Capc & computer monitoring

ME 2402 – COMPUTER INTEGRATED
MANUFACTURING (CIM)
YEAR/SEMESTER : IV/VII
UNIT V COMPUTER AIDED PLANNING AND CONTROL AND COMPUTER
MONITORING
Prepared By
MANIMARAN.M
ASSISTANT PROFESSOR
K.RAMAKRISHNAN COLLEGE OF ENGINEERING
TRICHY
1/25/2016 1
MANIMARAN M 8115 KRCE TRICHY

UNIT V COMPUTER AIDED PLANNING AND CONTROL
AND COMPUTER MONITORING
Production planning and control – cost planning and control –
inventory management – material requirements planning (MRP) –
shop floor control. Lean and Agile Manufacturing. Types of
production monitoring systems – structure model of manufacturing
– process control and strategies – direct digital control
1/25/2016 MANIMARAN M 8115 KRCE TRICHY 2

Production planning and control (PPC)
It may be defined as the direction and coordination of firm’s material and
physical facilities towards the attainment of pre-specified production of
goods with highest production of efficiency
PPC = production planning +production control

Production planning
It is a pre-production activity. It is defined as the determination,
acquisition and arrangement of all facilities necessary for future
production of products
Activities of production planning
• Aggregate production planning
• Master production planning
• Master requirements planning
• Capacity planning

Production control
It is concerned with determining whether the necessary resources to
implement the production plan have been provided or not
Activities of production control
• Shop floor control
• Inventory control
• Manufacturing resource planning (MRP II)
• Just in time (JIT) production system

ACTIVITIES IN A PPC (FUNCTIONS OF PPC)
Aggregate production planning
• Aggregate planning is a high-level corporate planning activity.
• Aggregate planning plan must be coordinated with the plans of
the sales and marketing departments. (inventory, employment
and subcontracting)

ACTIVITIES OF PPC
MASTER PRODUCTION SCHEDULE
• Aggregate production planning must be converted into master
production schedule (MPS)
• It is a listing of the products to be manufactured, when they are
to be delivered, and in what quantities
• It is developed from customer order and forecasts of the future

ACTIVITIES OF PPC
MATERIAL REQUIREMENT PLANNING
• Material requirements planning (MRP) is a computational technique
that converts the master schedule for final products into a detailed
schedule for the raw materials and components used in the final
products.
CAPACITY PLANNING
• Capacity planning is concerned with determining what labor and
equipment resources are required to meet the current MPS as well as
long-term future production.

ACTIVITIES OF PPC
SHOP FLOOR CONTROL
A shop floor control system is defined as a system for utilizing data
from as well as data processing files to maintain and communicate
information on shop orders and work centers. It also known as
Production Activity Control (PAC).
INVENTORY CONTROL
• Minimize the cost of holding inventory( investment, storage
and spoilage )
• Maximize customers service.

ACTIVITIES OF PPC
MANUFACTURING RESOURCE PLANNING (MRP II)
• It combines MRP and capacity planning as well as shop floor control and other
functions related to PPC
• It can be defined as a computer-based system for planning, scheduling, and controlling
the materials, resources, and supporting activities needed to meet the Master
production schedule
JUST-IN-TIME PRODUCTION SYSTEM
It is a management philosophy that strives to eliminate source of manufacturing waste
by producing the right part in the right place at the right time.

MATERIAL REQUIREMENTS PLANNING (MRP)
Material requirements planning (MRP) is a computational technique that
converts the master schedule for final products into a detailed schedule for
the raw materials and components used in the final products.
Inputs of MRP
1. Master production schedule (MPS)
2. Bill of materials file and
3. Inventory record file

MATERIAL REQUIREMENTS PLANNING (MRP)

1.MASTER PRODUCTION SCHEDULE (MPS)
The production quantities of the major product lines listed in the aggregate plan
must the converted into a very specific schedule of individual products, known as
the master production schedule (MPS).
Master production schedule (MPS) is a detailed plan that how many final product
will be available for sale during specific periods.
Inputs to MPS
1. Market requirements
2. Production plan from aggregate planning
3. Resource available

2.Bill of materials
The bill of materials (BOM) file is used to compute the raw material and
component requirements for end products listed in the master schedule.

3. INVENTORY RECORD FILE
Item master data This provides the item's identification (part number) and
other data about the part such as order quantity and lead times.
Inventory status This gives a time-phased record of inventory status.
Subsidiary data It provides subsidiary data such as purchase orders, scrap
or rejects, and engineering changes.

Benefits of MRP
 Reduced inventory levels
 Better production scheduling
 Reduced production lead time
 Reduced setup cost
 Better machine utilization
 Improved product quality
 Quicker response to changes in demand

COST PLANNING AND CONTROL
Cost planning and control system consist of the database to determine the
expected costs of manufacture each products of the company
• Cost estimating is the process of determining the probable cost of the
product before the start of the product and before the start of its
manufacture.
• Cost accounting is the determination of an actual cost of a component after
adding different expenses in various departments.

REQUIREMENTS FOR COST ESTIMATING
 General design specification of product (function, performance and
purpose)
 Assembly or layout drawings
 Subassemblies of the product
 Detail drawings and bill of materials for the product
 Test and equipment procedures and equipment
 Machine tool and equipment requirement
 Packaging and transportation requirements
 Standard time data
 Material release data
 Operation analysis and workplace studies

INVENTORY MANAGEMENT
It may be defined as the scientific method of determining what to order, when to
order and how much to order and how much to stock so that costs associated with
buying and storing are optimal without interrupting production and sales.
Objectives of inventory control
• To ensure the continuous supply
• To maintain the overall investment
• To minimize the holding, storage and replacement cost
• To avoid over and under stocking

INVENTORY COST
1. Ordering costs
 Cost of staff purchase dept.
 Cost of stationary
 Inspection cost of incoming materials
2. Holding costs
 Cost of storage facilities
 Handling cost
 Costs of record keeping
3. Shortage cost and
 Loss of future sales
 Loss of goodwill
4. Purchase cost
 Price paid to labour, material and overhead charge

Economic order quantity (EOQ)
Economic ordering quantity (EOQ) is that size of order which minimizes
the total cost of carrying inventory and ordering.

TYPES OF INVENTORY SYSTEM
1. Fixed-order quantity models (Q-models)
1. Re-order quantity (how much to order)
2. Re-order level (when to order)

TYPES OF INVENTORY SYSTEM
2.Fixed-time periods models (p-models)

• It combines MRP and capacity planning as well as shop floor control and
other functions related to PPC
• It can be defined as a computer-based system for planning, scheduling, and
controlling the materials, resources, and supporting activities needed to
meet the Master production schedule

• Management planning. Business strategy, aggregate production planning,
master production scheduling, rough-cut capacity planning and budget
planning
• Customer service. Sales for recasting, order entry, sales analysis, and finished
goods inventory.
• Operations planning. This is the MRP module. enhanced with capacity
requirements planning. The output consists of purchase order and work order
releases.
• Operations execution. This includes purchasing, production scheduling and
control, WIP inventory control, shop floor control. and labor hour tracking.
• Financial functions These include cost accounting, accounts receivable,
account, payable, general ledger. and payroll.1/25/2016 MANIMARAN M 8115 KRCE TRICHY 27

Commercial software for MRP II
 Enterprise Resource Planning (ERP)
 Customer-oriented Manufacturing Management Systems (COMMS)
 Manufacturing Execution System
 Customer-oriented Management Systems (COMS)

JUST-IN-TIME PRODUCTION SYSTEMS
Just-In-Time (JIT) is a management philosophy that strives to eliminate
sources of manufacturing waste by producing the right part in the right
place at the right time. JIT also known as stockless production.
objectives of JIT
1. Zero defects 2. Zero setup time
3. Zero inventories 4. Zero handling
5. Zero breakdowns 6. Zero lead time
7. Lot of size one.

Elements of JIT
 Eliminate setup times
 Reducing manufacturing and purchasing lot sizes
 Reducing production and delivery lead times
 Preventive maintenance
 Stabilize and level the production schedule with uniform plant loading
 Flexible workforce
 Small unit conveyance

Kanban production system
• Production Kanban (P-Kanban)
It signals the need to produce more parts
• Transport Kanban (T-Kanban)
It signals the need to deliver more parts to the next work center
Pull system
product is made-to-order
Push system
the product is made-to-stock1/25/2016 MANIMARAN M 8115 KRCE TRICHY 31

Benefits of JIT
 Lower inventory cost
 Lower scrap and waste cost
 Improved quality and zero defect products
 Improved worker involvement
 Higher motivation and morale
 Increased productivity
 Reduced manufacturing lead time1/25/2016 MANIMARAN M 8115 KRCE TRICHY 32

LEAN PRODUCTION
 Lean manufacturing may be defined as an adaption of mass production in
which workers and work Cells are made more flexible and efficient by
adapting method that reduce waste in all form.
 “more and more with less and less-less human effort, less equipment, less
time, and less space-while coming closer and closer to providing customers
with exactly what they want“
 Lean manufacturing is a set of tools and methodologies that aims for the
continuous elimination of all wastes in the production process1/25/2016 MANIMARAN M 8115 KRCE TRICHY 33

LEAN PRODUCTION
Lean production is based on four principles
1. minimize waste
2. perfect first-time quality
3. flexible production lines
4. continuous improvement

LEAN MANUFACTURING CONCEPTS
 Value creation and waste
 Main kinds of waste
 Pull production
 Continuous flow
 Continuous improvement
 Worker improvement
 Standard work1/25/2016 MANIMARAN M 8115 KRCE TRICHY 35

Mass Production vs Lean Production
S.No Mass Production Lean Production
1 Inventory Buffers Minimum waste
Minimum inventory
2 Just in-case deliveries Just in-time deliveries
3 Acceptable quality level Perfect first time quality
4 Taylor made to production Worker teams
Worker involvement

AGILE MANUFACTURING
Agile manufacturing is an enterprise levels manufacturing strategy of introducing new
product into rapidly changing market, an organizational ability to thrive in a
competitive environment characterized by continuous and sometimes unforeseen
change
Principles of Agile manufacturing
• Organize to Master change
• Leverage the Impact of People and Information
• Cooperate to Enhance Competitiveness
• Enrich the Customer1/25/2016 MANIMARAN M 8115 KRCE TRICHY 37

Mass production vs Agile production
S.no Mass production Agile production
1 Standardized products Customized products
2 Longer market life Shorter market life
3 Produce-to-forecast Produce-to-order
4 Low information content High information content
5 Single time sales Continuing relationship
6 Pricing by production cost Pricing by customer value

COMPUTER PROCESS MONITORING
Computer production monitoring is a data collection system in which
the computer is connected directly to the workstation and associated
equipment for the purpose of observing the operation. It is also known
as computer process monitoring.

STRUCTURE OF MANUFACTURING PROCESS
Manufacturing
system
Material
Energy
Labour
Inputs outputs
Decisions Disturbances
Product
Scrap
Waste

PROCESS CONTROL STRATEGIES
 Feedback control strategy
 Regularity control strategy
 Feed forward control strategy
 Preplanned control strategy
 Steady-state optimal control strategy
 Adaptive control strategy

FEEDBACK CONTROL STRATEGY

REGULARITY CONTROL STRATEGY

FEED FORWARD CONTROL STRATEGY

STEADY-STATE OPTIMAL CONTROL

ADAPTIVE CONTROL STRATEGY

DIRECT DIGITAL CONTROL (DDC)
DDC is computer process control system in which certain components in a conventional analog
control system are replaced by the digital computer.
BENEFITS OF DIRECT DIGITAL CONTROL
 DDC is more efficient control actions
 DDC provides more control options than traditional analog control system
 DDC has the ability to integrate feedback measurements multiple loops and to implement
optimizing strategies to improve overall performance
 A digital computer in DDC makes editing the control programs much easier and less costlier

DIRECT DIGITAL CONTROL (DDC)

Capc & computer monitoring

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