1.1 INTRODUCTION

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An integrated system requires that there be two or more computers connected to pass information. A simple example is a robot controller and a programmable logic controller working together in a single machine. A complex example is an entire manufacturing plant with hundreds of workstations connected to a central database. The database is used to distribute work instructions, job routing data and to store quality control test results. In all cases the major issue is connecting devices for the purposes of transmitting data.

Automated equipment and systems don't require human effort or direction. Although this does not require a computer based solution

Automated systems benefit from some level of integration

1.1.1 Why Integrate?

There is a tendency to look at computer based solutions as inherently superior. This is an assumption that an engineer cannot afford to entertain. Some of the factors that justify an integrated system are listed below.

a large organization where interdepartmental communication is a problem

the need to monitor processes

Things to Avoid when making a decision for integration and automation,

- ignore impact on upstream and downstream operations

- allow the system to become the driving force in strategy

- believe the vendor will solve the problem

- base decisions solely on financials

- ignore employee input to the process

- try to implement all at once (if possible)

Justification of integration and automation,

- consider "BIG" picture

- determine key problems that must be solved

- highlight areas that will be impacted in enterprise

- determine kind of flexibility needed

- determine what kind of integration to use

- look at FMS impacts

- consider implementation cost based on above

Factors to consider in integration decision,

- volume of product

- previous experience of company with FMS

- product mix

- scheduling / production mixes

- extent of information system usage in organization (eg. MRP)

- use of CAD/CAM at the front end.

- availability of process planning and process data

* Process planning is only part of CIM, and cannot stand alone.

1.1.2 Why Automate?

Why ? - In many cases there are valid reasons for assisting humans

- tedious work -- consistency required

- dangerous

- tasks are beyond normal human abilities (e.g., weight, time, size, etc)

- economics

When?

Figure 1.1 - Automation Tradeoffs

Advantages of Automated Manufacturing,

- improved work flow

- reduced handling

- simplification of production

- reduced lead time

- increased moral in workers (after a wise implementation)

- more responsive to quality, and other problems

- etc.

Various measures of flexibility,

- Able to deal with slightly, or greatly mixed parts.

- Variations allowed in parts mix

- Routing flexibility to alternate machines

- Volume flexibility

- Design change flexibility