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Jack H.Integration and automation of manufacturing systems.2001.pdf

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page 502

18. INTEGRATION ISSUES

18.1 CORPORATE STRUCTURES

•First consider the major functions within a company,

-Production

-Materials

-Process Planning

-Design

-Customer Orders / Service

-Marketing

-Accounting

-Management

•All of these functions generate and use common information which must be communicated between departments.

•Since computers handle information, we must be aware of what we get, and what we pro-

duce.

18.2 CORPORATE COMMUNICATIONS

•Previous paper based systems provided support for data transfer between departments, and provided a good basis for the introduction of computers

•ASIDE: Computers can make a good system better, but they will always make a bad system worse. This is because a system which is not well defined and poorly understood cannot be programmed, or optimized.

•Characteristics of paper based manufacturing systems,

page 503

-Multiple copies of same information.

-Revising information is hard when multiple copies exist.

-Delays for the transfer of paper.

-Easy to lose paper.

-Paper is not interactive.

-Paper requires bulky storage.

•Computers overcome and reduce the problems above, but introduce some technological challenges,

-Creating programs to support corporate functions.

-Software to support interdepartmental communication and data sharing.

-Hardware to support the software.

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??? - [source flow information the and

-com manufacturing large a for structure system computer hierarchy functional Assumed •

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tory

Requirements•

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page 506

plex [source - find]

Management

Plant

Data

Management

Level4

Presentation

Information

Operational and

Plant Production

Scheduling and

Production

Operational

Supervision

Management

Supervisor’s

Inter-area

Level3

Coordination

Console

(Shop coordination)


	Supervisor’s	Work Cell
Level2	Supervisor’s	(Direct Numerical
	Console	(Direct Numerical
		Control)


Operator’s		Work Station
Operator’s		(Computerized
Console		(Computerized
Console	numerical Control)
	numerical Control)

Level 1

Dedicated

Programmable

Logic Controllers

PROCESS

Sales	Orders
Communications	with other areas
Communications	with other	supervisory systems
Communications	with other	control systems

page 507

• Report interfacing to corporate management and staff functional entities from the factory

ACCT

Cost

reporting

operational

performance

Policies

Human

RES

Manpower

performance

data and reqmts

CORP

MGMT

Corporate

Performance

MKTG

RD&E and

SALES

Requests for Status of

information, Production

plant tests orders

FACTORY LEVEL 0.0

External

Entities

PURCH

raw material, energy

and spare parts

orders

[source - find]

page 508

• The Shop Floor Production Model (SFPM):

[ source - find]

	Level	Sub-Activity	Responsibility

		Supervise shop	Supervising and coordinating
4	Section/	floor production process	the production and supporting the
	Area		jobs and obtaining and allocating
			resources to the jobs.

		Coordinate shop	Sequencing and supervising
3	Cell	floor production	the jobs at the shop floor produc-
		process	tion process

		Command shop	Directing and coordinating the
2	Station	floor production process	shop floor production process

		Execute shop floor	Executing the job of shop
1	Equipment	production process	floor production according to com-
			mands

The ISO Reference Model for Factory Automation adds a couple of layers

[ source - find]

Level/	Area of Con-	Responsibility	Basic Functions
Hierarchy	trol

6 /	Managing the	Achieving the	Corporate management
Enterprise	corporation	enterprise’s mission	Finance
		and managing the	Marketing and sales
		corporation	Research and Development

page 509

Level/	Area of Con-	Responsibility	Basic Functions
Hierarchy	trol

5 /	Planning Pro-	Implementing	Product design and production
Facility or	duction	the enterprise func-	engineering
plant		tions and planning	Production management (upper
		and scheduling pro-	level)
		duction	Resource management (upper
			level)
			Procurement (upper level)
			Maintenance management
			(upper level)

4 /	Allocating and	Coordinating	Production management (lower
Section or	supervising materi-	production and	level)
area	als and resources	obtaining and allocat-	Procurement (lower level)
		ing resources to jobs	Resource management (lower
			level)
			Maintenance management
			(lower level)
			Shipping
			Waste material treatment

3 / Cell	Coordinating	Sequencing and	Shop floor production (cell level)
	multiple machines	supervising shop
	and operations	floor jobs and super-
		vising various sup-
		porting services

2 / Station	commanding	Directing and	Shop floor production (station
	machine sequences	coordinating the	level)
	and motion	activity of the shop
		floor equipment

page 510

Level/	Area of Con-	Responsibility	Basic Functions
Hierarchy	trol

1 / Equip-	Activating	Taking action on	Shop floor production (equip-
ment	sequences and	commands to the	ment level)
	motion	shop floor equipment

page 511

• A LAN (Computer Network) Hierarchy for Shop Floor Control [source - find]

E n te rp ris e L A N

L e v e l 6 :

E n te rp rise

L e v e l 5 :

F a c to ry B a c k b o n e L A N

F a c ility o r P la n t

S e c tio n

C o n tro lle r A

C o n tro lle r B

C o n tro lle r C

s im ila r to A

sim ila r to A

L e v e l 4 :

S e c tio n A L A N

S e c tio n o r A re a

C e ll

C o n tro lle r A

C o n tro lle r B

L e v e l 3 :

C e ll A L A N

C e ll B L A N

C e ll

L e v e l 2 : S ta tio n

L e v e l 1 :

E q u ip m e n t

D e v ic e	D e v ic e	D e v ic e	D e v ic e
C o n tro lle r A	C o n tro lle r B	C o n tro lle r A	C o n tro lle r B

D e v ic e

page 512

• Typical Architecture for Manufacturing Components [ update]

Item	Equipment	Workstation	Cell

EXAM-	Lathe, Mill, T-10	Robot tended	Variable Mission
PLES	Bridgeport Series I	Machine Center, Car-	System, Several Inte-
	IBM 7545 Robot	trac Material Handling	grated workstations
Hardware		System

	Mark Century	Allen-Bradley	Windows NT,
Controller	2000, Accuramatic	PLC-5, IBM-PC, etc.	SUN workstation, etc.
Hardware	9000, Custom-single-
	board system.

Type Con-	Single-board pro-	PLC, PC, Mini-	PC, Microcom-
troller	cessors, Machine tool	computer	puter, Super-MiniCom-
	controller, Servo-Con-		puter
	troller, etc

Language	Assembler, Part	C, Ladder logic,	C, LISP, FOR-
Application	programming, Robot	Pascal and other	TRAN, and other high
	programming, etc.	sequential languages	level languages

Memory/	8k-128k RAM	32M RAM, >1M	128M RAM,
Size Require-	plus custom ROM,	Hard Drive	>1Gigabyte Hard drive
ments	EPROM, etc.

Response	< 10-3 sec	< 1 sec	< 20 sec
Time

Machines/	1-1 connect	1-many	1-many
Interconnects		1-[1,8] Machine	1-[1-15] worksta-
		tools,	tions
		1-[1-50] Material
		handling

page 513

• Functional Breakdown of Control Architecture

	Equipment	Workstation	Cell

Planning	Tool selection, parame-	•Resource allocation	Batching, Workload
	ter specification, tool path	jobs	balancing between worksta-
	refinement, GMT code, tool	•Batch splitting and	tions, Requirements planning
	assignment to slots, job setup	equipment load balancing	Task allocation to
	planning		workstations
Planning	Milliseconds - Minutes	Minutes - Hours/Days	Hours - Days/weeks
Horizon

Schedul-	•Operation sequencing	•Sequence equipment	•Assignment of due
ing	at individual equipment	level subsystems	dates to individual worksta-
		•Deadlock detection	tions
		and avoidance	•Look ahead ES/simu-
		•Gantt chart or E.S.	lation based scheduling
		based scheduling	•Optimization based
		•Buffer management	tech
			•Batch sequencing

Control	•Interface to worksta-	•Monitor equipment	Organizational control
	tion controller	states and execute part and	of workstations, Interface
	•Physical control	information flow actions	with MPS, generation of
	(motion control at NC and	based on states	reports, etc.
	robot pick and place level)	•Synchronize actions
	•Execution of control	between equipment (eg.
	programs (APT, AML, etc.)	robot & machine while load-
		ing/unloading parts)
		• Ladder logic execu-
		tion

• In all of these models we must consider the value of the information being passed. At the low level control stages, information that is more than a few seconds old may be completely

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