shortcuts to frequently used commands. The specific toolbar buttons will be introduced in the activities you will perform in this module.
♦ CIM TIME counter: The CIM time counter indicates the time
elapsed since the onset of the production cycle.
♦ Order View: The Order View, located below the toolbar in the left
portion of the window, displays data regarding the order of parts and their production status. This area will be introduced in the activities you will perform in this module.
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♦ DeviceView: The Device View, located below the toolbar in the right
portion of the window, displays data regarding the activity taking place in the devices during the production process. This area will be introduced in the activities you will perform in this module.
♦ Viewing Area: The Viewing area enables you to monitor various
aspects of the production cycle on a real-time basis by selecting one of seven tab views. By default, the Graphic Display tab is selected and the viewing area displays 3D graphic simulation of the CIM production cycle. The specific tab views will be introduced in the activities you will perform in this module.
♦ Graphic Display Toolbar: The Graphic Display toolbar, located in
the left of the Viewing area when the Graphic Display tab is selected, consists of buttons that enable you to alter the graphic display. The specific toolbar buttons will be introduced in the activities you will perform in this module.
♦ PLC Status Bar: The PLC Status Bar, informs us whether or not the
connection is active.
♦ Information Bar: The Information Bar displays general messages that
occur during production.
♦ Status Bar: The application’s status bar, located at the bottom of the
window, displays the status and location of the application. Such as, the current operation mode and the location of the WSO.ini file used by the manager.
OpenCIM Software Viewing Features The OpenCIM 3D Image window simulates a video camera output screen. You can control the camera to focus in on the CIM cell actions, and rotate, angle, zoom or adjust the view by redirecting the camera. The following options enable you to change the view of the CIM cell: ♦ Top View: Places the camera on top of the cell at the center of the image. ♦ Redirect Camera: Defines the position that will be in the center of the
image.
♦ Zoom In/Zoom Out: Zooms in and out of the image by pressing the
right mouse button and moving it forward or backward.
♦ Rotate the Image: Rotates the view of the image by pressing the right
mouse button and moving it to the right/left.
♦ Moving the Camera Up/Down: Use the window’s scroll bar to adjust
the viewing angle of the image.
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CIM Production How is production executed in a fully automated system? Naturally, it should be executed using the shortest route available with the most efficient timing of duty cycles. In order to determine the shortest route and most efficient timing, you must first outline the production route by planning the steps that the system should execute. As you already know, the goal of CIM production is to manufacture a product. For this basic CIM system, the product is to be produced by a milling machine (the only manufacturing device available). The CIM cell produces this product by performing the following steps: 1
A part (raw material) is taken from the storage station and conveyed to the CNC station.
2
The CNC machine mills the part.
3
The part (product) is returned to the storage station.
In this activity you will observe this simple CIM production cycle.
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PROCEDURES Task 2-1: Accessing Working Cells from the Project Manager In this task you will copy the required cell from the project manager archives, save it in the user projects list and activate the CIM Manager application for the selected cell. 1
From your Windows Start menu, select OpenCIM | Project Manager . The CIM Project Manager window is displayed.
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From the Archive tab select 102_ACT1-5, the project for this activity.
3
From the Project menu select Save As or select the button on the toolbar. The Save 102_ACT1-5 as window is displayed.
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4
In the Project name field, enter your user name followed by 2 (2), for example, JOHN2, and then click OK. This project is displayed in the User Projects tab.
5
From the User Projects tab select this 2 project and click the CIM Manager button on the toolbar to activate the CIM Manager application for this project. All the tasks described in this activity refer to this selected 2 project.
Note: Alternatively, you can also activate the CIM Setup application by selecting the 2 project and then selecting the CIM Setup button on the toolbar.
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Task 2-2: Identifying Components of OpenCIM Software. Q Circle the OpenCIM toolbar in the OpenCIM Manager window. Q Circle the OpenCIM menu bar in the OpenCIM Manager window. Q Circle the CIM TIME counter in the OpenCIM Manager window. Q Circle the Part area in the OpenCIM Manager window. Q Circle the Device area in the OpenCIM Manager window. Q Circle the Simulation Viewing area in the OpenCIM Manager window. Q Circle the 3D Image toolbar in the OpenCIM Manager window. Q Circle the PLC Status Bar in the OpenCIM Manager window. Q Circle the status bar in the OpenCIM Manager window.
Figure 2-3: OpenCIM Manager Window
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Task 2-3: Rotating and Zooming in the Graphic Display Window 1
From the OpenCIM Manager window, click the Top View button. This command places the camera in the center of the cell ceiling facing downwards.
Figure 2-4: The OpenCIM Manager Window
Imagine that the image shown in the Viewing Area is the output of a video camera installed in the CIM cell.
Figure 2-5: OpenCIM Manager Window - Top View
Note that the scroll box of the vertical scroll bar is at the top.
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2
Place the cursor on the vertical scroll bar and drag it downward. This moves the camera up and down, changing the viewing angle.
3
Hold down the right mouse button (anywhere inside the Graphic Display window) and drag the mouse upward. The cursor turns into a magnifying glass. Your action is similar to a video camera zoom in feature. The zooming in is performed so that the center of the cell stays in the center of the camera output image.
4
Hold down the right mouse button and drag the mouse downward. This action is similar to the zoom-out feature.
5
Hold down the right mouse button and drag the mouse to the right. The display is rotated counterclockwise.
6
Hold down the right mouse button and drag the mouse to the left. The display is rotated clockwise.
Task 2-4: Redirecting the Camera In this task you will define a position that will be in the center of the image. 1
Click the Redirect Camera button
.
The cursor turns into a magnifying glass with an arrow.
Figure 2-6: OpenCIM Manager Window – Redirecting the Camera
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2
Click the ASRS. The ASRS now appears in the center of the window. This feature enables you to determine the object (or position) that will be in the center of the image.
Figure 2-7: OpenCIM Manager Window – Determining the Image Center 3
Deactivate the Redirect Camera feature by re-clicking the depressed button.
4
Place the cursor anywhere inside the Graphic Display window.
5
Hold down the right mouse button and drag the mouse upward and downward. Now the zoom in feature is performed so that the ASRS stays in the center of the camera output image.
Figure 2-8: OpenCIM Manager Window – Zooming In
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6
Hold down the right mouse button and move to the right and left. This rotates the displayed image. The center of rotation is the position selected when you executed the Redirect Camera command.
Figure 2-9: OpenCIM Manager Window – Center of Rotation
Throughout this module you will learn to adjust the viewing tools in order to find the most comfortable viewing angle and position for you. Task 2-5: Observing a CIM Production Cycle You will now initiate a CIM production cycle and follow the route of one part. OpenCIM software features an excellent tool for observing the actions of a particular object throughout program execution – the Follow Me Camera tool. By selecting this tool and clicking a part, the “camera” will automatically follow this part through its production cycle. 1
To initiate the cycle, click the Start button toolbar.
from the OpenCIM
The following message is displayed:
Figure 2-10: CIM Manager - Refresh Storage Confirmation Message
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Click OK.
3
To start the simulation of the production cycle, click the Run button from the OpenCIM toolbar.
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4
Click the Follow Me Camera button toolbar.
from the Graphic Display
The cursor turns into an arrow.
Figure 2-11: OpenCIM Manager Window – Follow Me Camera Option 5
Zoom in on the ASRS to locate the part.
Figure 2-12: OpenCIM Manager Window – Zoom in to Locate Parts
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6
Click the part in the ASRS (the red square on a gray template) to define the object that is to be followed by the camera.
Figure 2-13: OpenCIM Manager Window – Defining the Follow Me Object
The camera will now automatically follow the selected part’s route throughout the production process. 7
You may pause the cycle at any time by clicking the Pause button from the OpenCIM toolbar. After pausing a cycle, you can restart it by clicking the Continue button from the OpenCIM toolbar.
8
Observe the whereabouts of the part at each point in time. To re-run the production cycle, repeat steps 5 to 7.
9
Complete the following sentences based up on the exact sequence that took place in the simulated production cycle. Re-run the production cycle if you need assistance. Use the Pause and Continue options as required.
Q Phase 1: Is the raw material/product retrieved, transferred, or
processed from the ASRS? Q Phase 2: Is the raw material/product retrieved, transferred, or
processed to the machine? Q Phase 3: Is the raw material/product retrieved, transferred, or
processed in the machine? Q Phase 4: Is the raw material/product retrieved, transferred, or
processed to the ASRS? Q Does the ASRS retrieve parts and put them in the milling machine? Q Does the ASRS take parts from the conveyor and place them in
storage?
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Q Does the CNC machine receive parts from the conveyor that are
picked by a robotic arm? Q Does the CNC machine process the part after it has been stored in the
ASRS? Q Does the CNC machine wait for the robotic arm to insert the part in it
before commencing operation? Q Does the conveyor move parts from one stop station to another? Q As a part arrives at the stop station, does the conveyor change the
direction of its movement? Task 2-6: Team Discussion and Review Q Can OpenCIM be used to represent an actual installation or a virtual
cell? Q Can OpenCIM perform online tracking of the production process? Q Once simulation of the production cycle has begun, can it be paused
and restarted only once? Q Which one viewing option redefines the center of graphic viewing
image?
Top view
Redirect Camera
Follow Me Camera
Q Which one viewing option enables you to focus on the location of
specific part during a production cycle?
Top view
Redirect Camera
Follow Me Camera
Q Which one viewing option places the camera in the center of the cell
ceiling facing downwards?
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Top view
Redirect Camera
Follow Me Camera
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Activity 3
Parts and Production Flow OBJECTIVES In this activity you will accomplish the following: ♦ Define the term production ♦ Distinguish between a raw material and product ♦ Identify the following CIM components: part, template, stop station,
and buffer
♦ Differentiate between temporary and long-term storage devices ♦ Observe part flow in CIM and analyze the interaction of the various
components involved
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Describe the role of industrial safety
Describe the CIM production workflow
♦ Occupational and Technical:
Identify template parts
Review the production components
Run a basic CIM Production and observe and track part flow
Identify the location of a part at a given time
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
Parts and Production In the previous activity you tracked the production of a part by a machine. The term part was often used but was not clearly defined. In this activity you will learn to define the word part in terms of CIM, as well as define the relationship between a part and its production. In CIM, parts are divided into two categories that refer to the nature of the part in its pre and post-production phase: ♦ Supplied Part: A part in its pre-production phase. It is also referred to
as a raw part.
♦ Product: The finished part produced from the raw material in the
production process. Production can consist of several processes or actions on the raw material, which together produce a final product.
The production process creates the product. Production is designed according to various production parameters, such as, cost, time, number of parts to be produced, available resources and more. In the previous activity you observed that part flow was related to the production process and occurred in the following sequence: ♦ A unit of raw material (or supplied part) was retrieved by the ASRS. ♦ The ASRS robotic arm placed the part on the conveyor. ♦ The part was conveyed to the station that contains the milling machine. ♦ The robot that tends the milling machine retrieved the part from the
conveyor and placed it into the mill.
♦ The part was machined according to the activated G-Code. ♦ The product was conveyed to the ASRS station for storage.
As you tracked part flow, you probably noticed that additional components in the CIM cell enabled easier and more efficient part flow.
Important Production Components Templates In OpenCIM, a template is used to move the part from one place to another. The template is mobilized with the part on it. Templates contain fixturing pins that define the location of the part on the template and assure that the part is held in a stable manner. These pins are arranged according to the part dimensions.
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The template shown holds a rod-shaped part kept in place by six fixturing pins.
Figure 3-1: Template with a fixture for the part ♦ Metal (or plastic) pins determine the part location and keep it in place.
To hold the part firmly in place an additional fixture is required. These pins can be placed in any number of configurations, enabling the storage of many different parts of varying shapes and dimensions.
♦ The template contains a handle that is designed according to the
gripper of the robot. This handle enables the robot to easily pick and place the template.
Pallets In order to convey the template along the conveyor, a carrier device is required. This device, known as a pallet (shown in figure 3-2, below), is designed to carry a template. The robot places the template carrying the part onto a pallet on the conveyor. The conveyor then transports this pallet in a continuous cycle from station to station. A PLC (Programmable Logic Controller) controls the movement of the pallets on the conveyor.
Figure 3-2: Pallet on Conveyer
Figure 3-3: Virtual Pallet
The pallets always remain on the conveyor. When a part is needed, the template holding that part is unloaded from the pallet by a robotic arm; the pallet continues to travel on the conveyor. However, a robot cannot unload a template, if the pallet is in motion. The pallet must be immobilized to allow a template to be unloaded. Activities Book 0503
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Stop Station In OpenCIM, stop stations contain magnetic sensors that are connected to the PLC controller to enable pallet identification and control of the stop pistons. Pallets are immobilized at stop stations, as discussed briefly in the first activity. A stop station employs a stop mechanism that halts a pallet at a pre-defined location, where the robotic arm can unload the template from the pallet. Using templates placed on pallets that stop at stop stations along the conveyor, you now have a practical way to transport the parts from one station to another.
Figure 3-4: Stop Station
Buffer In a typical CIM cell, a part is stored on a template in the ASRS. When the CIM Manager orders the part, the template with the part on it is retrieved by the ASRS robotic arm and is placed on the pallet. The pallet is transferred to the target station designated by the production order. At that station, the template is unloaded from the pallet by a robotic arm. The pallet continues to travel along the conveyor. Templates are stored at a temporary storage device at each robotic station, known as a buffer in OpenCIM. Some stations (such as, the ASRS, Pneumatic Feeders, Welding stations) do not contain buffers. A buffer is a tray designed to hold a template when it is removed from the conveyor, for as long as it is needed at the station. Buffers are used to optimize the production flow in a production system. Figure 3-5: Robot Lifting Template off Pallet (Buffer faces Pallet.)
In OpenCIM, at most stations, the buffer is designed to hold two templates. The buffer is generally attached to the outer rim of the conveyor at a station. It serves as a holding station between the conveyor and the machining/storage processes.
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CIM Production Workflow In the previous activity, we observed the production cycle using the basic CIM cell and noted the overall route traveled by a part. Closer examination of the route of the part in terms of the CIM components described previously shows that the basic CIM cell carries out the following sequence of actions: 1
A pallet (empty) is stopped at the ASRS stop station (station 1).
2
The ASRS retrieves a template (with the raw part on it).
3
The ASRS puts the template on the pallet at station 1.
4
The pallet (with the raw part) is released from station 1.
5
The pallet (with the raw part) is stopped at the stop station of the CNC machine (station 2).
6
The robot at station 2 lifts the template with the supplied part off the pallet.
7
The empty pallet is released from station 2.
8
The robot at station 2 puts the template (with the raw part) on the buffer.
9
The robot takes raw part from the template in the buffer.
10 The robot inserts the raw part into the CNC machine. 11 The machine mills the part. 12 The robot takes the finished part (product) from the machine. 13 The robot puts the product onto the template in the buffer. 14 An empty pallet is stopped at station 2. 15 The robot takes the template with the product from the buffer and puts
it on the pallet. 16 The pallet (with the product) is released from station 2. 17 The pallet with the product is stopped at station 1. 18 The ASRS takes the template with the product from the pallet. 19 The empty pallet is released from station 1. 20 The ASRS stores the template with the product in one of its cells.
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Industrial Safety Industrial Safety is an area of safety engineering and public health that deals with the protection of workers' health, through control of the work environment to reduce or eliminate hazards. Industrial accidents and unsafe working conditions can result in temporary or permanent injury, illness or even death. They also take a toll in reduced efficiency and loss of productivity. Annually in the United States, 1 of every 11 workers in private industry experiences a work-related injury or illness. Although most of these incidents are minor, approximately two million cases each year involve lost work time, and about 14,000 American workers die each year because of work-related injuries or accidents. In recent years, engineers have attempted to develop a systems approach (termed safety engineering) to industrial accident prevention. Because accidents arise from the interaction of workers and their work environments, both must be carefully examined to reduce the risk of injury. Injury can result from poor working conditions, the use of improperly designed equipment and tools, fatigue, distraction, lack of skill, and risk taking. The systems approach examines the following areas: all work locations to eliminate or control hazards, operating methods and practices, and the training of employees and supervisors. The systems approach, moreover, demands a thorough examination of all accidents and “near misses.” Key facts about accidents and injuries are recorded, along with the history of the worker involved, to check for and eliminate any patterns that might lead to hazards.
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PROCEDURES Task 3-1: Identifying Parts of a Template Q In the template shown, circle the gripping location. Q In the template shown, circle the fixturing pins. Q In the template shown, circle the raw part.
Figure 3-6: Template for Hotspot Q Are parts on a template always raw materials? Q Can the template with a part arrive at any station of the CIM cell?
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Task 3-2: Review of Production Components Q Match the following terms to their definitions:
Q A buffer is used to temporarily store which one of the following:
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Parts
Templates
Pallets
Products
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Task 3-3: Running a Basic CIM Production In this activity, you will again run a production cycle using the basic CIM cell from the previous activity. You will now analyze that production cell in terms of the CIM components described above. While observing the production cycle, you will monitor the exact location of a part at all times. 1
From your Windows Start menu, select OpenCIM | Project Manager
. The CIM Project Manager window is displayed.
2
From the Archive tab, select 102_ACT1-5, and then click Save as to save the project as 3 (for example, JOHN3) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 3 project and then click CIM Manager to activate the CIM Manager application for this project. All the tasks described in this activity refer to this selected 3 project.
4
From the OpenCIM Manager main window click Start toolbar to initiate a production cycle.
on the
5
When the “Do you want to refresh storage” message appears, click OK.
6
To start simulation of the production cycle, click the Run button from the OpenCIM toolbar. The production cycle starts.
7
Observe and track the part flow. Pay special attention to the actions the robotic arms are performing and make note of all of the actions that take place during the cycle. Make sure you identify the location of the part at each given time. You may pause the cycle at any time by clicking the Pause button from the OpenCIM toolbar.
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If you want to continue observing the current production cycle, click the Continue button from the OpenCIM toolbar.
9
Close the OpenCIM Manager module.
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Q Place the following actions into the correct order based upon your
observation of the CIM production cycle.
The ASRS puts the template on the pallet at station 1.
The ASRS retrieves a template (with the raw part on it).
The pallet (with the raw part) is released from station 1.
A pallet (empty) is stopped at the ASRS stop station (station 1).
The pallet (empty) is released from station 2.
The robot at station 2 puts the template (with the raw part) on the buffer. The pallet (with the raw part) is stopped at the stop station of the CNC machine (station 2).
The robot at station 2 picks the part from the pallet.
The machine mills the part.
The robot inserts the raw part into the CNC machine.
The robot puts the product onto the template in the buffer.
The robot takes the finished part (product) from the machine.
The robot takes the raw part from the template in the buffer.
An empty pallet is stopped at station 2.
The pallet with the product is stopped at station 1.The robot takes the template with the product from the buffer and puts it on the pallet.
The ASRS stores the template with the product in one of its cells.
The pallet (with the product) is released from station 2.
The empty pallet is released from station 1.
The ASRS takes the template with the product from the pallet.
Task 3-4: Team Discussion and Review Q Is a part that is taken out of a machine known as a raw material? Q Can a part be raw material, a partially processed part or a finished
part? Q Can a finished part be stored in the ASRS after production? Q Does the production process transform raw material into a finished
product? Q Are fixturing pins arranged according to the part dimensions? Q Do pallets stop at predefined stations along the conveyor?
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Q Are pallets placed on and removed from the conveyor by robotic
arms? Q Do buffers serve as temporary storage stations for pallets or for
templates? Q Can industrial accidents and unsafe working conditions result in
temporary or permanent injury, illness or even death? Q Which of the following three factors may contribute to industrial
accidents:
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Improperly designed equipment and tools
Fatigue
Low salaries
Inadequate training
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Activity 4
Storage Setup OBJECTIVES In this activity you will accomplish the following: ♦ Prepare the ASRS station for operation ♦ Understand the purpose of storage in CIM ♦ Identify various types of templates ♦ Identify two new storage devices: feeder and palletizing rack ♦ Set up storage management ♦ Insert parts into storage according to a given production definition ♦ Use the Storage utility program to prepare the CIM for production
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Define how the ASRS storage settings determine the quantity of parts that are available for processing. Understand how stock management of the ASRS works and the advantages of ASRS as opposed to other storage options.
♦ Occupational and Technical:
View the number of parts in storage Identify the location of parts in storage according to part name, Template ID and Cell number. Set the storage stock by adding parts to the ASRS storage device and observe the contents of the ASRS after production Submit a subpart report
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity Activities Book 0503
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OVERVIEW
Storage and Stock Management As you may recall, a typical CIM cell includes an ASRS (Automated Storage and Retrieval System) that is used to store and retrieve parts. The ASRS is used as the main source of raw material for the cell, and can also serve as a warehouse for parts in various stages of production. A CIM cell may contain multiple ASRS stations.
Figure 4-1: ASRS Station
In this activity you will learn how to view storage information and define the stock and location of parts in storage. When managing an automated factory, the management system must have the ability to track the contents of the storage devices (ASRS, racks, feeders and more) and temporary storage devices (robots, buffers and more) at all times. It is critical that the following information be collected and available to users: ♦ Number and type of parts in stock. ♦ Location of all parts (i.e., on which template, in which storage device,
in which cell of the storage device).
OpenCIM software enables the user to determine the exact contents of the storage databases all times, keeping track of which parts are in storage and which templates are available to move the parts.
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Part Name, Template ID# and Cell Numbers Certain storage devices (such as the ASRS, pallets, and buffers) store parts on templates in the storage device. In this activity you will identify the location of the parts (on the templates) in storage according to the following information: ♦ Part name ♦ Template ID (including template type) ♦ Cell number
This CIM Storage Definition window shows a part named BASE_PROD. BASE_PROD is stored on a template with template ID number 090002. The template type that is indicated by the first two digits of the template ID enables users to assign a specific part related to the pin layout. Finally, you can see that the part is stored in the ASRS in cell 1A.
Figure 4-2: Example of an OpenCIM storage management screen
Note: Most temporary storage devices (feeders, racks) do not contain templates. Therefore, for these storage systems, you cannot identify the exact location of the parts.
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Feeders and Palletizing Racks In addition to the ASRS, other types of storage devices are often used in CIM cells. In the OpenCIM system feeders and racks are used in addition to the ASRS, as described below: ♦ Feeder: The feeder is a device that dispenses parts at a station (typically
to a robot). Feeders are used to supply raw materials or parts at various stations around the cell. Each parts feeder supplies only one type of part. Feeders are typically located close to the station that is to process the part, for example, a milling machine or lathe. The gravity feeder, in which parts move one after another to the feeder mouth (for retrieval) by means of gravity, is one of the more popular feeder types. Another popular feeder type is the pneumatic feeder.
Figure 4-3: Gravity feeder
Figure 4-4: Pneumatic feeder
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♦ Palletizing rack: A palletizing rack is a type of storage compartment
used to store parts at a specific station either before or after they are processed at that station. Each storage location in a rack is identified by an index number. The palletizing rack is built in a grid structure, divided by fixed limits.
Figure 4-5: Palletizing rack
Feeders and palletizing racks offer the following advantages: ♦ Retrieving and storing materials or parts at (or adjacent to) a station
shortens the part flow and reduces production time.
♦ When feeders and racks are used properly they can increase the product
output of the system.
Feeders and palletizing racks will be discussed more thoroughly later in this module.
Storage Definition Storage settings determine the quantity of parts available for processing. It is important that storage settings be defined to include the number of parts required for a production batch. A shortage of parts will disrupt the part flow in the middle of production. Storage settings can be defined before the start of each production cycle, or you can define default storage settings that are stored in the system and reloaded for future production cycles. Default storage settings eliminate the need to edit the storage settings before each cycle.
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PROCEDURES Task 4-1: Identifying the Location of a Part in Storage In this task, you will use the OpenCIM Storage Definition utility to view the number of parts located in storage and identify the location of a specific part. 1
From your Windows Start menu, select OpenCIM | Project Manager
. The CIM Project Manager window is displayed.
2
From the Archive tab, select 102_ACT1-5, and then click Save as to save the project as 4 (for example, JOHN4) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 4 project and then click CIM Manager to activate the CIM Manager application for this project. All the tasks described in this activity refer to this selected 4 project.
4
From the OpenCIM Manager main window, select File | Default Storage to define the default storage settings.
5
Select Utility Programs | Storage Manager. The CIM Storage Manager window is displayed.
Figure 4-6: OpenCIM Storage Manager Main User Interface
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The window shows data for one storage device, ASRS1, including the following parameters:
Storage Type: The type and name of the storage device (ASRS1).
ID: The ID number of the storage device (206).
Part Name: The name of the part(s) contained in this device.
Quantity: The quantity of the part(s) in the storage device or the number of empty cells in the storage device, as applicable.
In this instance, the 36-cell ASRS1 currently holds one part named BASE_SUP, whereas its other 35 cells are empty. The window does not show the location of the part (the cell number). In some instances, the number of parts located in storage may be sufficient information; however, in other cases it may be important to know the exact location of the part in storage. 6
To determine the exact location of the part, click the EDIT button in the CIM Storage Manager window. The CIM Storage Definition window is displayed:
Figure 4-7: Storage definition editing screen
The CIM Storage Definition window now shows the exact location of the part. Q Identify whether or not the following statements are correct:
The only part in storage is known as BASE_SUP.
There is only one cell in the storage device.
BASE_SUP is located in cell 1A.
Cell 3C is empty.
Q #090002 is the ID number for:
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The part.
The template.
The cell. 4-7
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Task 4-2: Setting the Storage Stock In this task you will add parts to the storage device. Subsequently you will be able to view the number of parts located in the device throughout the production process. 1
Click the Initialize Storage button window.
in the CIM Storage Manager
The following message is displayed:
Figure 4-8: Initializing Storage – Confirmation Message 2
Click Yes. Note that the content of the storage location is cleared (as a result of its initialization).
Figure 4-9: CIM Storage Manager Window
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3
Click the Add New Row to ASRS Block button
.
A new row is created, as shown in the figure.
Figure 4-10: CIM Storage Manager Window – Adding Rows 4
Place the cursor on the new row and click to open the dropdown list.
Figure 4-11: CIM Storage Manager Window – Selecting a Part
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5
Select BASE_SUP from the list. BASE_SUP is inserted into storage; however, you do not know the exact location of the part.
Figure 4-12: CIM Storage Manager Window –BASE_SUP Part Inserted
The next task describes the method for inserting parts when information regarding their exact location is required. Task 4-3: Setting the Storage Stock and Part Location In some instances, it may be important to know the exact location of parts in storage, for example when using the OpenCIM in conjunction with online production. In this task you will add a part named BASE_SUP into cell 1F to the storage location and define its exact location as cell 1F. 1
Click the Initialize Storage button window.
in the CIM Storage Manager
The following message is displayed:
Figure 4-13: Initializing Storage – Confirmation Message
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2
Click Yes. Note that the content of the storage location is cleared (as a result of its initialization).
Figure 4-14: CIM Storage Manager Window – Storage Location Cleared 3
Click the EDIT button
.
The following window is displayed:
Figure 4-15: CIM Storage Definition Window
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4
Double-click the cell 1F or click the cell once and select Edit | Insert Part/Template. The following window is displayed:
Figure 4-16: Cell Edit Window 5
Select BASE_SUP from the PART dropdown list. Note that the template is chosen automatically to match the part (TEMPLATE#090001).
6
Click the Save button
.
Note that cell 1F now contains the part BASE_SUP on TEMPLATE#090001.
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Close the CIM Storage Definition window and return to the CIM Storage Manager window.
8
Close CIM Storage Manager window.
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Task 4-4: Observing the ASRS Contents after Production You will now run the basic CIM cell with the storage updated to include the part BASE_SUP, which you just added. For the purpose of this simulation, BASE_SUP has been defined as the raw material used to produce the final product, BASE_PROD. Note you must ensure that the production cycle is stopped, before you access the MODES dialog box. 1
The goal of this task is to see the result of production, rather than to track production itself. Therefore, you will increase the speed of the simulation by doing the following:
Click the CIM Modes button
or select File | Modes.
The MODES dialog box is displayed:
Figure 4-17: MODES Dialog Box
Set the simulation speed to a faster speed by dragging the slider to the right. Then click SAVE.
2
Click the Start button
to initiate a production cycle.
3
When the “Do you want to refresh storage” message appears, click Cancel.
4
Click the Run button cycle
to start the simulation of the production
The production cycle starts.
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5
Observe and track the part flow. Note that the simulation speed is significantly faster now.
6
Wait for a message indicating that the order is complete. You can maximize the window to view the messages in their entirety.
Figure 4-18: Message indicating that the order is complete 7
Select Utility Programs | Storage Manager to recheck the contents of the storage device. Observe the current storage contents.
Figure 4-19: CIM Storage Manager Window – Storage Contents Q Which of the following statements is true?
BASE_SUP is back in the storage device.
BASE_PROD is now in the storage device.
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It is impossible to determine which of the two parts is in the storage device.
Close the CIM Storage Manager window.
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Task 4-5: Setting Default Storage Setting default storage will enable you to run a production cycle for this CIM with specific storage settings, without having to edit the storage settings before each cycle. 1
Select Utility Programs | Storage Manager.
2
Click the Initialize Storage button window.
in the CIM Storage Manager
The following message is displayed:
.
Figure 4-20: Initializing Storage – Confirmation Message 3
Click Yes.
4
Insert BASE_SUP into the storage.
5
Click the Create Default Storage button
.
The following message is displayed:
Figure 4-21: Save Current Storage as Default – Confirmation Message 6
Click Yes.
7
Close the Storage Manager window.
You have set the storage default to contain one BASE_SUP part. In the future, each time that you restart production, you will prompt the system to reload this default storage. 8
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Close the OpenCIM Manager module.
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Task 4-6: Team Discussion and Review Q Can an ASRS store both raw materials and finished parts? Q Can a CIM cell include more than one storage station? Q In CIM, what does ASRS stands for?
Automatic Storage and Removal System.
Automated Storage and Retrieval System.
Automated Stock Retrieval System.
Q Are parts stored on templates or pallets in the storage device? Q Can a feeder dispense a specific type of raw materials or parts to a
specific station? Q Which of the following stations would be the appropriate location for a
feeder?
The ASRS station.
The milling machine station.
Q Can a palletizing rack be used to store parts before as well as after
processing at the station?
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Q Which of the following are examples of storage devices:
Figure 4-22
Figure 4-23
Figure 4-24
Figure 4-25
Q Is a feeder typically used to dispense raw materials to a CNC station? Q Which two of the following are advantages in using feeders and
palletizing racks:
The distance of the part flow is shortened, reducing production time. Raw materials are located adjacent to the processing station, increasing production time. Increased storage space is available on the main storage device for raw materials. Increased storage space is available on the main storage device for products.
Q Does initializing storage clear the contents of the storage location? Q The location of parts must be, can be, or cannot be defined when they
are added to storage? Q Does defining default storage eliminate the need to edit the storage
settings each time a production cycle is run?
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Activity 5
Production Planning OBJECTIVES In this activity you will accomplish the following: ♦ Understand the purpose of changing a production work order ♦ Order a part ♦ Set up a production plan ♦ Set up and submit a manufacturing order ♦ Run and observe a cycle for a submitted manufacturing order ♦ Define the actions performed in the manufacturing order ♦ Define a new customer in the system
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Define a production plan (meaning a production work order)
Identify material requirements planning MRP
Describe the advantages of MRP (Material Requirements Planning) in the production process
♦ Occupational and Technical:
Modify customer order parameters
Update and submit a manufacturing order
Track production flow following MRP modification
Order parts for a new customer
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
Defining the Production Plan CIM cells are automated factories capable of producing products for several customers. All CIM cells work according to a preset production plan, also referred to as a production work order. This plan should provide the detailed step by step production sequences and also handle exceptions due to the occurrence of specific events (such as, QC failure and more) A production plan may need to be changed for many reasons, including the following: ♦ The customer wants to reduce or increase the production quantity. ♦ Priorities have changed –the order of the planned production must be
adjusted to produce a certain product before other products.
♦ A new customer has decided to buy products from you.
In this activity, you will learn how to view and edit a production plan using OpenCIM software. (These tasks cannot be performed on running orders.) In addition, you will also maintain a customer list and learn how to add a new customer to the list.
MRP (Material Requirement Planning) MRP (Material Requirement Planning) is a methodology for defining the raw material requirements for a specific item, component, or sub-assembly ordered by a customer, or required by a business process. MRP systems will usually define what is needed, when it is needed, and by having access to current inventories and pre-existing commitment of that inventory to other orders to other customers, will indicate what additional items need to be ordered to fulfill this order. Some MRP software applications can automatically place those raw material orders to the preferred supplier by fax, e-mail, or EDI (Electronic Data Interchange). MRP has been mostly replaced by the super-set MRP II. MRP II has been replaced in some cases by the even more complex & comprehensive ERP (Enterprise Resource Management).
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The basis of MRP is usually accomplished by a one-to-many relationship; linking one SKU (Stock Keeping Unit) to all the nuts, screws, metal, software (and so on) that go into that unit. This is usually defined by a hiearchial Bill of Materials (BOM) system
MRP in OpenCIM The OpenCIM MRP utility is used to create and define three types of orders: ♦ Customer Orders ♦ Manufacturing Orders ♦ Purchase Orders
In general OpenCIM MRP allows you to create a list of customers and define the products ordered by each customer. Once customer orders are created in the Customer Order tab, the MRP utility automatically create the manufacturing order, which creates a table containing all the parts to be manufactured in the Manufacturing Order tab. This table can contain more than one manufacturing order. The manufacturing orders in this table are grouped according to order date. Only the product containing the same due date can be submitted for manufacturing at the same time. Meaning only one manufacturing order is currently active. When the Manufacturing Order is submitted, the production work plan is set. In addition, the MRP creates a Purchase Order for items that must be supplied to the CIM to enable production to take place. The MRP utility also enables you to change the production work order in response to changing requirements. In OpenCIM, this applies only to Manufacturing Orders whose production has not yet begun. In this activity, you will learn about the basic operation of OpenCIM’s MRP utility, as well as how to perform following tasks: ♦ Access the MRP utility. ♦ View the current production plan. ♦ Edit the production plan. ♦ View the production cycle of the edited production plan.
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Viewing Customer Order Details The details of a Customer Order are displayed in the Customer Order tab of the MRP window.
Figure 5-1: CIM MRP Window – Customer Order Tab
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The Customer Order tab displays information regarding the order of parts per customer, including the following parameters:
Customer: The name of the customer for whom the part has been ordered. Part Name: The name of the part ordered. This customer has put in an order for a product named BASE_PROD. Required Quantity: The number of parts required. The total quantity required for this customer is 1 part. Priority: The priority assigned to the customer order (1 = highest, 10 = lowest). Due Date: The date that the product must be supplied to the customer, relative to the current date. The value indicated for this order is 2, indicating that the part must be supplied two days from today.
Viewing Manufacturing Order Details The details of a Manufacturing Order are displayed in the Manufacturing Order tab of the MRP window.
Figure 5-2: CIM MRP Window – Manufacturing Order Tab
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The Manufacturing Order tab summarizes the part requirements for all of the customer orders. The requirements are listed according to their due date, indicating what the factory (or CIM cell) needs to produce within the designated number of days. The due date of the Manufacturing Order is the number of days (starting from today) when the products need to be delivered to the customer. This means that the production process should be completed one day before (that is, order date in OpenCIM) the required due date to enable time for purchasing and shipment. Note: In OpenCIM, one day is reserved automatically for this purpose. In a real production cycle, this may vary depending on the products packing and shipment requirements) The Manufacturing Order tab also includes the following parameters, not previously mentioned:
Order Date: The date that the product must be produced, relative to the current date. The value indicated for this order is 1, indicating that the part must be produced one day from today (tomorrow). Initial Quantity: The initial quantity of a specific part released from the storage device at the start of the production process.
This particular Manufacturing Order shows that one unit of the part BASE_PROD is required for due date 2. No other parts are currently required. In the next task, you will learn how to change the quantity of parts in the system and how to add customers to the customer list.
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PROCEDURES Task 5-1: Editing a Customer Order In this task, you will learn how to change the parameters of a customer order. The first step is to change the number of parts for production. You will then order the system to change the CIM production plan in order to fulfill the new order. 1
From your Windows Start menu, select OpenCIM | Project Manager
2
. The CIM Project Manager window is displayed.
From the Archive tab, select 102_ACT1-5, and then click Save as to save the project as 5 (for example, JOHN5) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 5 project and then click CIM Manager to activate the CIM Manager application for this project. All the tasks described in this activity refer to this selected 5 project.
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From the OpenCIM Manager main window, select Utility Programs | MRP. The CIM MRP window is displayed.
5
Click the Customer Order tab to view the customer order details.
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6
Right-click anywhere on the green row and select Insert After from the dropdown menu. A new row is created in the Customer Order for Customer1.
Figure 5-3: CIM MRP Window – Adding Rows to Customer Order 7
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Click in the empty Part Name field. A dropdown arrow is displayed.
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Select BASE_PROD from the dropdown list (at present it is the only part that appears in the list).
Figure 5-4: CIM MRP Window – Selecting Parts for Customer Order 9
Enter 2 in the empty Required Quantity field to indicate that two parts are required.
10 Enter 1 in the empty Priority field to assign the order the highest
priority.
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11 Enter 5 in the empty Due Date field to indicate that the part must be
ready five days from today. View the details, as they should appear in the window.
Figure 5-5: CIM MRP Window – Viewing Customer Order Information 12 Save the new order by selecting File | Save Order or by clicking on
the Save button.
A confirmation message is displayed.
13 Click OK. An additional order of two BASE_PROD parts has been
added to Customer 1. Q Which one of the following statements accurately states the total
production order for what Customer1 now includes:
Two BASE_PROD: one for due date 2 and another one for due date 5. One BASE_PROD and 1 BASE_SUP: both for due date 5. Three BASE_PROD: one for due date 2 and another two for due date 5. Three BASE_PROD: one for due date 5 and another two for due date 1.
You are now ready to update the production plan for the CIM cell to reflect the modified customer order.
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Task 5-2: Updating a Manufacturing Order 1
Click the Create MRP button.
Figure 5-6: MRP Confirmation Message 2
Click OK.
3
Click the Manufacturing Order tab.
Figure 5-7: CIM MRP Window – Manufacturing Order Tab 4
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Compare the current manufacturing order with the previous one.
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Q Which one of the following statements is true relative to how the two
manufacturing orders differ?
The previous manufacturing order called for one BASE_PROD and the new order calls for three. The previous manufacturing order called for one BASE_PROD and the new order calls for two. The previous manufacturing order called for one BASE_PROD and one BASE_SUP and the new order calls for three BASE_PROD and one BASE_SUP. The two manufacturing orders are the same.
5
Click in the second row in the Manufacturing Order window. The row is now highlighted in green.
6
Click the Manufacturing Order button in the Manufacturing Order window.
Figure 5-8: Manufacturing Order Confirmation Message 7
Click OK. You have now inserted a new order of production, based upon the data in the Manufacturing Order window. Since you selected the second line in the order, only the data in that line (grouped according to due date) is submitted to the system. Meaning, the current process will not produce parts containing a different due date.
8
Close the MRP window.
Q The manufacturing order that you just submitted contains which one of
the following:
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One part of type BASE_PROD.
Two parts of type BASE_PROD.
Three parts of type BASE_PROD.
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Task 5-3: Tracking Production Following MRP Modification You will now track production, paying special attention to the changes you entered in the MRP manufacturing order. As you may recall, BASE_SUP has been defined as the raw material that is used to produce the final product, BASE_PROD. Q How should the storage be changed to accommodate the new
manufacturing order?
The storage should contain at least two parts of type BASE_SUP. The storage should contain at least two parts of type BASE_PROD. There is no need to change the storage, regardless of its current content.
1
To add the necessary parts into storage, select Utility Programs | Storage Manager.
2
Add the required parts, as follows:
Click the Add New Row to ASRS Block button
.
Select BASE_SUP from the Part Name dropdown list and enter the required number of parts in the Quantity field.
For further details on defining storage stock, refer to the previous activity, Storage Setup.
Figure 5-9: CIM Storage Manager Window 3
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Run the production cycle.
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4
Track the actions of the system until a message is displayed indicating that the order is complete.
Q The main difference between the current production cycle and the
cycles viewed in previous activities is:
The number of stations.
The quantity of parts.
The machine type.
The number of products in storage.
Q Are the BASE_SUP parts retrieved from the ASRS one at a time? Q Are the BASE_SUP parts processed one at a time? Q Are all of the BASE_PROD parts conveyed to the ASRS at the same
time? Task 5-4: Editing the Customers List In this task you will edit the list of customers and add a new customer to the list. 1
Select Utility Programs | MRP to open the MRP window.
2
In the Customer Order window, click the New Customer button. The New Customer dialog box is displayed.
Figure 5-10: New Customer Dialog Box 3
In the Name field, enter Customer2. This field is mandatory. You may enter additional details in the remaining fields. These fields are optional in OpenCIM. However, in a real production cycle, the customer details are important for customer service, shipment and more.
4
Click Save.
You have added a new customer into the CIM customers list. You are now ready to create a customer order for the new customer.
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Task 5-5: Ordering Parts for the New Customer In this task, you will create a new order for the new customer added in the previous task. 1
Click the New Order button in the CIM MRP window. A new row will appear in the Customer Order tab.
Figure 5-11:CIM MRP Window – New Customer Order 2
Place the cursor in the Customer field in the new line and click to open the dropdown list. Select Customer 2 from the dropdown list.
3
Place the cursor in the Part Name field in the new line and click to open the dropdown list. Select BASE_PROD from the dropdown list.
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Enter 1 in the empty Required Quantity field to indicate that one part is required.
5
Enter 1 in the empty Priority field to assign the order the highest priority.
6
Enter 5 in the empty Due Date field to indicate that the part must be ready five days from today.
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7
Save the new order by selecting File | Save Order or by clicking on the Save button. A confirmation message is displayed.
8
Click OK. An order of one BASE_PROD parts has been added to Customer 2. View the details, as they should appear in the window.
Figure 5-12: CIM MRP Window – Viewing Customer Orders
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9
Click the Manufacturing Order tab. The following window is displayed:
Figure 5-13: CIM MRP Window – Viewing Manufacturing Orders Q The current Manufacturing Order contains which one of the following:
Two BASE_SUP for due date 5 and one BASE_SUP for due date 1.
Two BASE_SUP for due date 1 and three BASE_SUP for due date 4.
Three BASE_SUP for due date 5 and one BASE_SUP for due date 2.
One BASE_SUP for due date 2, and three BASE_SUP for due date 5.
10 Close the OpenCIM Manager module.
Task 5-6: Team Discussion and Review Q Is the OpenCIM MRP utility used to create and define Customer
Orders, Manufacturing Orders and Purchase Orders? Q Which one of the following is generated as the result of creating a
Customer Order:
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A Purchase Order
A Manufacturing Order
Both
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Q When the Manufacturing Order is submitted, the MRP creates which
of the following:
A Customer Order
A production work order
A Purchase Order
Q Circle the Create MRP button in the MRP window shown below. Q Circle the New Customer button. Q Circle the New Order button.
Figure 5-14: CIM MRP Window – Customer 1 Q Does the Customer Order tab list the part requirements for each of the
customer orders separately? Q Does the Manufacturing Order tab summarize the part requirements
for all of the customer orders according to due date?
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Answer the following questions according to the data that is displayed in the following window:
Figure 5-15: CIM MRP Window – Customers 1 and 2 Q Does the total order of production for Customer1 include two, three,
or four BASE_PROD parts: one, two, or four for due date 1 and one, two, or four for due date 4. Q Does the order of production for Customer2 include two, three, or four
BASE_PROD parts for due date 1, 4 or 5.
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Activity 6
Processes and Machine Definition OBJECTIVES In this activity you will accomplish the following: ♦ Define the term process in terms of CIM. ♦ Identify several types of CIM processes. ♦ Add a new process to a CIM production cycle.
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Describe how processes are actions related directly to the manufacturing of a part into a product. Define the process types based on the characteristics of the actions performed. Describe how the processes to be carried out by a CIM cell depend on the product(s) that the company intends to manufacture.
♦ Occupational and Technical:
Describe the process types that exist in the CIM system
Add a new process to an existing machine in the CIM cell
Describe the various data parameters that are displayed in the CIM Machine Definition window.
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
What is a Process? In previous activities, we have discussed the structure of a CIM system in basic terms. We have seen that each device in the system has a specific role that it is designed to carry out. However, the core of the manufacturing process distinguishes itself by the fact that if we removed all of the automated conveying tools (i.e. robots, conveyors) from the system, we would still be able to manufacture a product. In OpenCIM a process is an action performed on a specific machine. The descriptions of the different process types in OpenCIM (machining, assembly and so on) are described below.
Process Types in OpenCIM Process is therefore a term widely used to define each production action performed upon a part throughout a production cycle. In OpenCIM software, processes are divided into processes types based on the characteristics of the actions required. OpenCIM includes the following categories of process types: ♦ CNC: Produces a machined part (i.e., milled, lathed, engraved, etc.) ♦ Assembly: Produces a new part in which two or more parts are
combined together to create that part.
♦ QC: Produces a pass/fail result of a quality control check on the part. ♦ Process (Generic): A process identified by a general name. This
process type will be discussed in a later activity.
A CIM system (that includes all the devices and processes) is designed for a specific product range. It should be flexible and allow adjustments for limited changes in the product range.
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OpenCIM Machine (Process) Definition OpenCIM software includes a utility – known as the Machine Definition table – to define the characteristics of the processes for a CIM cell. When you define a machine in OpenCIM, you actually define the specific process or processes that the machine will perform. During setup, OpenCIM collects information about all the devices that will be performing any type of process in the CIM cell (i.e., CNC machines and QC devices) and prepares a table containing the information required for each process. In the basic CIM cell you have worked with in this module – CIM 102 – only one process is defined, a milling process. You will now review the OpenCIM Machine Definition window to understand how processes are defined using the software.
Viewing Machine Definition Details The details of the processes defined for the machines in the CIM cell are displayed in the Machine Definition window.
Figure 6-1: CIM Machine Definition Window
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Review each of the bulleted items below to view that parameter’s location in the CIM Machine Definition window.
WS (Workstation): The workstation at which the process will take place. In CIM 102, the process takes place at WS2 (the milling machine). Machine Type: The type of equipment used to perform the process. In CIM 102, the M-Machine (mill) is used, for example. Action: The type of process that will be performed as previously defined (i.e., QC, assembly, CNC). In CIM 102, the relevant action is CNC. Machine Name: The specific name assigned by the user to the devices used in the process. The machine name, which must be unique, is assigned to the device when setting up the CIM cell. Process: The name of a production process that can be performed by the machine. The user assigns the process name. In our example, the MILL1 device (referring to the Milling machine) is performing only one process, named MILL BASE. Note that a device can have more than one process. In practice this means that in a CIM, a CNC machine can produce several part types. The user can assign additional processes to MILL1 at any time, however a process name can be used only once for a specific machine. Duration: The time it takes for this process to produce one part. For example, the MILL1 process lasts 10 seconds, starting from when the robot has placed the part in the machine until the machine has finished milling the part.
Additional parameters in this window will be introduced later in this module.
Process Definition and System Behavior In the machine definition of CIM 102, currently only one process is defined (MILL1). As we have already seen, this process is defined for the milling machine. But how does the process definition influence system behavior? At the beginning of this activity, we defined the term process, an OpenCIM concept, carried out on a part by a specific machine. For example, a process in the mill would be the milling of a part. The milling process is conducted according to a production plan (an OpenCIM term), called the NC code. The milling process is controlled by a NC Program that contains commands for axis movement (G-Code) and machine commands (M-Code). NC code is a program that provides a CNC machine with step-by-step instructions on how to machine a part.
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CNC and Part Production Numerical control is a method of controlling machine tools using coded programs. By writing a different NC-Code (also referred to as G-Code) the same machine can manufacture different parts (within limits defined by machine geometry, power, tools and more). This ability to reprogram a machine provides the CNC machine the flexibility required for CIM. Many types of machines can be numerically controlled, for example, mills, drills and lathes. As you already know, the basic CIM cell in this module uses a CNC mill to perform production processes on parts. These two examples show the machining processes in the mill for two different parts.
Figure 6-2: Machining examples (two files)
Using the OpenCIM machine definition utility, you can define different processes for the same machine.
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Adding a New Process in CIM Let us consider a scenario in which a new process needs to be added to the system: ♦ One of your customers is interested in ordering a new product that can
be manufactured in the CIM cell.
♦ The new product requires a different machining program in the CNC
machine that requires the creation of a new NC program.
♦ Both the new and previous NC programs relate to the same machine
(i.e. the milling machine).
♦ We need to distinguish the two machining processes from one another,
making sure that the first NC program is activated on the first product, and the second NC program is activated on the second product. The two processes must therefore be assigned different names.
When working “offline” (without CIM hardware), a NC program does not actually need to be created. In that case, it is sufficient to add a new process using the procedure described in the next task.
Designing a Part The design of the part or product is typically performed using CAD/CAM (Computer-Aided Design and Computer-Aided Manufacturing) software. CAD/CAM enables the designer to create an accurate, detailed, scalemodel drawing of the part that is to be produced. The drawing can be easily studied, edited and revised. Powerful CAD/CAM software not only draws objects, but also can perform calculations on the objects, for example, identify the object’s center of gravity or predict stress points on a part. These graphic applications are capable of designing a product that addresses a customer’s needs and the characteristics that were defined for the specific product.
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The example shows the graphical model of two different products created according to customer requirements.
Figure 6-3:Graphical Model – Example 1
Figure 6-4: Graphical Model - Example 2
Naturally, the design stage takes place prior to the actual manufacturing of the part. Once the part has been designed, one or more NC (numerical control) programs are created according to the virtual model built using the CAD/CAM software. The NC program is then loaded into a computer (or controller) that controls the machine. Once the raw material is inserted into the machine, the machine is activated to run the NC program, and the part is processed accordingly. The number of processes that are required to manufacture a part are a function of the complexity of the part. Distinct NC programs are created for each process performed in the manufacture of the part. (The actual design of the part and the creation of the NC code are not addressed in this module.)
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PROCEDURES Task 6-1: Process Types in OpenCIM Choose which of the following statements is true for each question. Q A process in a CIM cell is defined as:
The part flow through the CIM cell.
The production action carried out on a part.
The movement of robots and the conveyor.
The location of a part in each phase of the part flow.
Q Which of the following are processes?
The robot taking a template from a conveyor.
A CNC machine milling a part.
A QC device measuring the height of a part.
A storage device storing a part on a template.
A conveyor moving a pallet from station to station.
Task 6-2: Adding a New Process to an Existing Machine In this task, you will define and add a new process to an existing machine in the CIM cell. 1
From your Windows Start menu, select OpenCIM | Project Manager
. The CIM Project Manager window is displayed.
2
From the Archive tab, select 102_ACT6, and then click Save as to save the project as 6 (for example, JOHN6) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 6 project and then click CIM Manager to activate the CIM Manager application for this project. All the tasks described in this activity refer to this selected 6 project.
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4 From the OpenCIM Manager window, select Utility Programs |
Machine Definition. The CIM Machine Definition window is displayed.
Figure 6-5: CIM Machine Definition Window 5
Select Edit | Insert After or right click in the MILL1 row and select Insert After from the popup menu. A new row is added to the MILL1 machine, enabling you to add a new process for the machine.
Figure 6-6: CIM Machine Definition Window – Adding Process Rows
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6
Double-click in the empty Process field in the new row. Enter the words MILL WOOD in the Process field.
7
Double-click in the empty Duration field. The Duration field is divided into subfields for hours, minutes and seconds (HH:MM:SS). Enter a duration of 50 seconds by typing in the following sequence: 00 00 50. Duration expresses an estimate of the production time of this process. In future activities, you will discuss in greater depth the significance of the process duration and its influence on system behavior.
8
Click the Action field. A dropdown arrow is displayed. Select CNC from the dropdown list. (This defines the process type as a CNC machine process).
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The following details should now be displayed in the Machine Definition window:
Figure 6-7: CIM Machine Definition Window – Viewing Details 9
Save the new process by clicking the Save button or selecting File | Save Selected Machine. Note: You can delete a line from the process list by right-clicking the line to be deleted and selecting Delete Row from the popup menu.
10 Close the OpenCIM Manager module.
Task 6-3: Team Discussion and Review Q Are the size, shape and complexity of a product among the leading
considerations in the design of a CIM system? Q Can only one process be defined for a specific device? Q Can a process name be used only once for a specific machine?
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Q Identify which three of the following are CIM process types:
Machining
Storage
Assembly
Quality control
Q Which one of the following is true regarding the following statement:
In the Machine Definition window, duration refers to:
The time required to produce one part, from when the robot removes the part from the storage device until the machine has finished milling the part. The time required to produce one part, from when the robot places the part in the machine until the machine finishes milling the part. The time required to produce one part, from when the robot places the part in the machine until the finished product is placed in storage. The time required to produce one part, from when the robot removes the part from the storage device until the finished product is returned to storage.
Q Can multiple processes be defined using a single NC code? Q Circle the field that represents the unique name assigned to a device.
Figure 6-8A: CIM Machine Definition Window
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Q Circle the field that represents the location at which the process takes
place.
Figure 6-8B: CIM Machine Definition Window Q Circle the field that represents the way in which the process is
performed.
Figure 6-8C: CIM Machine Definition Window - Define Process Type
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Q Circle the field that represents the type of device that performs the
process.
Figure 6-8D: CIM Machine Definition Window Q Circle the field that represents the total time required for the process.
Figure 6-8E: CIM Machine Definition Window
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Q Circle the field that represents the name assigned by the user to a
process.
Figure 6-8F: CIM Machine Definition Window Q Which one of the following statements is true relative to the basic CIM
cell you have worked with in this module:
Only one process is defined: milling.
Several processes are defined; some of them are not used.
Two processes are defined: storage and milling.
No processes are defined because there is only one machine.
Q Is NC code a program that provides a CNC machine with detailed
instructions on how to machine a part?
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Activity 7
Part Definition OBJECTIVES In this activity you will accomplish the following: ♦ Understand the key factors in designing a CIM cell. ♦ Identify the manufacturing processes for a part in the Part
Definition utility.
♦ Understand the difference between supplied parts and product parts
and their roles in the manufacturing process.
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
The exact specification and manufacturing needs of a product are the leading considerations in the design of a CIM system. Describe the important characteristics that are taken into consideration when designing the CIM cell product. Describe the factors that are derived from the product that you are going to produce. Define the materials and processes required to produce a finished product.
♦ Occupational and Technical:
View the supplied part information that serves as the raw material in the production process View the product part information containing the actions required to manufacture the product.
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
Considerations in CIM Cell Design Everything we have learned thus far leads to one outcome: the creation of a product. In essence, a CIM system is an automated tool for manufacturing a product. As discussed in the previous activity, the CIM cell structure is derived from the characteristics of the products that it must produce. Therefore, the exact specifications and manufacturing needs of a product are the main considerations in the design of a CIM system. Define a CIM system according to customer requirements, as follows: ♦ Define the companies' existing products that can be suitable for CIM ♦ Define the companies' current forecast for future part variations ♦ Define a CIM system that covers the companies existing suitable
products taking into account changes that can occur in the next 5 to 10 years
♦ Define the quantity and quality required and so on.
Additional questions that must be taken into consideration when designing a CIM cell include: ♦ Which manufacturing facilities should the system incorporate (e.g.,
CNC machine, engraving machine)?
♦ How will the system verify that the product was produced according to
customer demand (e.g., QC devices)?
♦ What is the duration of the production cycle? How much time does it
take to produce the part?
♦ How complex is the part that is to be produced? How many processes
are required for its manufacture?
♦ What are the size limitations and speed of the conveyor and robots?
All of these factors are derived from the product(s) that we intend to produce. Once the current product range is defined (with future reserves), the system components are selected based on the technological and economical requirements.
Producing a Variety of Products The variety of products that can be produced by automated manufacturing systems in general, and a CIM system in particular, is limited to the devices. These include robots, machines, conveyer and more. A CIM system that enables the production of a wide product range will request a higher investment. A company needs to analyze the market
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needs and plan their specific automated manufacturing system accordingly, taking into account, financial resources and more. The need for a large variety of parts increases the range of machines and other devices required in the CIM cell, resulting in a correspondingly increase in the cost of the system.
CIM Definitions The CIM definitions ♦ Machine Definition: Enables you to define the machines in OpenCIM
as well as the specific processes that the machine will perform. Machines are generally predefined in the CIM Setup. The process name enables the CIM Manager to determine which machine is capable of performing the specific work required to produce a part.
♦ Part Definition: Enables you to define the parts that OpenCIM can
manufacture, including available parts and parts that need to be manufactured. These include Supplied Parts, Product Parts and Phantom Parts. When defining a Product Part you must select the raw material (meaning, a Supplied Part) used to produce the Product Part, as well as the production process (that was previously defined in the Machine Definition window)
♦ MRP: Enables you to create a list of customers and define the
products ordered by each customer. Once customer orders are created a manufacturing order is generated.
♦ Storage Manager: The CIM Manager manages and keeps track of
parts in storage and informs the system of the part location. Based on this information the system can then determine the quantity of parts available for processing. Three types of storage locations exist in OpenCIM. These include the ASRS storage locations, racks and feeders.
The Product in the Basic CIM Cell So far, we have simulated the production of one product in the basic CIM cell, named BASE PROD, and the part named BASE SUP has been defined as the raw material used to produce this part. Though the milling machine is the only manufacturing tool used in the basic CIM cell (i.e. the only device that can process a part), a variety of products can be produced, by defining various processes for the same machine in the Machine Definition window. Each of these processes uses a different G-Code.
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In addition, it may be required that the same product undergoes two processes on the same machine. This may require a change of orientation of the robot (between these two processes). This ability of the same machine to perform different processes provides the basic flexibility required in CIM. For example, the part may need to be flipped over by a robotic arm at some point after the first machining process and then machined again.
Part Definition A product can be manufactured from a single part or an assembly of sub parts that are combined together according to a specified set of machine processes. The OpenCIM Part Definition utility enables you to define the materials and processes required to produce a finished product. The Part Definition utility contains the data required by the system regarding the different types of parts, as follows: ♦ Supplied Parts: Supplied parts are parts that are required for a
specific production process in the system. Supplied parts can either be raw material or pre-manufactured parts.
♦ Product Parts: Parts that can be ordered from the CIM cell. The part
definition includes the sequence of actions for manufacturing the product parts.
♦ Phantom Parts. Parts that have failed QC. (The Part Definition utility
is used to handle failed parts in the system. Phantom parts cannot be ordered.)
Information regarding each type of part is displayed in the corresponding tab of the Part Definition window.
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Interpreting a Part Definition Window Examine the Part Definition window shown. This window contains information about the sequence of steps that comprise the manufacture of a different product – PART1. This part has been defined in a demo system (shown below) and is not part of the current basic CIM cell for this activity. It is discussed here on order to give you a better sense of the format of the part definition.
Figure 7-1: CIM Part Definition Window – Product Parts
You should be able to identify some of the processes on your own. As you can see, the manufacture of PART1 involves more than three processes, as follows: ♦ The first supplied part (subpart) used in the production of PART1 is
named BOXRED1. Note that in the first row of the part definition, the Process and the Parameters fields are empty. In this case, the default action of the system is to retrieve the designated part from the ASRS.
♦ The second supplied part used for production is BOXYELL1.
BOXYELL1 and BOXRED1 are conveyed to a process named ASSEMBLY1. We cannot determine the precise nature of the process without examining the machine definition; however, we can simplify our explanation by stating that the process named ASSEMBLY1 stands for an assembly process. From this we understand that BOXYELL1 and BOXRED1 are assembled together in order to construct the product PART1.
♦ The next process to be carried out is WELD1. WELD1 is defined in
the machine definition as a General process. Therefore, we understand that the assembled part is now directed to a welding station.
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♦ VISION1 is defined in the machine definition as a QC process.
Therefore, we understand that the assembled part is next directed to a QC inspection device. If PART1 passes the QC inspection, it is returned to a storage device. Unless otherwise indicated, the system assumes the target device for the final product is the ASRS. Other storage devices can be designated as the target location, as required. In this case the TARGET command is displayed in the Process column of the storage device.
♦ The last row indicates how the system will handle the unique situation
when a part fails the QC check; the failed part is assigned a new name (PHANTOM1) and is directed to an ONFAIL target condition, in this case a trash box (named TRASH1). Production of another unit of PART1 is then initiated by the system automatically.
The assembling and QC processes will be discussed in greater detail in the more advanced CIM modules. Note: Process names are defined in the Machine Definition window. You can then select these processes in the Part Definition window. Ensure you define a logical name for the process (such as, Welding, Milling) in the Machine Definition to enable you to easily identify the required process from the Part Definition window. For further information on Part Definition, refer to the OpenCIM User Manual.
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PROCEDURES Task 7-1: Viewing Supplied Part Information In this task you will identify the supplied part that serves as the raw part in the production process and examine the supplied part details in the Supplied Part tab of the Part Definition window. By default, the Supplied Parts tab is displayed when you access the CIM Part Definition window. In this window, all raw parts are assigned and registered in the CIM cell. From this window, you can see the following: ♦ The only part currently in the system is BASE SUP. ♦ The Part ID. This is a unique number assigned to each part by the user.
Two parts should not be assigned the same ID. In a later module, you will learn more about the use of this ID number.
♦ Additional information (Supplier Name, Catalog Number, and so on)
related to the supplier of the raw material. This information will be discussed later on as you learn about planning factory inventory.
Figure 7-2: CIM Part Definition Window – Supplied Parts
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Task 7-2: Viewing Product Part Information Now that we have identified the raw part that was defined in the system, we are ready to view data regarding the sequence of actions to be performed in order to manufacture the product. For example, in the basic CIM cell, the Part Definition defines the route for BASE SUP from the ASRS to the milling machine, where it is manufactured, and then back to the ASRS. The product part details are displayed in the Product Parts tab of the Part Definition window.
Figure 7-3: CIM Part Definition Window – Product Parts
This window displays information about the stages in manufacturing the product, in this case, BASE PROD. As you can see, BASE PROD is created via three processes that define the route of the part from its initial to final state: ♦ GET: The first process is known as GET, where the subpart named
BASE SUP is taken from the ASRS. The word GET is often used for taking or retrieving processes.
♦ MILL BASE: The second process, MILL BASE, is obviously related
to the mill. You may recall that this process name was defined in the Machine Definition window in a previous activity. This process is selected whenever the MILL BASE process is to be performed on the part. In this example, the part (BASE SUP) will be sent to the milling machine (according to the definition of the MILL BASE process).
♦ TARGET: The third process of the sequence indicates that the part
will be stored in the ASRS. The reserved process name used here is TARGET, and this process defines the location to which the part is to be sent.
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Q Circle the process that indicates a “pick” action. Q Circle the process that indicates a milling process. Q Circle the process that indicates a “place” action. Q Circle the name of the piece that is picked at the beginning of the
sequence. Q Circle the name of the storage device in the Part Definition window.
Figure 7-4: BASE PROD Characteristics
Three processes are required for manufacturing the BASE PROD subpart, as shown above. Task 7-3: Team Discussion and Review Q The design of a CIM cell is determined by:
The size of the conveyor and the robotic arms.
The location of the part before and after processing.
The product range that must be produced.
Q Which one of the following statements is true about a CIM cell?
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Part size and shape determine the production tools.
The product complexity has no relevance in CIM cell design.
Once a CIM cell is designed, it cannot be changed.
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Q Which two of the following statements are true relative to the products
in the basic CIM cell:
Are made from parts that fit into the mill.
Can go through several processes.
Can be in the machine no longer than one minute.
Q Are Product parts, Supplied parts, or Phantom parts received from
outside sources? Q Parts that have failed QC are displayed in the Product Parts, Supplied
Parts, or Phantom Parts tab of the Part Definition window? Q Where else could a part be retrieved from?
Feeders
CNC machine
Robotic arm
Q After welding, the next process to be carried out in the production of
PART1 is:
PHANTOM1
VISION1
ONFAIL
TRASH1
Q Other possible storage targets include:
A feeder
A palletizing rack
Conveyor
Q Are the size, shape and complexity of the product among the leading
considerations in the design of a CIM system? Q Which one of the following process names is typically used for taking
or retrieving processes?
GET
MILL1
TARGET
Q Which one of the following process names typically defines the
location to which a part is to be stored?
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MILL1
TARGET
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Q The materials and processes required to produce a finished product
are defined in which one of the following:
The Machine Definition utility.
The Part Definition utility.
The Storage Manager utility.
Q The processes for each CIM cell are defined in which one of the
following:
The Machine Definition utility.
The Part Definition utility.
The Storage Definition utility.
Q The quantity of parts available for processing is defined in which one
of the following:
The Machine Definition utility.
The Part Definition utility.
The Storage Manager utility.
Q In the previous activity, you added a new process related to the milling
machine, namely MILL WOOD. Adding the new process named MILL WOOD represented which one of the following:
Implementation of a new NC code for the milling machine.
Addition of a new CNC machine to the basic CIM cell.
Creation of a new product in the part definition.
We can thus conclude that by defining the new process we have laid the basis for producing a new type of product. For example, we could suppose that the following two products are manufactured by the basic CIM cell.
Figure 7-5: Parts that can be produced by the basic CIM cell
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Q In the last sentence, it was indicated that we could “suppose” the
manufacture of these two parts because:
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The parts shown cannot actually be produced by a milling machine. We do not define the actual NC programs in our simulated system. The basic CIM cell does not include the facility for producing these parts. Both these parts can be manufactured, providing the milling machine with the required features (such as, tool changer, clamping and more) is selected.
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Activity 8
Defining a Product Part OBJECTIVES In this activity you will accomplish the following: ♦ Understand the impact of size limitations on part production
and processing.
♦ Add a supplied part to the CIM cell. ♦ Add and define a new product part.
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Explore the ability of the CIM system to use a new supplied part to produce a new product in the CIM cell. Consider the impact of the limitations of the overall system structure on the ability of the cell to produce new products.
♦ Occupational and Technical:
Adding new supplied parts in the part definition utility Adding and defining product parts to the product list in the part definition utility
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
Limitations on Part Production In the previous activity we discussed the relationship between the product and CIM cell design. In this activity you will explore the ability of the CIM system to use a new supplied part to produce a new product in the CIM cell. We know that each machine can only produce parts within a certain range of sizes and materials. The basic CIM cell includes only one machine and therefore is able to produce only a limited variety of parts. In this activity you will consider the impact of the limitations of milling machine and the overall system structure on the ability of the cell to produce new products.
Part Size Limitations We know that in the basic CIM cell there is only one machine – the CNC mill. In simulation software there is no obvious definition of the size of the machine. In reality, however, the size of parts in the educational (non-industrial) system can range from 5-20 centimeters in width and length, with a height of between 2 and 5 centimeters). In industrial systems, of course, the product size can vary drastically from one production system to another. For example, the manufacture of microchips illustrates a product that is very small, whereas considerably larger parts are obviously produced in the automobile industry. In theory, the wide variety of manufacturing systems available enables the production of an almost unlimited variety of parts. In practice, however, the size limitations of the specific machines contained in a given CIM cell determine the range of products that can be produced by that cell. Raw material, in turn, must be supplied to the cell according to the size limitations of the existing machines.
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Limitations of Existing System Structure Let’s first discuss the factors that must be taken into consideration when adding a new product into the CIM cell. During the design phase of a real system, many parameters were considered in order to adapt the system to the intended product range (object max/min dimensions, weight, material and more). Before adding a new part into the manufacturing system, it is important to verify that the system structure can support the new product. The criteria to be verified include the following: ♦ Part size (maximum):
Template surface size.
Size of the vise in the machine.
♦ Part weight:
Robots payloads
Conveyor motor power
Material
`
Figure 8-1: robot with part
In some cases (when a specific process is missing) you can expand the system by adding a new station or by adding new features to an existing station.
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Milling Machine Product Dimensions In this activity, we will add a new part to our basic CIM cell. The new part will be machined in the milling machine. (It is currently the only machining device in the basic CIM cell.) As previously explained, numerous considerations and calculations are involved in adding a part to the system. We will now address some of the limitations imposed by the milling machine in the basic CIM cell. The milling machine shown here serves as the basis for the sample specifications presented in this section.
Figure 8-2: Milling Machine
The specifications of the machine’s vise indicate that the vise has a maximum throw span of: ♦ Length: 37.3 mm (1.2") to inner measurement of 114 mm (4.5") ♦ Width: 16.7 mm (0.7") to inner measurement of 80.6 mm (3.2")
Any raw material that exceeds these dimensions cannot be processed by the machine, and therefore cannot be supported by a CIM cell that is based on these hardware specifications. In such a case, you can either change the vise (if the manufacturer supports it) or you would have to add another machine that is capable of machining larger parts.
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The limitations imposed by the physical specifications are key criteria in determining the potential for producing a part in a real system. Note: These considerations are not required when adding a part or product to a simulated production system, since the part or product does not contain physical dimensions or attributes. The parts list of the basic CIM cell currently contains only one product – the BASE PROD. In this activity, we will add a new part to the basic CIM cell. The part will be added in two stages: 1
A new supplied material will be added to the cell.
2
A new product will be added to the cell.
PROCEDURES Task 8-1: Adding a New Supplied Part to the Basic CIM Cell Although an OpenCIM simulated system, enables you to manufacture any part from the supplied material, frequently we add different types of supplied material in order to obtain a more realistic storage supply that would be used in a real system. In this task, you will add a new supplied part to the basic CIM cell. 1
From your Windows Start menu, select OpenCIM | Project Manager
. The CIM Project Manager window is displayed.
2
From the Archive tab, select 102_ACT7-8, and then click Save as to save the project as 8 (for example, JOHN8) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 8 project and then click CIM Manager to activate the CIM Manager application for this project. All the tasks described in this activity refer to this selected 8 project.
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4 From the OpenCIM Manager window, select Utility Programs | Part
Definition. By default, the Supplied Parts tab of the CIM Part Definition window is displayed.
Figure 8-3: CIM Part Definition Window – Supplied Parts 5
Click the New Order button
on the toolbar.
A new row is added to the table.
Figure 8-4: CIM Part Definition Window – Adding Supplied Parts 6
In the new row, enter the name of the new supplied part WOOD SUP in the empty Part Name field. This part will be used in the production plan that you will set up in the next task.
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7
Enter the new product stock data in the relevant fields, as follows:
Supplier Name: INTELITEK
Catalog Number: KCH-400Y
Min Order: 10
Safety Stock: 4
Cost: 2
Supply Time: 1
Description: Wooden Piece
Note: In order to view and modify the remaining columns, click the horizontal scroll bar arrows.
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8
Enter 02 in the empty Template Type field. The template type field assigns a specific template type to the selected part. In a real CIM cell this template would be designed to carry the specific part dimensions.
Horizontal scroll bar
Figure 8-5: CIM Part Definition Window – New Supplied Part Definition 9
Click the Save button
.
You have now added a new raw material definition into the part list of the basic CIM cell.
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Task 8-2: Adding and Defining a Product Part In this task, you will add a new product to the product list of the basic CIM cell, and define the materials and processes required for its production. 1
Click the Product Parts tab in the CIM Part Definition window.
Figure 8-6: CIM Part Definition Window – Product Parts Definition 2
Click the New Order button
.
A new line is created for the new product.
Figure 8-7: CIM Part Definition Window – Adding Product Parts
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3
Enter the name of the new product WOOD PROD in the empty Part Name field. The first action that we want to perform on WOOD SUP is to retrieve it from the storage device.
Q According to the above description of the first action, the appropriate
line for the first row for WOOD PROD should be:
Hint: Before a part can be produced, it must first be retrieved from the storage device. 4
Click in the empty Subpart field. A dropdown arrow is displayed.
Figure 8-8: CIM Part Definition Window – Adding Subparts
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5
Select WOOD SUP from the dropdown list.
Figure 8-9: CIM Part Definition Window – Selecting WOOD SUP Subpart 6
Click in the empty Process field. A dropdown arrow is displayed.
Figure 8-10: CIM Part Definition Window –Defining the Part Process 7
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Select GET from the dropdown list.
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8 Enter ASRS1 in the empty Parameters field.
Figure 8-11: CIM Part Definition Window –Defining the Part Parameters 9
Right-click anywhere on the new line. A popup window is displayed.
Figure 8-12: CIM Part Definition Window – Product Part Popup Menu 10 Select Insert After from the popup menu. A new line is added.
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11 Click in the empty Process field and select MILL WOOD from the
dropdown list.
Figure 8-13: CIM Part Definition Window –Defining a Process (MILLWOOD) 12 Right-click the line again and select Insert After from the popup
menu. A new line is added.
Figure 8-14: CIM Part Definition Window –Product Part Popup Menu
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13 Click in the empty Process field and select TARGET from the
dropdown list.
Figure 8-15: CIM Part Definition Window –Defining a Process (TARGET)
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14 Enter ASRS1 in the empty Parameters field.
Figure 8-16: CIM Part Definition Window –Defining the Part Parameters (ASRS1) 15 Enter 02 in the Template Type field.
Figure 8-17: CIM Part Definition Window –Defining the Template Type
Template type 02 stands for the same template type of the supplied part WOOD SUP. Therefore, the template structure is built for the same shape.
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16 Click the Save button
to save the new product.
A popup message is displayed.
Figure 8-18: CIM Part Definition - Save Confirmation Window 17 Click OK. The product is now inserted into the product list of the basic
CIM cell. 18 Close the CIM Part Definition window and exit the OpenCIM Manager
module.
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Task 8-3: Team Discussion and Review Q Can each machine in the CIM cell only produce parts within a certain
range of sizes and materials? Q If the raw material exceeds the maximum dimensions of the vise, can
the machine, in its current configuration, process the part? Q Depending on the manufacturer, which can you change, the robot or
the vise of the machine, to enable the production of larger parts? Q Which one of the following tasks must be performed before you can
define a product part?
Add a supplied part in the Part Definition utility. Add the supplied part to the Storage Device in the Storage Manager utility. Create a Customer Order for the product part in the MRP utility. Create a Manufacturing Order for the product part in the MRP utility.
Q The product list for your CIM cell now contains which two of the
following two parts?
BASE PROD
BASE SUP
TARGET PROD
WOOD PROD
Q Which two processes are defined for both WOOD PROD and BASE
PROD?
GET
MILL WOOD
PLACE
TARGET
Q Is a CIM cell capable of running multiple manufacturing programs
and producing several different products? Q Is the size of the raw material supplied to an industrial system subject
to specific size limitations? Q Do the specifications of a machine’s vise determine the maximum or
minimum dimensions of the raw material to be used to produce a new part?
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Activity 9
Producing a New Part OBJECTIVES In this activity you will accomplish the following: ♦ Prepare the ASRS to produce a new part. ♦ Create a Customer Order for a new part ♦ Observe the production cycle for the new part.
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Describe how simulation, as a tool can predict on-line system behavior Describe the tasks required to enable the CIM cell to produce a new part.
♦ Occupational and Technical:
Update the storage settings by adding a new part into storage Creating a new customer order for the new product part in the MRP window Activating and tracking the production of the new part in the CIM cell (using the viewing options)
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
Simulation as a Tool in Predicting On-line System Behavior Off-line simulation of the production cycle enables us to observe the system behavior prior to running the production cycle in on-line mode. When setting up or modifying a CIM cell, the production cycle should be run in simulation mode before real (on-line) production is attempted. Simulating the production cycle helps eliminate some of the problems that may occur during real production. If problems are detected in the simulation, changes can be implemented accordingly and the simulation can be performed again. After the simulation is running correctly, you are ready to run the actual (on-line) production cycle. In this activity we will simulate the production cycle for the new part, WOOD PROD. Due to the simplicity of the basic CIM cell, simulating the production of the new part is unlikely to provide unexpected results. Nonetheless, potential problems including mistakes in production related definitions (such as, part, machine and storage) could cause specific errors or create a production deadlock. In addition, the production of multiple parts can cause too much idle time in the duration of the overall production cycle. In this module we are working with a simulated CIM cell only. Actual production will be covered in more advanced CIM modules.
Preparing to Run Production of a New Part In the previous activity, you added a new WOOD SUP supplied part to the CIM cell and defined a new WOOD PROD product to be produced from the part. In this activity you will prepare the CIM system to produce the new product, WOOD PROD, which was defined in the previous activity. You will then run and observe the production cycle of the CIM cell as it produces the product. The following tasks must be performed to enable the CIM cell to produce WOOD PROD: ♦ The ASRS (storage) needs to be prepared for the new production using
the Storage Manager utility program.
♦ The part needs to be ordered in the MRP utility program. ♦
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PROCEDURES Task 9-1: Updating Storage In this task you will add the WOOD SUP part into the storage. The procedures for defining and updating storage settings are described in detail in the Storage Setup Activity. 1
From your Windows Start menu, select OpenCIM | Project Manager
. The CIM Project Manager window is displayed.
2
From the Archive tab, select 102_ACT9, and then click Save as to save the project as 9 (for example, JOHN9) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 9 project and then click CIM Manager to activate the CIM Manager application for this project. All the tasks described in this activity refer to this selected 9 project.
4
From the OpenCIM Manager window, select Utility Programs | Storage Manager. The CIM Storage Manager window is displayed.
Figure 9-1: CIM Storage Manager Window
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5 Click the Reset Storage button
in the CIM Storage Manager
window. The following message appears.
Figure 9-2: CIM Storage Manager – Restoring Default Storage 6
Click Yes. The storage settings are reset to reflect the previously defined default storage settings.
Figure 9-3: CIM Storage Manager Window - Default Storage Settings 7
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Click the Add New Row to ASRS button
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8 Select WOOD SUP from the Part Name dropdown list.
Figure 9-4: CIM Storage Manager Window - Adding Parts to Storage 9
Click the Save button to save the new storage settings. Now, we will make these settings the default settings, eliminating the need to edit the storage settings before each production cycle.
10 Click the Create Default Storage button
to set the new storage as the default. A confirmation message is displayed.
11 Click Yes. The new default settings are saved. 12 Close the Storage Manager window. Q To resume preparations for running production cycle of WOOD
PROD, what should you do next?
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Add a new process to the machine definition.
Insert a WOOD PROD part into the ASRS.
Run the CIM cell with its current order of part.
Create an order for WOOD PROD part in the MRP utility.
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Task 9-2: Placing an Order for the New Product Part The last phase before the running the production cycle for a new part is to order the part. In this task, you will create an order for WOOD PROD in the MRP window. Note: The procedures for defining and updating storage settings are described in detail in the Production Planning Activity. 1
Select Utility Programs | MRP. The Customer Order tab of the MRP window is displayed:
Figure 9-5: CIM MRP Window - Customer Order Tab 2
Right-click anywhere in the Customer2 row and select Insert After from the popup menu. A new row is added in the Customer Order for Customer 2.
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3 Click in the empty Part Name field and select WOOD PROD from the
dropdown list.
Figure 9-6: CIM MRP Window – Selecting the WOOD PROD Part
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4
Enter 1 in the empty Required Quantity field to indicate that two parts are required.
5
Enter 1 in the empty Priority field to assign the order the highest priority.
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6
Enter 3 the empty Due Date field to indicate that the part must be supplied three days from today.
Figure 9-7: CIM MRP Window - Defining the Part Details 7
Save the new line in the Customer Order by selecting File | Save Order or by clicking the Save button
.
A confirmation message is displayed. 8
Click OK. An order of one WOOD PROD part has been added to the Customer Order for Customer2.
Q The total order for Customer2 now includes one BASE PROD part for
either due date: 2, 3, or 5; and one WOOD PROD part for either due date: 2, 3, or 5. Q Which one of the part orders needs to be supplied within the shortest
period of time:
9
Customer2’s order for 1 BASE PROD part.
Customer2’s order for 1 WOOD PROD part.
Customer1’s order for 1 BASE PROD part.
Customer1’s order for 2 BASE PROD parts.
Select the order for Customer2 and click the Create MRP button.
10 When the popup message is displayed, click OK.
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11 Click the Manufacturing Order tab to view the order according to the
dates when the parts are required. Q The current manufacturing order calls for production of a total of
either: one, two, three, or four WOOD PROD; and either: one, two, four, or five BASE PROD parts.
Figure 9-8: CIM MRP Window – Manufacturing Order Tab
You are now ready to submit a new production order based on the data in the Manufacturing Order window. The previous production order will be replaced. 12 Select the line for WOOD PROD. (The selected line is highlighted in
green.) Only the information in the selected line will be submitted. 13 Click the Manufacturing Order button
.
14 When the popup message is displayed, click OK.
You have now inserted the production order for the part WOOD PROD. 15 Close the MRP window.
You are now ready to activate the production (simulation) cycle for WOOD PROD.
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Task 9-3: Tracking Production of WOOD PROD in the CIM cell In this task, we will activate and observe the production cycle for manufacturing the part WOOD PROD. 1
Click the Start button
to initiate the cycle.
2
When you are prompted to refresh storage, click OK.
3
The details of the current order are listed in the Order area of the OpenCIM Manager window. Verify that the current order corresponds with the manufacturing order that you submitted in the previous task. If the details do not match, return to the MRP utlity and resubmit the manufacturing oder. (Repeat steps 11-15 of the previous task.)
4
Click the Run button cycle.
to start the simulation of the production
The system is now activated. Production takes place as the part WOOD SUP is retrieved from the storage and then milled by the machine. 5
To make sure you can trace the part whereabouts during the production cycle, click the Follow Me Camera button from the Graphic Display toolbar. Note: The OpenCIM 3D viewing options are described in detail in the Introducing OpenCIM Software Activity.
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6
Zoom in on the ASRS to locate the part and click on the part to define it as the object that is to be followed by the camera.
7
Observe the production cycle. In particular, note the differences between this cycle and previously observed cycles.
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8
When production is complete, the following message is displayed:
Figure 9-9: OpenCIM Messages Dialog Box
You may not have been able to identify the changes in the simulation behavior that resulted from the production of the new part. One of the more easily observed differences is the time that was required for the machine to process the part. The transformation of the part from raw material to a final product can be tracked in additional views in the OpenCIM Manager module. These viewing options will be discussed in future activities. 9
Close the OpenCIM Manager module.
Task 9-4: Team Discussion and Review Q Simulating production is a tool provided to reflect the system behavior
in response to a change or an addition to the system. In this activity, “a change or an addition” refers to which one of the following:
The addition of a new device to the system.
The addition of a new part to the production cycle.
A change in the number of workstations.
Q The part that has to be inserted into the ASRS is which one of the
following:
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BASE SUP
WOOD SUP
BASE PROD
WOOD PROD
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Q A Customer Order needs to be created for which one of the following
parts:
BASE SUP
WOOD SUP
BASE PROD
WOOD PROD
Q Should the production cycle be run in off-line mode before, after, or at
the same time as it is run in on-line mode? Q Identify which of the following statements are true in response to:
Simulation of the production cycle enables you to:
Observe changes in system behavior that result from changes or additions to the system.
Detect problems in the part flow.
Manufacture real parts.
Q Which of the following tasks must be performed before you can create
a Customer Order for a new product part?
Add a supplied part in the Part Definition utility.
Define a product part in the Part Definition utility.
Add the supplied part to the Storage Device in the Storage Manager utility. Create a Manufacturing Order for the product part in the MRP utility.
Q Which one of the following tasks must be performed before you can
run the production cycle for a new part?
Add a supplied part in the Part Definition utility.
Define a product part in the Part Definition utility.
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Add the supplied part to the storage device in the Storage Manager utility. Create an order for the product part in the MRP utility. All of the above.
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Activity 10
Timing and Optimization OBJECTIVES In this activity you will accomplish the following: ♦ Understand the importance of timing in the production cell. ♦ Understand the relationship between timing optimization and cell
design.
♦ Operate the Scheduler Gantt tool. ♦ Analyze production timing to optimize production in the basic CIM
cell.
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Describe how to reduce the manufacturing cycle time Describe the factors involved to enable the CIM system to produce a part with minimum system resources Describe how you can improve the utilization of system resources during production
♦ Occupational and Technical:
Review the CIM Schedular Utility interface View the planned time range for the production of two different parts from the CIM MRP window Activate the production order and observe the timing of the processes using the CIM Schedular utility.
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
Reducing Manufacturing Cycle Time Great efforts are made to reduce manufacturing cycle time by improving manufacturing planning and control systems and developing more sophisticated scheduling procedures. It is clear that product design, which requires a specific set of manufacturing operations, has a huge impact on the duration of the manufacturing cycle. For this reason, product development teams need methods that can estimate the manufacturing cycle time of a given product design. Estimating the manufacturing cycle time enables development teams to evaluate the efficiency of the process in advance of production. If the forecasted manufacturing cycle time is too long, redesigning the product or modifying the production system can reduce it. Estimating the manufacturing cycle time early in the planning phase can help avoid the need for design modifications later on, thereby helping to reduce the total product development time and time-to-market.
Time Synchronization Time synchronization is a factor in all segments of production that are carried out in a CIM cell. It is important to achieve the best timing performance possible in a production sequence, enabling production of the part with the minimum resources. How can we improve the utilization of system resources during production? Duration is one of the main costly resources of a production cell. Here are some of the reasons: ♦ During production, the machines are occupied with the production of
the part that was ordered. Other parts cannot be produced at the same time by the same machine.
♦ The accumulated labor time of the machine determines the wear and
tear on the machine, which impacts on the number of spare parts, periodic treatments and maintenance actions required for the machine.
As a result, optimizing timing in the production sequence is an important factor in reducing overall manufacturing cycle time.
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System Optimization We have discussed the need to produce each part with the minimum system resources. In multiple production – that is the production of more than one part in the CIM cell - we need to optimize the timing synchronization to maximize system functionality at minimum costs. This process is called system optimization. For example, the basic CIM cell currently has an order for the production of two parts: BASE PROD and WOOD PROD. BASE PROD’s process length is 10 seconds and WOOD PROD’s process time is 50 seconds. One possible scenario of the production sequence is as follows: ♦ BASE SUP is retrieved out of storage and then WOOD SUP is
retrieved. As a result BASE SUP is first to arrive at the milling machine. WOOD SUP arrives later and will probably have to wait in station 2 until the production of BASE PROD is complete.
The sequence can be mapped out in the schematic diagram shown. BASE SUP is retrieved BASE SUP is sent to WS2 BASE SUP is processed WOOD SUP is retrieved WOOD SUP is sent to WS2 WOOD SUP is processed
Waiting time
Figure 10-1: Production Sequence Schematic Diagram
Time Axes Waiting time in a production cell should be eliminated or reduced wherever possible. Optimally, each part will waste only a minimum amount of lapsed time during its production cycle. In the basic CIM cell, however, we cannot eliminate the waiting time of the second retrieved part, since the sequence of processing the parts is serial in nature. Even if you were to change the sequence of production (i.e., retrieve WOOD SUP first and then the BASE SUP), a waiting time would still exist. WOOD SUP would go into the machine first, but BASE SUP could only be milled once WOOD SUP has been milled and removed from the machine.
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Normally, the system automatically determines the sequence of production according to various parameters, such as the duration of the process(es) that the part undergoes. We will discuss some specific examples in future activities. You can therefore conclude that every production cell has built-in limitations that adversely affect efficiency. In some cases, however, you can improve system efficiency by changing the sequence in which the parts are retrieved from storage. As you begin to work with more complex CIM systems, you will begin to see the importance of the sequence of production and how some sequences exploit the system resources better others.
OpenCIM Scheduling Tool – Scheduler Gantt Gantt charts are widely used in industry to plan and monitor complex tasks and projects. Gantt charts are frequently used in project management, to provide a graphical illustration of a schedule that helps to plan, coordinate, and track specific tasks in a project. OpenCIM software includes a production-monitoring tool based on the structure of a Gantt chart – the Scheduler Gantt. This tool can be used in estimating the manufacturing cycle time of a given product design. The Scheduler Gantt produces a Gantt chart, a graphical scheduling tool for the planning and control of an activity. In its most basic form, a Gantt chart is a bar chart that plots the tasks of an activity versus time. The Scheduler Gantt displays a Gantt chart corresponding to an activity schedule or a schedule that is input directly to the procedure. In real time monitoring, the actual and projected parts production time and duration can be displayed and compared for each machine and work cell. Note: A PERT (Program Evaluation Review Technique) chart is another project management tool used to schedule, organize, and coordinate tasks within a project.
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The Scheduler Gantt produces color-coded charts characterized by several distinctive features: ♦ The horizontal axis represents time, and the vertical axis represents the
sequence of observations in the dataset.
♦ Both the time axis and the activity axis can be plotted across more than
one page.
♦ The procedure automatically provides extensive labeling of the time
axis, enabling you to determine easily the exact time of events plotted on the chart.
Task A
OCT 03 05
OCT 07 09 11
OCT 13 15 17
OCT 19 21
B C
Figure 10-2: Example Gantt chart
The CIM Scheduler Window The Gantt chart produced by the CIM Scheduler utility is displayed in the CIM Scheduler window.
Figure 10-3:CIM Schedular Window
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The CIM Scheduler window includes the following viewing options:
On/Off line: When online (default) the viewer is updated periodically by the current running production. You can toggle between online and offline viewing by clicking the On/Offline button on the toolbar or by selecting Display | On/Offline. Sort By Machine: The time readings are sorted by machine. This option is selected by clicking the Sort by Machine button on the toolbar or by selecting Display | Sort by Machine. Sort By Part: The time readings are sorted by part. This option is selected by clicking the Sort by Part button on the toolbar or by selecting Display | Sort by Part. Clean Data: Clears the viewer of data from any previous production runs. Load Data: Displays the Load Data dialog box, enabling you to load additional production schedules. (Enabled in Offline mode only.) Save Data: Displays the Save as dialog box enabling you to save the current production schedule. Planned/Actual: This button toggles between the two kinds of productions schedules. The process time reading is performed according to the requested option. •
Planned: This schedule is normally produced and displayed when the CIM Manager is operating in Simulation mode. In simulation, of course, there is no difference between the planned and actual cycles.
•
Actual: This schedule is normally produced and displayed when the CIM Manager is operating in Real mode.
Additional time readings can be selected for planned and/or actual production schedules by selecting the Start, Finish or Duration checkboxes. These time readings will not be addressed in this activity. For current purposes the only checkbox that should be selected is the Duration checkbox in the Planned row. Please verify that no additional checkboxes are selected before proceeding.
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Interval (min): The time increments for indicting the duration in the Gantt chart. Verify that the defined interval is 1 minute.
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PROCEDURES Task 10-1: Preparing to Observe Production Timing In this task you will learn how to view the timing for production of two different parts: BASE PROD and WOOD PROD. 1
From your Windows Start menu, select OpenCIM | Project Manager
. The CIM Project Manager window is displayed.
2
From the Archive tab, select 102_ACT10, and then click Save as to save the project as 10 (for example, JOHN10) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 10 project and then click CIM Manager to activate the CIM Manager application for this project. All the tasks described in this activity refer to this selected 10 project.
4
From the OpenCIM Manager window, select Utility Programs | MRP in the OpenCIM Manager window. The Customer Order tab of the CIM MRP window is automatically displayed.
Figure 10-4: CIM MRP Window – Customer Order Tab
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5
In the Customer2 section, change the due date for BASE PROD from 5 to 3. (Double-click the due date field in the BASE PROD row, delete the existing due date, and enter 3.) Note: Attempting to delete the due date without double-clicking the field will delete the row. If you delete the entire row by mistake, close and reopen the window and try again.
Figure 10-5:CIM MRP Window – Saving the Order
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6
Click the Save Order button to save the new schedule.
7
When the popup message is displayed, click OK.
8
Select the Customer2 section and click the Create MRP button.
9
When the popup message is displayed, click OK. The modified customer order has been inserted into the manufacturing order.
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10 Click the Manufacturing Order tab. The Manufacturing Order tab is
displayed.
Figure 10-6: CIM MRP Window – Manufacturing Order Tab
Note that two different parts have been assigned 3 as their Due Date (Order Date 2).
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11 In the Order Date 2 section, click anywhere in the WOOD PROD row.
The entire section (both lines) should be highlighted in green.
Figure 10-7: CIM MRP Window – Viewing the Manufacturing Order (BASE PROD, WOOD PROD)
Figure 10-8: CIM MRP Window –Selecting the Manufacturing Order (BASE PROD, WOOD PROD)
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12 Click the MO (Manufacturing Order) button
.
13 When the popup message is displayed, click OK. 14 Close the CIM MRP window.
You have inserted the production order for the parts WOOD PROD (quantity 1) and BASE PROD (quantity 1). You are now ready to activate the simulated production cycle. Task 10-2: Observing Production Timing with the Scheduler Gantt You will now activate production of the current order and use the OpenCIM Scheduler Gantt utility to observe the timing of the processes in the production cycle. 1
From the OpenCIM Manager window, select Utility Programs | Scheduler Gantt. The CIM Scheduler window is displayed. Note: The Scheduler Gantt may include cumulative data from previous production cycles. For this reason, the length of the bars displayed may vary from the example shown in the video.
2
Please verify that the only checkbox that selected is the Duration checkbox in the Planned row before proceeding. We will now activate the production cycle and observe the time readings in the CIM Scheduler window.
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3
Close the CIM Scheduler window.
4
In the OpenCIM Manager window, click the CIM Modes button. The CIM Modes window is displayed.
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5 To enable continuous update of the display, verify that Planned is
selected in the Report to Scheduler as area. If Planned is not selected, the OpenCIM Manager will not update the Scheduler Gantt.
Figure 10-9: MODES Dialog Box 6
Click Save.
7
From the OpenCIM Manager window, click the Start button.
8
When the refresh storage message is displayed, click OK.
9
Click the Run button to start the production flow.
10 Select Utility Programs | Scheduler Gantt to display the CIM
Scheduler window. As the production simulation progresses, the display is simultaneously updated. The first noticeable change will be detected only after one of the parts is inserted into the CNC machine. 11 Click the CIM Manager button on your Windows toolbar to return to
the Graphic Display without closing the Scheduler Browser window. 12 Trace the parts in the production cell, at each point in time.
Alternate between the two windows to attempt to see when a time reading is displayed on the Scheduler Browser window.
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13 Figure 10-10 reflects how the Scheduler Browser window should look
at the end of the production cycle.
Elapsed time for processing BASE PROD Total elapsed time Elapsed time for processing WOOD PROD
Figure 10-10:CIM Schedular Window – Elapsed Times Sorted by Machine
Verify that the Scheduler view is sorted according to machine, showing labor time per machine. (If the view is not already sorted by machine, click the Sort by Machine button.)
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From this view, you can see the following:
The total elapsed time from start of the first process until the end of the last process is indicated by the uppermost (and longest) blue bar. The processes are indicated by the two short blue bars. Note that the bar representing the BASE PROD process is shorter than the bar that describes the WOOD PROD process, indicating that the process time of the BASE PROD is shorter (10 sec) than that of WOOD PROD (50 sec).
By default, the Scheduler view is currently sorted according to machine, showing labor time per machine. 14 Select Display | Sort by Part or click the Sort by Part button
.
The view is now sorted according to part (i.e., for each part, the blue bar represents the length of the machining process it undergoes).
Figure 10-11: CIM Schedular Window – Elapsed Times Sorted by Part
Note that the machine that processes each part is listed beneath the part.
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15 Compare the bar representing the process for BASE PROD to the bar
indicating the duration of the part’s processing in MILL1. The total elapsed time from the start of the first process until the end of the last process is indicated by the uppermost (and longest) blue bar. The two bars are equal in this example because only one machine is used in the production of BASE PROD. Note that the bar representing the processing of BASE PROD in MILL1 is shorter than the bar that describes the processing of WOOD PROD in MILL1. 16 Close the OpenCIM Manager module.
Task 10-3: Team Discussion and Review In this activity you learned about the general aspects of timing in the production cell, and viewed the timing and production schedules in the Scheduler utility. We will address this subject in greater depth in our discussion of more complex systems in future activities. Q How does the functioning of the machine play a role in determining
the duration of the overall manufacturing cycle?
The design of a part is limited by the dimensions of the machine. More than one part can be produced at the same time in one machine. While producing a part, additional parts cannot be produced in the same machine. The greater the distance between machines in the cell, the longer the cycle will be.
Q Can the basic CIM cell only support serial production because:
The system has only one conveyor.
The system has only one machine.
The two parts are retrieved from the storage device.
Q Match tasks A, B and C to their scheduled dates as indicated in the
Gantt chart:
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A
Oct 15 – Oct 21
B
Oct 4 – Oct 9
C
Oct 11 – Oct 15
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Q Does the specific set of manufacturing operations required to
manufacture the product have no impact on the duration of the manufacturing cycle? Q Can the duration of the manufacturing cycle be reduced by improving
the utilization of time in the production sequence? Q Should waiting time in a production cell be increased or reduced
wherever possible? Q When the CIM Manager is operating in Simulation mode, what is the
potential for variation between the planned and actual cycles?
There may be only slight variations between the planned and actual cycles. There is no variation between the planned and actual cycles. There may be extensive variations between the planned and actual cycles.
Q Does the total elapsed time span from the start of the first process until
the end of the last process?
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Activity 11
Viewing Production Details in the Device View OBJECTIVES In this activity you will accomplish the following: ♦ Identify additional viewing options in the OpenCIM Manager window. ♦ Observe the production process in the Device View of the CIM
Manager window.
♦ Identify the data displayed during the production process as it pertains
to the activity that is taking place in the devices.
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Explore an additional viewing tool to monitor actions performed by system devices Identify the correlation between the messages displayed in the Device View area and the actions visible in the Graphic Display area
♦ Occupational and Technical:
View device activity at the ASRS storage station (station 1) from the Device and Viewing areas. View device activity at the CNC station (station 2) from the Device and Viewing areas.
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
OpenCIM Manager Viewing Areas The OpenCIM Manager window includes the following viewing areas: ♦ Order View: The Order View that is located below the toolbar in the
left portion of the window, displays data regarding the order of parts and their production status.
♦ Device View: The Device View that is located below the toolbar in the
right portion of the window, displays data regarding the activity taking place in the devices during the production process.
♦ Viewing Area: The Viewing Area enables you to monitor various
aspects of the production cycle on a real-time basis byDevice selecting one of View seven tab views.
Order View
Viewing Area
Figure 11-1: OpenCIM Manager Viewing Areas
In previous activities, you viewed the production cycle in the Graphic Viewing area of the OpenCIM Manager window. You may have noticed that it is rather difficult to trace the actions and the whereabouts of parts at all times during the production cycle.
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Tracing the status of the production cell at any given time is essential for the analysis of the system. The user needs to be able to ascertain the exact status of production. In this activity, you will follow the progress of the production cycle in the Device View, which provides a more accurate and detailed view of the production steps.
Viewing Production Details in the Device View Viewing production details in the Device View is perhaps the most commonly used and the easiest way to monitor the actions carried out in the CIM system during production. In this activity you will learn how to identify the actions performed by system devices as they occur in the production cycle. You will use the exact production order used in the previous activity, which, as you may remember, includes: •
1 part named BASE PROD
•
1 part named WOOD PROD
Viewing Production Details in the View Device Tab To view the 3D graphic simulation more clearly, you can maximum the Viewing Area by selecting the Maximize button. In this case the Device View is no longer displayed. The production details displayed in the Device View can also be viewed in the View Device tab of the Viewing Area. You can then alternate freely between the graphic and device views during the production cycle by selecting the respective tabs. For this activity, it is recommended that the screen not be maximized so that you can continue to view both the Viewing Area and the Device View at the same time.
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PROCEDURES Task 11-1: Viewing Device Activity at Station 1 In this task you will focus on the actions at the storage device (station 1) and closely observe the activities taking place at that station by viewing both the Device View and the Viewing Area. 1
From your Windows Start menu, select OpenCIM | Project Manager
2
. The CIM Project Manager window is displayed.
From the Archive tab, select 102_ACT11-13, and then click Save as to save the project as 11 (for example, JOHN11) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 11 project and then click CIM Manager to activate the CIM Manager application for this project. All the tasks described in this activity refer to this selected 11 project.
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4
In the OpenCIM Manager window, redirect the camera to the storage device.
5
Use the zooming and rotating options to clearly view the pallet station outside the ASRS, as well as the inside of the ASRS. The viewing angle should help you get a better sense of the actions that take place in the storage station.
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Figure 11-2 shows the recommended viewing angle of the cell.
Figure 11-2: OpenCIM Manager Window – Station 1 6
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Click the Save Camera button throughout the production cycle.
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to maintain the viewing angle
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7
In the OpenCIM Manager window, click the CIM Modes button
.
The CIM Modes window is displayed.
Figure 11-3: MODES Dialog Box - Current Speed x10 8
Drag the speed indicator to its minimum (left) to enable you to observe the graphic at its default speed (the slowest one).
Figure 11-4: MODES Dialog Box - Current Speed Normal 9
Click Save
.
10 From the OpenCIM Manager window, click the Start button.
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11 When the refresh storage message is displayed, click OK.
Figure 11-5: OpenCIM Manager Window – Production Flow Table (Station 1)
Note that the production flow table in the Device View lists the devices that exist in the cell, including the robotic arms and the machines. The device names that appear in the current device view are:
36ASRS1 – the name of the robotic arm of the ASRS (at station 1). ROBOT2 – the name of the robotic arm at the milling station (at station 2). MILL1 – the name of the milling machine (at station 2).
The row for each device includes a field to indicate the action being performed by the device. We will now activate the production cycle and see how the actions are displayed in the Device View: 12 Click the Run button to start the production flow.
Important:
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If at any stage you wish to review the action, click the Abort button. Then repeat steps 7 through 9 to rerun the production flow.
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13 Observe the production flow in the Device View, paying particular
attention to the row for the 36ASRS1.
Device details for 36ASRS1
Figure 11-6: OpenCIM Manager Window –Device Details for 36ASRS1
The first action that can be observed is displayed in the Action field for the 36ASRS1.
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Try to identify the correlation between the message and the action that is visible in the Viewing area.
Figure 11-7: OpenCIM Manager Window –Template Placed on Conveyer
The message indicates that a template numbered 090002 is being retrieved from the ASRS and placed on the conveyor. Q Based on what you have learned in the previous activities, what does
template 090002 currently carry?
A supplied part.
A product.
It is an empty template.
14 Observe the rest of the messages in the Device View until production
of the part is complete. Q Arrange the messages in the order in which they were displayed in the
production cycle you just observed: PLACE TEMPLATE#020002 on ASRS1 PLACE TEMPLATE#020002 on CNV1[1] PLACE TEMPLATE#090002 on CNV1[1] PLACE TEMPLATE#090002 on ASRS1
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As expected, the actions that are indicated by these messages enable us to conclude the following:
Two templates were retrieved from the storage device.
Two templates were returned to the storage device.
Observing the graphic viewing area, together with what we previously learned about the behavior of this specific order of parts, provides us with the following information:
Each of the two templates that were retrieved from the storage device carried a different supplied part (BASE SUP and WOOD SUP). The templates that where returned to the ASRS for storage contained two different products (BASE PROD and WOOD PROD).
Task 11-2: Viewing Device Activity at the CNC Station In this task, you will change the viewing angle of the graphic simulation to focus on the actions at the CNC station (station 2) and closely observe the activities taking place at that station in both the Device View (Device area) and the Viewing area. 1
Redirect the camera to the CNC machine.
2
Use the zooming and rotating options to clearly view the CNC machine from the front. The viewing angle should help you get a better sense of the actions that take place in the CNC machine (station 2). Figure 11-8 shows the recommended viewing angle of the cell.
Figure 11-8: OpenCIM Manager Window – CNC Station
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3
Click the Save Camera button throughout the production cycle.
to maintain the view angle
4
From the OpenCIM Manager window, click the Start button.
5
When the refresh storage message is displayed, click Yes.
6
Click the Run button to start the production flow. Important:
7
If at any stage you wish to review the action, click the Abort button. Then repeat steps 4 through 6 to rerun the production flow.
Observe the data displayed in the Device View (or in the View Device tab). Focus only on the lines for ROBOT2 and MILL1.
Device view for ROBOT2 and MILL1
Figure 11-9: OpenCIM Manager Window – Device Details for ROBOT2 and MILL1
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8
Try to identify the correlation between the messages and the actions displayed in the graphic simulation.
Figure 11-10: OpenCIM Manager Window – Template Placed on Buffer
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The first message for ROBOT2 indicates that the robot is placing a template in the buffer (BFFR1). In addition, we know (from looking at the graphic simulation) that the robot first took the template from the conveyor. We also know that this template carries the part called BASE SUP.
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Q How do we know that the current template carries BASE SUP?
It is stated in the message displayed in the Device View. We know from previous activities that BASE SUP is the first part retrieved. It can be seen by looking at the part in the graphic simulation. There is no other option available. BASE SUP is the only part available at this time.
Figure 11-11: OpenCIM Manager Window – BASE SUP Placed in MILL1
The next message indicates that the robot is placing BASE SUP in the milling machine (MILL1).
Q The main difference between the current action of the robot and the
previous one is that:
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This time the robot picks a template. In the previous action it picked a part. The robot is rotating to the left. In the previous action it rotated to the right. The robot is now picking a part. In the previous action it picked a template.
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The next message in the Device View indicates that the process is taking place in MILL1 (the CNC station). The message includes the following information: •
The process name is MILL BASE.
•
The process is being performed on the part named BASE SUP.
•
The process is being executed in the machine named MILL1.
Figure 11-12: OpenCIM Manager Window – MILL1 Processes
The subsequent messages should already be familiar to you. Monitor them until the end of the production.
Q Arrange the following actions in the order in which they occurred: MILL1 runs the process MILL WOOD on WOOD SUP Robot2 places WOOD PROD on the template (in the buffer). Robot2 places template 020002 in the buffer Robot2 places WOOD SUP in the CNC machine Robot2 places MILL PROD on template 090002 (in the buffer). Robot2 places template 020002 (carrying WOOD PROD) on the conveyor. Robot2 places template 090002 (carrying BASE PROD) on the conveyor
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Task 11-3: Team Discussion and Review In this activity you monitored the details of a complete production cycle in the Device View of the OpenCIM Manager window. You observed that some important information is available in the Device View, in addition to the information you already observed in other areas in previous activities. Nonetheless, it is still difficult to determine which part a template is carrying at any given time. In the next activity, you will explore an additional viewing tool that will enable you to more readily identify the location of parts on templates during the production cycle. Q Does the production data displayed in the Device View enable you to
identify the actions performed in the cell as they occur in the production cycle? Q Which two of the following statements are not true?
Maximizing the Viewing area of the window enables you to better view the Device View. Maximizing the graphic Viewing Area of the window enables you to better view the 3D simulation of the production cycle. When the graphic Viewing Area of the window is maximized, the Device View remains visible. When the graphic Viewing Area of the window is maximized, the Device View is no longer visible.
Q Is the information displayed in the Device View also displayed in the
View Device tab of the graphic Viewing Area? Q Do messages in the device area always include the name of the
relevant part? Q Is the name of the part included in all messages related the CNC
machine?
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Q Match the following messages to the activities they describe:
The robot is placing the template on the conveyor. A template is being placed in the storage device. The robot is placing the template in the buffer. The robot is placing BASE PROD on a template. The robot is placing WOOD PROD on a template. The robot is feeding the BASE SUP part to the milling machine. The template is being removed from the storage device and placed on the conveyor. MILL1 is performing the MILL WOOD process on the WOOD SUP part. MILL1 is performing the MILL BASE process on the BASE SUP part.
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Activity 12
Viewing Production Details in the Storage View OBJECTIVES In this activity you will accomplish the following: ♦ Understand the role of the Storage View in the OpenCIM Manager
window.
♦ Observe the production process in the Storage View of the CIM Manager
window.
♦ Identify the data displayed during the production process as it pertains to
the location of parts.
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Identify all the storage locations (including temporary storage) the CIM cell Describe how to verify the current location of parts in the storage view. Identify the correlation between the messages displayed in the Device View and the changes occurring in the Storage View.
♦ Occupational and Technical:
View the storage information of a specific part including the storage location, template and more. Activate the production flow and observe the production cycle as reflected in the Storage View.
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
Identifying Part Locations During Production In the previous activity you learned that viewing production in the Device area (or the View Device tab) does not always provide all of the information required. For example, when the ASRS retrieves a part from storage, the message displayed in the Device area does not indicate which part is on the template, nor does it indicate the location of a specific part. And, as you have already observed, all of the parts look the same in the graphic simulation. In this activity we will focus on the information available in the Storage View, which is displayed in the View Storage tab of the graphic Viewing Area.
The Storage View The Storage View provides information regarding all of the storage locations in the system (and not specifically the storage device or ASRS). Storage locations include temporary storage – meaning any place that a part can be at each given point of time. Examples of temporary storage locations are: ♦ The grippers of the robots. ♦ The vise of the milling machine. ♦ The pallet on the conveyor.
In this activity you will learn about all of the temporary storage places in the basic CIM cell and identify the location of parts in the Storage View during the production cycle.
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PROCEDURES Task 12-1: Viewing Production Details in the Storage View 1
From your Windows Start menu, select OpenCIM | Project Manager
. The CIM Project Manager window is displayed.
2
From the Archive tab, select 102_ACT11-13, and then click Save as to save the project as 12 (for example, JOHN12) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 12 project and then click to activate the CIM Manager application for this CIM Manager project. All the tasks described in this activity refer to this selected 12 project.
4
From the OpenCIM Manager window, use the zooming and rotating options to clearly view the basic CIM cell with the fronts of the three computers in the forward-most position. Figure 12-1 shows the recommended viewing angle of the cell.
Figure 12-1: OpenCIM Manager Window – Recommended CIM CELL Viewing Angle
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Click the Save Camera button the production cycle.
6
Click the Start button.
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7
When the refresh storage message is displayed, click OK.
8
Select the View Storage tab in the graphic Viewing Area. The View Storage tab is displayed.
Figure 12-2: OpenCIM Manager Window – Storage View (A)
Figure 12-3: OpenCIM Manager Window –Storage View (B)
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Q The section marked in red tells us that the ASRS1 contains:
BASE SUP on template 090002 and WOOD PROD on template 020002.
BASE SUP on template 020002 and WOOD SUP on template 090002.
BASE SUP on template 090002 and WOOD SUP on template 020002.
BASE PROD on template 090002 and WOOD SUP on template 020002.
Refer to the Index column. Each location in the production cell is indexed:
9
The cells in the ASRS1 are indexed from 1 to 36. The conveyor pallets are indexed from 1 to the maximum number of pallets. Each robot (i.e., 36ASRS1 and ROBOT2) has one indexed location and can hold only one part. The mill has one indexed location (its vise can hold only one part).
Scroll down to view the entire list. We can see that BASE SUP is in cell number 1 of the ASRS and that WOOD SUP is in cell number 2. Note that this corresponds to the default storage that we defined for the basic CIM cell.
10 Click the Run button
to start the production flow.
11 Observe the production cycle as reflected in the Storage View.
Figure 12-4: OpenCIM Manager Window – Storage View (C)
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The first change that can be observed is that BASE SUP was retrieved from ASRS cell number 1. The part is now displayed in the 36ASRS1 row (refer to the red arrow), indicating that it is currently being held by the gripper of the 36ASRS1 robot. Note the action message that is displayed in the Device area at that time. It refers to the same action: the ASRS robot is retrieving BASE SUP on template number 090002 from cell number 1 and placing it on the conveyor. 12 Watch for the next changes that are reflected in the Storage View. Note
that the changes may occur rapidly. Important: If at any stage have difficulty in viewing the details as they change, click the Abort button, then restart the production cycle to view the actions again.
Figure 12-5: OpenCIM Manager Window – Storage View (D)
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13 When WOOD SUP is displayed in the 36ASRS1 row, immediately click the
Pause button.
(Figure 12-6 shows the details in the Storage View.)
Figure 12-6: OpenCIM Manager Window – Storage View (E) 14 The cycle is frozen as soon as the 36ASRS1 has completed its current
operation. As you can see, the part WOOD SUP is no longer held by the gripper of the ASRS robot. Note: When you pause a cycle, the cycle completes any ongoing operations before it pauses.
Figure 12-7: OpenCIM Manager Window – Storage View (F)
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Q Where do you think BASE SUP and WOOD SUP are now:
In workstation number 2.
In one of the storage cells.
Being carried by the conveyor pallets.
15 You can verify the current location of the parts in the View Storage tab.
Scroll down until you can see the rows containing information for the pallets, designated as CONPALET.
Figure 12-8: OpenCIM Manager Window – Storage View (G)
Note that BASE SUP is currently being conveyed (on template 090002) by the conveyor pallet indexed 1 and WOOD SUP is current being conveyed (on template 030002) by the conveyor pallet indexed 2. Make sure you can identify this information in the current view. Note: The indexing of the pallets in your cell may vary slightly from the example shown here.
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16 Click the Graphic Display tab. The 3D simulation shows that the pallet
(with the part BASE SUP) is docking at station 2. The robot has not picked up the part because we have paused the system.
Figure 12-9: OpenCIM Manager Window – Graphic Display View 17 Return to the Storage View (click the View Storage tab) and scroll back
up to the top of the table. 18 Click the Continue button
to allow the production cycle to proceed.
The next visible change occurs when ROBOT2 picks the part BASE SUP.
Figure 12-10: OpenCIM Manager Window – Storage View (H)
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We have now reviewed the first steps in the production cycle. You should now be familiar with how to read the information contained in the Storage View. You will now observe the main steps that take place in the remainder of the current production cycle, as they are displayed in the Storage View. Make sure you can identify these steps on your own. Scroll up and down on your own to view additional rows in the Storage View. 19 Scroll down to view the rows for the mill and the buffers. Observe the
locations of the parts as they are moved one at a time from the conveyor to the buffer and into the mill. (The actions performed by Robot2 can be viewed by scrolling up to the top). 20 Figure 12-11 shows the intermediate status. As you can see, the following
data is included:
The part BASE SUP is in the milling machine.
An empty template is waiting in the buffer of station 2.
WOOD SUP is current being conveyed (on template 030002) by the conveyor pallet indexed 2.
Figure 12-11: OpenCIM Manager Window –Storage View (I)
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Figure 12-12 is a later intermediate status that indicates the following:
BASE PROD (finished part) is on template 090002 in the buffer of station 2 (the location index in the buffer is 1). (Note that the name BASE SUP has been changed to BASE PROD.) WOOD SUP is in the vise of the mill. An empty template is waiting for WOOD SUP in the buffer of station 2 (location indexed 2).
Figure 12-12: OpenCIM Manager Window – Storage View (J) 21 Observe the location of the parts until the production cycle is complete.
Close the message windows that are displayed notifying you when the production of each part is complete.
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Q Select the figure that most closely resembles the View Storage tab that
appears in the final status of the system (at the end of the production cycle).
Figure 12-13: OpenCIM Manager Window – Storage View Final Status (A)
Figure 12-14: OpenCIM Manager Window – Storage View Final Status (B)
Figure 12-15: OpenCIM Manager Window – Storage View Final Status (C)
Figure 12-16: OpenCIM Manager Window – Storage View Final Status (D) 22 Close the OpenCIM Manager module.
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Task 12-2: Team Discussion and Review In this project, you learned how to use the Storage View as an additional tool for viewing the production status. The Storage View is useful mainly in cases where we need to know the location of a part at a certain point of time. You have seen that the Storage View can be used together with other views (such as the Graphic Display or Device View), and that crossing information from several views provides a reasonably clear picture of the system status. The additional viewing options available in OpenCIM will be addressed in the context of more advanced activities, as the need arises. Q Does the Storage View enable you to see the exact location of a part at
any time during the production cycle? Q The Storage View provides information regarding:
Only the temporary storage locations in the system
Only the centralized storage devices in the system
All of the storage locations and devices in the system (both temporary and centralized)
Q Is the location of a specific part always, sometimes, or never indicated in
the Device View? Q Is the location of a specific part always, sometimes, or never indicated in
the Storage View?
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Activity 13
Adding a CNC Machine OBJECTIVES In this activity you will accomplish the following: ♦ Understand the purpose of adding a machine to the basic CIM cell. ♦ Use the setup program to add a machine to the CIM cell. ♦ Understand the importance of connectivity in the CIM cell.
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Describe how to integrate a new device into an existing CIM cell Observe and evaluate the behavior of the modified production cycle. Explain the need to expand an existing CIM system in order to meet customer requirements
♦ Occupational and Technical:
Adding new machines to the basic CIM cell Configure the connectivity settings (physical and logical) between all the devices in the cell
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
Limitations of the Basic CIM Cell You have seen that the ability to produce a specific product is limited by the equipment included in the system. Nonetheless, there is always the possibility to expand the system by adding a new device to meet the growing needs of the factory. Integrating a new device into an existing CIM system is sometimes more complicated than designing the cell in its entirety. Naturally, it is far simpler to modify the CIM cell in simulation mode. Simulation enables us to observe and evaluate the behavior of the modified production cycle. In this activity we will learn how to insert an additional device into the basic CIM cell. The new device - a CNC lathe - will be added to station number 2. (More than one device can be located at each station.) But first we will discuss the reasons for implementing this change.
Why Expand a CIM System? The need to expand or modify a CIM system may arise as the result of different system production requirements; for example if a customer needs a new part and the existing system is not capable of producing the required part using its current machines. Let us assume that one of our customers needs a new product, according to the design shown here:
Figure 13-1: New Part Structure Design
It is clear that the milling machine cannot produce this part. A lathe (turning machine) typically produces this type of part. Therefore, in order to produce the part to meet customer requirements, a lathe must be added to the production cell.
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A CNC lathe is frequently used for processing rounded (cylinder-like) raw materials. Below are photos that illustrate the processing of a new part and the finished part.
Figure 13-2: Part During Processing
Figure 13-3: Finished Part
Adding a Machine to the Basic CIM Cell The production cycle in the CIM cell can combine processes performed by both the lathe and the mill. For example, a part can be processed in the lathe and then in the mill, or vice versa, as required. In this activity, however, you will run two separate production processes. You will continue to produce the existing parts, and you will add another part to be produced in the lathe. You will now learn how to add a new device into the basic CIM cell, specifically a PLT3000 machine, which is a type of lathe. You will then perform the additional actions (some of which you have previously performed) that are preconditions to producing the part in the lathe.
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PROCEDURES Task 13-1: Inserting a New Object into the Basic CIM Cell ¾ Warning! You are about to enter the Setup application. Pay special attention not to move or to change anything in the system, which is not specifically indicated in the project task instructions. 1
From your Windows Start menu, select OpenCIM | Project Manager . The CIM Project Manager window is displayed.
2
From the Archive tab, select 102_ACT11-13, and then click Save as to save the project as 13 (for example, JOHN13) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 13 project and then click CIM Setup to activate the Virtual CIM Setup application for this project. All the tasks described in this activity refer to this selected 13 project. The Virtual CIM Setup window is displayed.
Figure 13-4: Virtual CIM Setup Window – Side View
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4
From the Virtual CIM Setup window, click the Top View . The viewing camera is placed at the top of the cell at the button center of the image.
Figure 13-5: Virtual CIM Setup Window – Top View 5
Click the New Object button
.
The New Objects window is displayed.
Figure 13-6: New Objects Dialog Window
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6
Double click the Machines folder.
Figure 13-7: New Objects Dialog Window – Machines Folder
A list of machines is displayed under the Machines folder.
Figure 13-8: New Objects Dialog Window – PLT3000 7
Select PLT3000 from the list and click the OK button. A placement cursor
is displayed.
Note: the PLT3000 machine is a type of lathe (turning machine)
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Place the cursor below the CNC mill and to the left of the computer table. Then left click.
Figure 13-9: Virtual CIM Setup Window – Cursor Below CNC Mill
The PLT3000 lathe image is placed into the virtual cell.
Figure 13-10: Virtual CIM Setup Window – Adding PLT3000 Lathe Image
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8 Click the Cancel button in the New Objects window. The cell is
displayed in the window (with the embedded lathe image).
Figure 13-11: Virtual CIM Setup Window – PLT3000 Lathe (Before Rotation) 9
A hand-shaped cursor is displayed
.
10 Place the cursor on the lathe image and drag the image to a location
that is slightly below and to the left of the mill.
Figure 13-12: Virtual CIM Setup Window – Dragging PLT3000 Lathe
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11 Double-click the PLT3000 lathe image. A popup menu is displayed. 12 Select Rotate from the popup menu. A dialog is displayed.
Figure 13-13: PLT3000 Dialog Box 13 Enter –90 (to rotate the lathe image 90 degrees clockwise) and click
the OK button. The lathe image (PLT3000 in this case) is rotated accordingly in the window.
Figure 13-14: Virtual CIM Setup Window – PLT3000 Lathe After Rotation 14 Double-click the robotic arm. A popup menu is displayed.
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15 Select Show Envelope from the popup menu to display the robot’s
work envelope.
Figure 13-15: Virtual CIM Setup Window – Robot's Popup Menu
The positions within the robot’s reach are a function of its arm length and structure. This range of accessible positions is known as the robot’s work envelope. A robot’s work envelope is defined as the span of the robot’s working range. A drawing of the robot’s work envelope is displayed in the window:
Figure 13-16: Virtual CIM Setup Window – Robot's Work Envelope
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16 Zoom in on the lathe and make sure that the chuck (or vise) of the
machine is inside the robot’s work envelope. It must be in order for the robot to accurately place a part within the vise.
The chuck should be inside the robot’s work envelope Figure 13-17:Robot's Work Envelope – Zooming In On Chuck
Note: You can hide the robot’s work envelope by double clicking the robot and then deselecting Show Envelope from the popup menu. If the chuck is not in the robot’s work envelope, select the Drag Object tool ( ) and move the lathe image until it is. When the lathe is in place, zoom back out. This lathe is now situated in the CIM cell, however it is in effect “hanging in the air”. When working with a simulated system, it is not mandatory that you place the lathe on a table, however it is recommended that you do so. When working with a real (on-line) system, the CIM cell must include all of the required furnishings. You will now proceed to add a table for the new machine. 17 Click again on the New Object button.
The New Object
window is displayed.
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18 Double-click the General folder. A list of objects is displayed under
General folder.
Figure 13-18: New Objects Window – General Folder Items 19 Select Table from the list and then click OK. The TABLES window is
displayed.
Figure 13-19: Table Window 20 Click the Colors button. The Color window is displayed.
Figure 13-20: Color Window
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21 Select the turquoise color from the color pallet, and then click OK. The
Tables window is redisplayed. 22 Click OK again.
This type of cursor
is displayed.
23 Place the cursor in the cell where you originally placed the lathe –
below the mill and to the left of the computer table. Then click once.
Figure 13-21: Virtual CIM Setup Window – Defining Table Location
An image of a table is pasted into the window. 24 Click the Cancel button in the New Objects window.
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25 Place the cursor (now hand shaped) over the new table image and drag
it to the center of the lathe image.
Figure 13-22: Virtual CIM Setup Window – Placing Table Below Mill
Figure 13-23: Virtual CIM Setup Window – Dragging Table to PLT3000 Lathe Center
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26 Click the Save button
to save the modified setup.
Q Match the following Setup buttons to their functionality:
The Drag Object tool enables you to move a component within the OpenCIM setup. The Top View button enables you to view the cell layout as if the camera is placed in the center of the ceiling The New Object enables you to add a component to the OpenCIM setup. Task 13-2: Configuring the Connectivity Settings The connectivity in the OpenCIM cell comprises the functional connections between the devices in the cell. There are two types of connectivity: ♦ Physical connectivity –the accessibility of the robotic arm to a device. ♦ Logical connectivity – the communication path between the devices
In this activity you will learn about physical connectivity. Logical connectivity will be addressed in a later module, in the context of the online CIM cell. 1
Double-click the PLT3000 lathe machine image. A popup menu is displayed.
2
Select Connectivity from the popup menu. The Connections window for the lathe is displayed.
Figure 13-24: PLT3000 Connections Window – Viewing Possible Connections 3
Select ROBOT2 in the Possible Connections list. Important Note: If ROBOT 2 does not appear in the Possible Connections list, it means that the chuck of the machine is not located entirely within the robot’s work envelope. To rectify the situation, select the Drag Object tool and move the
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lathe image closer to the robot. Repeat step 2 and continue the procedure. 4
Click the Add button. ROBOT2 is moved to the Active Connections list.
Figure 13-25: PLT3000 Connections Window – Adding Active Connections 5
Click the OK button in the Connections window. A red line is displayed in the Virtual CIM Setup window indicating the connection(s) of the PLT3000 lathe machine.
Figure 13-26: Virtual CIM Setup Window – Lathe Connections
The red line indicates that ROBOT2 now has access to the PLT3000 lathe (meaning that it can place a part into the PLT3000 lathe machine). 6
Click the Save button. To apply the changes and enable use of the PLT3000 during production, we must recreate the setup file.
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7
Select Create | Setup File. The following message is displayed:
Figure 13-27: Virtual Setup Confirmation Message 8
Click the OK button.
9
An additional confirmation message is displayed. Click the OK button.
Figure 13-28: Virtual Setup Confirmation Message
The setup file of the CIM cell is overwritten and the modifications made in this activity will be reflected in the CIM cell the next time you open the OpenCIM Manager. 10 Select File | Exit to close the setup window. 11 Click the OK button when the confirmation message is displayed.
Task 13-3: Team Discussion and Review In this project you learned the reasons for adding a new device to the production cell. You have learned how to use the OpenCIM software to add a new device to the simulative basic CIM cell and how to define its connectivity to other components of the cell. In the next activity, you will implement production of a new part in the modified CIM cell. Q Does the quantity and type of equipment in the cell restrict the variety
of parts that the system can produce and is not subject to change? Q Can lathes and milling machines be used interchangeably in the
production of parts? Q Can additional machines be added to a CIM cell to enable the system
to produce a more diverse range of parts?
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Q Which type of machine is typically used in the production of cylinder-
like parts?
Mill
Lathe
ASRS
Q The range of positions to which the robot has access is known as
either the robot’s connectivity or work envelope. Q Does physical connectivity refer to the accessibility of the robotic arm
to a device?
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Activity 14
Defining Part Production in the Lathe OBJECTIVES In this activity you will accomplish the following: ♦ Define a production process for the lathe machine. ♦ Add a new supplied part to the part definition. ♦ Define a product part that is to be manufactured using the new
production process.
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Describe the processes related to the CNC lathe that are used to create the new production part in the CNC lathe machine. Observe the link between the production infrastructure of the basic CIM to the CNC lathe that was created in the previous activity
♦ Occupational and Technical:
Add a new process to the Machine Definition window Define the process as a CNC machine process and define the duration time of the process. Add a new part, select the subparts and define the processes to be implemented on the part.
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
Part Production in the Lathe In the previous activity you added a CNC lathe to the basic CIM cell. In this activity you will define the production of parts in the lathe. In order to do so, you need to define the processes related to the lathe, similar to the way in which you added a process to the mill in the Processes and Machine Definition activity. Once the process is defined, we can use the Part Definition utility to create a new part using the new process, similar to the way in which we created the WOOD PROD part in the Defining a Product Part activity. PROCEDURES Task 14-1: Defining a New Process for the Lathe In this task you will add a new process to the machine definition of the basic CIM cell. The process will apply to the CNC lathe machine (PLT3000 in this case). 1
From your Windows Start menu, select OpenCIM | Project Manager . The CIM Project Manager window is displayed.
2
From the Archive tab, select 102_ACT14, and then click Save as to save the project as 14 (for example, JOHN14) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 14 project and then to activate the CIM Manager application for click CIM Manager this project. All the tasks described in this activity refer to this selected 14 project.
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4 Select Utility Programs | Machine Definition in the OpenCIM
Manager window. The CIM Machine Definition window is displayed.
Figure 14-1: CIM Machine Definition Window
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5
Select the Lathe1 section. (The selected section is highlighted in green
6
Click the Action field. A dropdown arrow is displayed.
7
Select CNC from the dropdown list to define the new process as a CNC machine process.
Figure 14-2: CIM Machine Definition Window – Selecting the CNC Machine Process 8
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Click in the empty Process field in the row for Lathe1 and enter TURN METAL in the field.
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Figure 14-3: CIM Machine Definition Window – Defining a Process (TURN METAL) 9
Double-click in the empty Duration field.
10 Enter a duration of one minute and fifty seconds by typing in the
following sequence: 00 01 50. The window should now contain the following data for LATHE1:
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Machine Name: LATHE1
Process: TURN METAL
Duration: 00:01:50
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Figure 14-4 shows the Machine Definition window with the correct data:
Figure 14-4:CIM Machine Definition Window – Defining the Process Duration Time Q Which of the defined processes takes the longest time?
MILL BASE
MILL WOOD
TURN METAL
11 Save the new process by clicking on the Save button or selecting File |
Save Selected Machine. 12 When the popup message is displayed, click the OK button. 13 Click the
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button to close the Machine Definition window.
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Task 14-2: Adding a New Part In this task you will define a new part to be produced by the lathe. 1
Select Utility Programs | Part Definition in the OpenCIM Manager window. The Supplied Parts tab of the CIM Part Definition window is displayed.
Figure 14-5: CIM Part Definition Window – Supplied Parts Tab
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2
Click the New Order icon
. A new row is added.
Figure 14-6: CIM Part Definition Window – Adding a Supplied Part Order 3
Click in the empty Part Name field and enter the name of the new supplied part, METAL SUP, in the field. Note: Additional supplied part data is optional and does not need to be entered for the purpose of this activity.
Figure 14-7: CIM Part Definition Window – Defining the Suppled Part Name (METAL SUP)
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4
Enter 03 in the Template Type field.
Figure 14-8: CIM Part Definition Window – Defining the METAL SUP Template Type 5
Save this part by selecting File | Save Current Part or by clicking the Save button . A confirmation message is displayed.
6
Click the OK button. The part is saved.
7
Click the Product Parts tab.
Figure 14-9: CIM Part Definition Window – Supplied Parts Tab
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8
Click New Order icon
. A new row is added.
Figure 14-10: CIM Part Definition Window – Adding a Product Part Order 9
Enter METAL PROD in the empty Part Name field.
Figure 14-11: CIM Part Definition Window – Defining the Product Part Name (METAL PROD)
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10 Click the Subpart field and open the dropdown list.
Figure 14-12: CIM Part Definition Window – Selecting the Subparts
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Q According to the logic explained so far, what is the name of the
supplied part that will be chosen from the list?
WOOD SUP
BASE SUP
METAL SUP
This cannot be determined from the information at hand.
11 Select METAL SUP from the dropdown list.
You will now define the processes to be implemented on METAL SUP. The first process will be the GET process, which will retrieve the part from storage. 12 Click in the Process field and select GET from the dropdown list.
Figure 14-13: CIM Part Definition Window – Defining the Product Part Process
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13 Enter ASRS1 in the Parameters field. The first row for METAL PROD
should match the following:
Part ID: 6
Subpart: METAL SUP
Process: GET
Parameters: ASRS1
Figure 14-14: CIM Part Definition Window – Viewing the METAL PROD Information Parameters
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14 Right-click anywhere in the green row and select Insert After from the
popup menu. A new row is added for METAL PROD.
Figure 14-15: CIM Part Definition Window – METAL PROD Popup Menu
Figure 14-16: CIM Part Definition Window – Adding Rows to METAL PROD
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Q The next step to be carried out should be:
Select METAL PROD from the Subpart dropdown list.
Select MILL BASE from the Process dropdown list.
Select TURN METAL from the Process dropdown list.
Select WOOD PROD from the Subpart dropdown list.
15 In the new line, select TURN METAL from the Process dropdown
list.
Figure 14-17: CIM Part Definition Window – Selecting the TURN METAL Process 16 Right-click anywhere in the second row of the METAL PROD section
and select Insert After from the popup menu. A third line is added to the METAL PROD section.
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17 Select TARGET from the Process dropdown list.
Figure 14-18: CIM Part Definition Window – Selecting the TARGET Process 18 Enter ASRS1 in the Parameters field. 19 Enter 03 in the Template Type field. The window should now contain
the following data for METAL PROD:
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Part Name: METAL PROD
Subpart: METAL SUP
Processes: GET, TURN METAL, TARGET
Parameters: ASRS1 (in GET and TARGET rows only)
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Figure 14-19 shows the window with the correct data.
Figure 14-19: Viewing the METAL PROD Processes (GET, TURN, TARGET) Q Which three of the following processes have been defined for METAL
PROD?
GET
MILL BASE
TURN METAL
TARGET
MILL METAL
20 Save these changes by selecting File | Save Current Part or by
clicking the Save button
. A confirmation message is displayed.
21 Click the OK button. The changes are saved. 22 Close the Part Definition window. 23 Close the OpenCIM Manager module.
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Task 14-3: Team Discussion and Review In this activity you linked the production infrastructure of the basic CIM cell to the CNC lathe that was added in the previous activity. This entailed the following steps: ♦ In the Machine Definition utility, you created a new process for the
lathe, called TURN METAL.
♦ In the Part Definition utility, you added two parts:
A new supplied part named METAL SUP.
A new product named METAL PROD.
You defined TURN METAL as the process to be implemented by the lathe on METAL SUP after it has been retrieved from storage. After processing, the resulting part - METAL PROD - is to be returned to the storage device. In the next activity, you will run the production cycle for METAL PROD and analyze the system’s behavior. Q The new process for the lathe was defined:
In the Machine Definition utility
In the MRP utility.
In the Part Definition utility.
In the Storage Manager utility.
Q The processes performed in the production of METAL PROD were
defined:
In the Machine Definition utility.
In the MRP utility.
In the Part Definition utility.
In the Storage Manager utility.
Q Using a process named TURN METAL, is METAL PROD to be
produced by the lathe or by the mill?
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Activity 15
Integrated Production OBJECTIVES In this activity you will accomplish the following: ♦ Understand how more than one machine is integrated into the
production cycle.
♦ Review the procedure for placing customer orders in the MRP utility. ♦ Run the production cycle for a new part for a new customer. ♦ Prepare to run the production cycle for a manufacturing order for two
different product parts.
SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Describe how the integration of two different CNC machines, enables the manufacture of a wider product range Describe how using different types of parts enables you to perform a variety of processes.
♦ Occupational and Technical:
Create a new manufacturing order that includes one part processed in the lathe and another part processed in the mill. Update the inventory of raw parts (type and quantity) in the storage device to correspond to the new manufacturing order.
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
Integrated Manufacturing Integrated manufacturing is the basic concept of CIM. Until now you have taken advantage of only a few of the capabilities of the CIM system. Now that you have added another production tool (a CNC lathe) to the basic CIM cell, you can make more extensive use of the CIM system. The integration of two different CNC machines (the mill and the lathe) enables the cell to manufacture a much wider range of products. The cell can now use different types of parts (rounded, square and so on) and can perform a variety of processing actions (milling, turning, and combinations thereof). In the previous activity you updated the part and machine definition of the basic CIM cell, in order to connect the new machine (lathe) to the production layout. In this activity you will activate production using the new machine, and then observe variations of the production cycle in the basic CIM cell. PROCEDURES Task 15-1: Setting the MRP Manufacturing Order You will now insert a new manufacturing order using the MRP utility program. This order will include one part processed in the lathe and another part processed in the mill. You will order parts that are already included in the parts list of the basic CIM cell. Q Which one of the following combinations could not be produced in the
framework of the production order described above?
1
WOOD PROD and METAL PROD.
BASE PROD and WOOD PROD.
BASE PROD and METAL PROD.
From your Windows Start menu, select OpenCIM | Project Manager . The CIM Project Manager window is displayed.
2
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From the Archive tab, select 102_ACT15, and then click Save as to save the project as 15 (for example, JOHN15) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
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3
From the User Projects tab, select this 15 project and then to activate the CIM Manager application for click CIM Manager this project. All the tasks described in this activity refer to this selected 15 project.
4
From the OpenCIM Manager window, select Utility Programs | MRP Utility in the. The Customer Order tab of the MRP window is displayed:
Figure 15-1: CIM MRP Window - Customer Order Tab
First you will add a new customer, for whom the METAL PROD part is to be ordered. 5
Click the New Customer button displayed.
. The new customer window is
Figure 15-2: New Customer Dialog Box 6
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Enter Customer3 in the Name field. 15-3
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7
Click the Save button. (Additional details are optional.)
8
Click the New Order button added to the window.
9
Click in the Customer field and select Customer3 from the dropdown list.
. A new Customer Order line is
Figure 15-3: CIM MRP Window – Selecting a Customer (Customer3)
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10 Click in the empty Part Name field and select METAL PROD from
the dropdown list.
Figure 15-4: CIM MRP Window – Selecting the Part to Order (METAL PROD)
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11 Enter the required data in the remaining fields, as follows:
Required Quantity: 1
Priority: 1
Due Date: 3
Figure 15-5: CIM MRP Window – Customer Order Details 12 Save the new line in the Customer Order by selecting File | Save
Order or by clicking the Save button. A confirmation message is displayed. 13 Click the OK button. An order of one METAL PROD part has been
added to the Customer Order for Customer3. 14 Click the Create MRP button. 15 When the popup message is displayed, click the OK button. Q As a result of the latest manufacturing order, the total parts ordered
for due date 3 are:
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Four BASE PROD parts, one WOOD PROD part and one METAL PROD part. One BASE PROD part, one WOOD PROD part and one METAL PROD part. Three BASE PROD parts, two WOOD PROD parts and one METAL PROD part. Two METAL PROD parts, two BASE PROD parts and one WOOD PROD part. 15-6
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16 Click the Manufacturing Order tab to view the order according to the
dates when the parts are required.
Figure 15-6: CIM MRP Window – Manufaturing Order Tab 17 Click on the section for the orders for Due Date 3. (The section will be
highlighted in green). 18 Click the Manufacturing Order button
to insert a manufacturing
order for the selected parts. 19 When the popup message is displayed, click OK.
You have now inserted three WOOD PROD parts into the production order. 20 Close the MRP window.
You are now ready to activate a production (simulation) cycle for the new manufacturing order, which contains:
1 BASE PROD
1 WOOD PROD
1 METAL PROD
The three parts will now be manufactured, but first you have to make sure that the required supplied parts are in the storage device.
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Task 15-2: Updating Storage In this task you will verify that the type and quantity of parts required to complete the manufacturing order are ready in the storage device. The storage device should contain at least the minimum quantity of parts required for production. The procedures for defining and updating storage settings are described in detail in the Storage Setup activity. 1
Select Utility Programs | Storage Manager. The CIM Storage Manager window is displayed.
Figure 15-7:CIM Storage Manager Window
Note: You can click the Initialize Storage button in the CIM Storage Manager window and then click Yes at the confirmation dialog box to reset the storage definition according to the changes in the CIM Setup. Do not click Reset Storage , since this configuration database file does not include the latest lathe machine that was added. Define your storage settings to match the contents detailed below. Refer to Activity 4: Storage Setup, for assistance. Storage Type ASRS1
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ID 206
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Part Name
Qty
BASE SUP
1
WOOD SUP
1
EMPTY
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Figure 15-8 shows the details in the CIM Storage Manager window.
Figure 15-8:CIM Storage Manager Window – Default Storage Settings Displayed
Before you can start production, you need to add another supplied part to the storage device. Q The supplied part you need to add to storage is:
2
BASE SUP
METAL SUP
WOOD SUP
Click the Add New Row to ASRS1 Block button added.
. A new row is
Figure 15-9:CIM Storage Manager Window – New Row Added to ASRS1 Block Activities Book 0503
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3
Click the new row and open the Part Name dropdown list.
Figure 15-10: CIM Storage Manager Window – Defining Storage Data 4
Select METAL SUP from the dropdown list.
5
Click the Save button
6
Click the Create Default Storage button to define the current contents of storage as the default storage setting.
7
When the popup message is displayed, click Yes.
8
Close the CIM Storage Manager window.
9
Close the OpenCIM Manager module.
to save the updated storage data.
Task 15-3: Team Discussion and Review In this activity you prepared the manufacturing order for a production cycle to be carried out by two machines. For this purpose, you ordered the parts named BASE PROD and WOOD PROD to be manufactured by the milling machine, and METAL PROD to be manufactured by the lathe. You also updated the inventory of raw parts in the storage to correspond to the new manufacturing order. In the next activity you will activate the production cycle according to the current manufacturing order. Throughout this cycle you will explore the system actions and understand their sequences. Q The current manufacturing order calls for the production of either:
one, two, three, or four different types of parts. The parts are to be manufactured by either: one, two, three, or four different machines in the CIM cell.
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Q The lathe in the CIM cell will be used to produce which part?
BASE PROD
METAL PROD
WOOD PROD
Q Match the product parts to the supplied parts from which they are
manufactured, the process that is performed on the part and the CNC machine performs the process.
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Product Part
Supplied Part
Process
Machine
WOOD PROD
BASE SUP / WOOD SUP / METAL SUP
MILL WOOD MILL BASE TURN METAL
MILL /LATHE
METAL PROD
BASE SUP / WOOD SUP / METAL SUP
MILL WOOD MILL BASE TURN METAL
MILL /LATHE
BASE PROD
BASE SUP / WOOD SUP / METAL SUP
MILL WOOD MILL BASE TURN METAL
MILL /LATHE
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Activity 16
Tracking Integrated Production OBJECTIVES In this activity you will accomplish the following: ♦ Understand the significance of the sequence of actions in an integrated
production cycle, ♦ Run the production cycle for a manufacturing order for two different product parts. ♦ Use the Gantt Scheduler utility to observe the sequence of actions in the production cycle and understand the criteria that determine the sequence of production. In the last activity you prepared the basic CIM cell for a manufacturing order that uses two machines (a mill and a lathe). In this activity you will activate this production cycle and identify the sequence of actions that the system performs to complete the current manufacturing order. The sequence of the actions can be observed from the Gantt Scheduler utility. Therefore this tool is used in this activity. SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Describe the significance of the sequence on actions in an integrated production cycle. Observe the sequence of actions in the integrated production cycle in terms of scheduling. ♦ Occupational and Technical: Activate and observe the manufacturing cycle for manufacturing three parts included in the manufacturing order. Increase the duration of one of the manufacturing processes and viewing the impact on the production sequence.
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
Determining the Sequence of Production The number of production scenarios grows with each part that is added to the manufacturing order. Hence, in the current manufacturing order, there are several possible sequences for retrieving the parts from the storage and for their manufacturing. The sequence of the production (meaning the order in which the various parts are manufactured in the machines) is defined in the production plan (i.e. Workplan or A-Plan). However, once various parts are under production, the sequences may be more random due to occupied devices. The order of retrieval may be changed in order to optimize the production time. As you learned when exploring system optimization, you know that one sequence of production can be shorter than another sequence of production while both include the same parts.
Bottlenecks and System Optimization It is clear from what you have just observed that the system is not fully optimized. It is obvious that you could use shorter slacks between completing the manufacture of the one part and beginning another. The slack between completion of WOOD PROD and the start of MILL PROD is longer than necessary, taking into consideration the fact that the mill becomes free immediately upon removal of WOOD PROD. Why does this happen? In this production cycle, it is the result of a bottleneck at Station 2. A bottleneck occurs when a greater number of parts or templates arrive at a given station than that station can handle at that given time. Since bottlenecks inevitably result in a suspension in the production and a subsequent increase in the duration of the overall manufacturing cycle, every effort is made to eliminate the bottlenecks in the production system. In this case, the buffer causes a bottleneck. The bottleneck can be solved, as described in Activity 17, Improving System Performance.
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PROCEDURES Task 16-1: Tracking the Sequence of Production You will now monitor the production cycle, paying special attention to the sequence of production. In this task, you will activate and observe the production cycle for manufacturing the three parts included in the Manufacturing Order. 1
From your Windows Start menu, select OpenCIM | Project Manager . The CIM Project Manager window is displayed.
2
From the Archive tab, select 102_ACT16, and then click Save as to save the project as 16 (for example, JOHN16) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 16 project and then click CIM Manager to activate the CIM Manager application for this project. All the tasks described in this activity refer to this selected 16 project.
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4
From the OpenCIM Manager window, click the Start button on the toolbar to initiate the cycle.
5
When you are prompted to refresh storage, click OK.
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6 Verify that the three products you ordered are listed in the Order View
BASE PROD
WOOD PROD
METAL PROD
The Order View
Figure 16-1:OpenCIM Manager Window - Order View
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7
Select Utility Programs | Scheduler Gantt. The CIM Scheduler Browser window is displayed:
Figure 16-2: CIM Schedular Browser Window – Before Proceeding
Notes: Verify that the Duration checkboxes are deselected before proceeding. You can click the Sort by Part Sort By Machine required.
button or
button on the toolbar to display the data as
You will now follow the progress of the production cycle. Before you start, note the following factors to which you should pay special attention:
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During the production cycle, the mill and the lathe sometimes work in parallel; one part is being manufactured in one machine while the other machine is manufacturing another part. If the buffer in station 2 is filled with templates, the station is locked; hence no new part can be taken into the station until a manufactured part is sent out of the station. The sooner you begin the longest process, the sooner the production cycle can be completed. For this reason, the first part retrieved from the storage is the part with the longest process duration. Therefore, METAL PROD is the first part selected. (The process duration of the METAL PROD was set to 01:50 minutes). The system automatically makes this selection in order to achieve more efficient division of time across the production cycle.
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Q The first part to be produced is the one with the longest process
duration. This is so that:
Production will be finished in the minimum time possible.
It will be the first part completed.
Other ordered parts will not be delayed.
Other parts ordered will be finished first.
8
To start the simulation of the production cycle, click the Run button from the OpenCIM toolbar . The system is now activated.
9
Observe the progress of the production cycle in both the Scheduler Browser window and the graphic Viewing Area. Take into consideration the previously raised points.
10 Find the correlation between the processes in the machines and the
time readings in the Scheduler Browser window. 11 Wait until the popup window is displayed indicating that the all three
products have been finished and the order is complete. Then close the Messages window.
Figure 16-3:Messages Window – Order is Completed 12 Click the Abort button.
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View the production details in the Scheduler Browser window.
Figure 16-4: CIM Schedular Browser Window – Production Progress Q The data in the Scheduler Browser window indicates that which two of
the following statements are true?
BASE PROD is manufactured in parallel to the WOOD PROD.
BASE PROD is manufactured in parallel to the METAL PROD.
WOOD PROD is manufactured in parallel to METAL PROD.
WOOD PROD and BASE PROD are manufactured one after the other. WOOD PROD and METAL PROD are manufactured at the same time on the same machine.
Q The reason for not manufacturing both BASE PROD and WOOD
PROD in parallel to METAL PROD is that:
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The manufacturing duration of WOOD PROD is longer than BASE PROD. The manufacturing duration of METAL PROD is not long enough. The buffer in station 2 is full; hence BASE PROD cannot be taken into the station. The buffer is full; hence METAL PROD cannot be removed from the station.
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Task 16-2: Tracking the Sequence of Production with Updated Process Durations Your next task is to increase the duration of one of the manufacturing processes and identify its impact on the sequence of production. In this task you will define the duration of the MILL BASE process as 03:10 minutes (instead of 10 sec) and you will observe the system's response to this change. 1
From the OpenCIM Manager window, select Utility Programs | Machine Definition. The CIM Machine Definition window is displayed.
Figure 16-5: CIM Machine Definition Window
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2
In the MILL BASE row, double-click in the Duration field and change the duration to 00 03 10.
3
Click the Save button to save the new duration.
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4
When the popup message is displayed, click OK. The Machine Definition window should now contain the following details: Machine Name Mill1 PLT3000_1
Process
Duration
MILL BASE
00:03:10
MILL WOOD
00:00:50
TURN METAL
00:01:50
Figure 16-6: CIM Machine Definition Window – New Duration Time for MILL BASE Q Which process now has the longest duration?
TURN METAL
MILL BASE
MILL WOOD
Q Which process now has the shortest duration?
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TURN METAL
MILL BASE
MILL WOOD
5
Close the Machine Definition window.
6
To initiate the cycle, click the Start button from the OpenCIM toolbar.
7
When you are prompted to refresh storage, click OK.
8
To start the simulation of the production cycle, click the Run button from the OpenCIM toolbar.
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9
Observe the progress of the production cycle in both the Scheduler Browser window and the graphic Viewing Area.
10 Find the correlation between the processes in the machines and the
time readings in the Scheduler Browser window. 11 Wait until the popup message is displayed indicating that the cycle is
complete. 12 Click the Abort button 13 View the production details in the Scheduler Browser window.
Figure 16-7: CIM Schedular Browser Window – Production Progress with Updated Durations
The data in the Scheduler Browser window indicates that:
The production of the part BASE PROD started first. METAL PROD is the second part to be produced. Its production starts (in the lathe, meaning the PLT3000) while the production of BASE PROD (in the mill) is still in progress. WOOD PROD is the last part to be produced. It is produced after BASE PROD and METAL PROD are complete. WOOD PROD has the shortest process duration.
14 Close the CIM Scheduler Browser window. 15 Close the OpenCIM Manager module.
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Task16-3: Team Discussion and Review In this activity you saw that the system performs basic calculations to optimize production. One of the results you observed is that the first part that was sent to production is the one with the longest manufacturing duration. The objective is to start the longest process as early as possible in order to finish production in the shortest overall time possible. Once processing of the first part is underway, the system proceeds to retrieve additional parts and handles them according to their respective processing duration. Nonetheless, the result is not always the optimum. For example, you can see from the last two tasks that one part was produced outside the time range of the first two parts; meaning, only after the first two parts had already been completed. In an optimized system you would want to see the production of WOOD PROD begin in the mill while METAL PROD was being produced in the lathe, thereby saving the extra time spent on the last part. However this was not possible due to the limitations of the buffer at Station 2. In the next activity you will discuss ways to make the system more efficient in its production of the current manufacturing order. Q Is there only one possible production scenario for a specific
manufacturing order? Q Does the number of possible production scenarios depend on the
number of parts included in the manufacturing order? Q Do bottlenecks typically decrease or increase the duration of the
overall manufacturing cycle? Q In the production cycle observed in this activity, a bottleneck
occurred:
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In the storage device.
In the milling machine
In the buffer at Station 2.
In the lathe.
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Activity 17
Improving System Performance OBJECTIVES In this activity you will accomplish the following: ♦ Understand the importance of the sequence of actions in the
production flow.
♦ Identify and implement potential solutions to bottlenecks in the
production flow.
♦ Use the setup program to add a buffer to a workstation in the CIM cell. ♦ Observe the changes in the sequence of actions in the production cycle
that result from the addition of the buffer.
In the previous activity you saw that the sequence of actions during the production cycle was not fully optimized. You saw that one of the reasons for this is the fact that the buffer in Station 2 is creating a bottleneck in the flow of the current production order for BASE PROD, WOOD PROD and METAL PROD. In this activity you will explore one of the methods used to overcome this problem and improve system performance. You will use the manufacturing order from the previous activity as a working example. SKILLS In this activity you will develop the following skills: ♦ Academic and Employability:
Describe the various methods used to improve system performance
♦ Occupational and Technical:
Adding a buffer to Station 2 Observing the system's performance using the additional buffer from the graphic Viewing Area and the CIM Schedular
MATERIALS In this activity you will need the following materials: ♦ A PC with OpenCIM software installed ♦ Worksheets for this Activity
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OVERVIEW
Improving System Performance There are several ways to improve system performance, including: ♦ Adding another workstation to the CIM cell (such as another conveyor
station or robotic arm), enabling you to move one of the CNC machines from Station 2 to the new station. The workload of Station 2 would then be divided with the new station.
♦ Adding a palletizing rack in Station 2. The finished parts will be stored
there instead of being returned to the ASRS. With this improvement, you save the waiting time of the template in the station. After the part is unloaded from the template to the machine, the template can be removed from the buffer, leaving the location free for other parts.
♦ Enlarging the capacity of the buffer: As already mentioned, the capacity of
a buffer in the system does not necessarily have to be limited to two templates. The OpenCIM software can manage buffers with greater capacities. You can enlarge the buffer capacity to hold more than two templates at a time, thus improving system performance.
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PROCEDURES Task 17-1: Enlarging the Buffer Capacity In this task you will optimize the system by enlarging the buffer capacity in station 2. This is one of the easiest ways to improve system performance with a minimum of actions. ¾ Warning! You are about to enter the Setup application. Pay special attention not to move or to change anything in the system that is not specifically indicated in the project task instructions. 1
From your Windows Start menu, select OpenCIM | Project Manager
2
. The CIM Project Manager window is displayed.
From the Archive tab, select 102_ACT17, and then click Save as to save the project as 17 (for example, JOHN17) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 17 project and then click CIM Setup to activate the Virtual CIM Setup application for this project. All the tasks described in this activity refer to this selected 17 project. The Virtual CIM Setup window is displayed.
Figure 17-1: Virtual CIM Setup Window
Note: If the viewing angle differs from the one shown here, click the Top View the image.
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button to place the camera at the top of the cell at the center of
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4
Click the New Object icon.
The New Objects window is displayed.
Figure 17-2: New Objects Window 5
Double-click Storage in the New Objects window. A list of the storage items is displayed.
Figure 17-3: New Objects Window - Storage Items 6
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Select Buffer 2 from the list and click the OK button. A placement cursor is displayed.
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7
Place the cursor directly below the CNC machines and to the left of the computer stations.
Figure 17-4: Virtual CIM Setup Window – Defining Location for Buffer
The buffer image is added to the cell (in front of station 2).
Figure 17-5: Virtual CIM Setup Window – Buffer Added to CIM Cell
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8 Click the Cancel button to close the New Object window.
Figure 17-6: Virtual CIM Setup Window – Closing New Objects Window
Double-click the robot in Station 2 and select Show Envelope from the popup menu. An outline of the robot’s work envelope is displayed.
Figure 17-7: Virtual CIM Setup Window – Robot's Work Envelope Displayed
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Place the hand-shaped cursor on the new buffer image and drag the image into the robot’s work envelope.
Figure 17-8: Virtual CIM Setup Window – Dragging Buffer Image into Work Envelope 10 Double-click the new buffer image and select Connectivity from the
popup menu. The Connections window for BFFR2 is displayed.
Figure 17-9: Connections Window – Buffer's Possible Connections 11 Select ROBOT2 in the Possible Connections list and click the Add
button.
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12 Verify that ROBOT2 is now displayed in the Active Connections list.
Figure 17-10: Connections Window – Buffer's Active Connections 13 Click the OK button.
Figure 17-11: Virtual CIM Setup Window – Red Line Indicating Buffer is Connected to Robot
A red line is displayed in the Virtual CIM Setup window indicating the connection(s) of the new buffer; in other words, the accessibility of the robot to the new buffer is now defined.
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14 Click the Save button.
To apply the changes and enable use of the additional buffer during production, you must recreate the setup file. 15 Select Create | Setup File. A confirmation message is displayed:
Figure 17-12: Virtual Setup Confirmation Window 16 Click the OK button. An additional confirmation message is displayed:
Figure 17-13: Virtual Setup Confirmation Window 17 Click the OK button. The setup file of the CIM cell is overwritten and
the modifications made in this activity will be reflected in the CIM cell the next time you open the OpenCIM Manager.
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Task 17-2: Observing System Performance with the Additional Buffer Now that you have modified the system structure by adding another buffer to station 2, you will observe the resulting change in the production cycle to verify that system performance has improved. Since the storage is erased whenever the setup file is modified, you need to reload the required supplied parts for the production into the storage device before you can run the production cycle. 1
From your Windows Start menu, select OpenCIM | Project Manager
. The CIM Project Manager window is displayed.
2
From the Archive tab, select 102_ACT17, and then click Save as to save the project as 17 (for example, JOHN17) in the User Projects tab, as described in Activity 2, Task 2-1: Accessing Working Cells from the Project Manager.
3
From the User Projects tab, select this 17 project and then click CIM Manager to activate the CIM Manager application for this project. All the tasks described in this activity refer to this selected 17 project.
4
From the OpenCIM window, select Utility Programs | Storage Manager. The CIM Storage Manager window is displayed.
Figure 17-14: CIM Storage Manager Window
Note: If the storage manager was not initialized you can click the Initialize Storage button
and then click Yes at the confirmation
dialog box to initialize the storage. Do not click Reset Storage , since this configuration database file does not include the latest lathe machine that was added.
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Using the Add New Row To ASRS button parts to storage:
BASE SUP
WOOD SUP
METAL SUP
, add the following
The storage settings should now include the parts shown in the table below. (Their order in the list is not important.) Storage Type ASRS1
ID 206
Part Name
Quantity
EMPTY
33
BASE SUP
1
WOOD SUP
1
METAL SUP
1
Figure 17-15: CIM Storage Manager Window – Updated Storage Data
Important: Make sure that your storage settings match the contents shown. If they do not match, add any missing supplied parts before continuing with this procedure. Refer to the Storage Setup activity for assistance. 6
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Click the Save button to save the updated storage data.
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Click the Create Default Storage button to define the current contents of storage as the default storage setting, and then click Yes at the confirmation message.
8
Close the Storage Manager window. Now that the storage settings include the required parts, you can proceed to run the production cycle
9
To initiate the cycle, click the Start toolbar.
button from the OpenCIM
10 If you are prompted to refresh storage, click OK. 11 Select Utility Programs | Scheduler Gantt. The CIM Scheduler
Browser window is displayed.
Figure 17-16: CIM Schedular Window – Before Proceeding
Note: You must verify that the Duration checkboxes are deselected before proceeding. 12 To start simulation of the production cycle, click the Run button
from the OpenCIM toolbar.
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13 Observe the progress of the production cycle in both the Scheduler
Browser window and the graphic Viewing Area. Find the correlation between the processes in the machines and the time readings in the Scheduler Browser window. Wait until the popup message is displayed indicating that the cycle is complete.
Figure 17-17: CIM Schedular Window – New Production Progress With Buffer
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14 Compare the schedule with the one received in the previous activity for
the same order of parts, but based on the previous system setup.
Figure 17-18: CIM Schedular Window – Previous Production Progress Without Buffer
Task 17-3: Team Discussion and Review Q Enlarging the buffer capacity can improve system performance
because:
Larger templates can be used in the production.
The robot working area in Station 2 will be expanded.
The parts will be placed into the station with fewer delays.
Q Can adding another workstation to the CIM cell help optimize system
performance? Q Can adding a palletizing rack in Station 2 increase the buffer capacity
of the station? Answer the following questions based on the data in the two schedulers (one from the current production and one from the previous production): Q Is the current production schedule more efficient than the previous one? Q Does it take less time to produce each part in the current production
schedule? Q Is the waiting time of each part is the same in both production
schedules? Q Does the previous production schedule take longer than the current one?
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Q Compare the time durations of the parts processes in the two
production cycles. Which of the following statements is false:
The waiting (delay) time of the WOOD PROD in the current schedule is two minutes shorter than in previous schedule. The sequence of production is maintained in both schedules and the first part to be retrieved from storage is BASE PROD. The waiting time of WOOD PROD is 1 minute shorter in the current production schedule than in the previous one.
In this activity you demonstrated one of the many ways in which it is possible to improve the system performance. You saw an example of how system optimization enables the reduction of production time, thus improving efficiency and lowering production costs. Normally, the manufacturing system is optimized during its design and engineering phase to gives its best performance. However, changes in an existing system may be required, for example, due to the changing needs of customers) and these changes bring with them a need for renewed optimization of system performance.
Conclusion This activity marks completion of the first Computer Integrated Manufacturing module. In this module you have learned about the basic concepts and components of CIM using a basic CIM system that included two workstations. You have learned to use OpenCIM software to simulate the basic CIM system, using various viewing options to observe the progress of the production cycle. You have identified the key factors in CIM cell design and have learned to add machines, processes and parts to the basic CIM cell to accommodate changing manufacturing needs. In future CIM modules, you will learn about additional CIM components and setup and operate CIM cells that contain three to four workstations. The next module will further explore the potential for expanding the system to improve production capabilities.
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