Pretace PART 1 INTRODUCTION TO ClM AND THE MANUFACTURING ENTERPRISE 1 The Manufacturing Enterprise 1-1 lntroduction 2 1-2 External ChaIlenges 5 1-3 lnternal Challenges 8 1-4 World-CIass Order-Winning Criteria 14 1-5 The Prohlem and a SoIution 21 1-6 Learning CIM Concepts 24 1-7 Going for the Glohe 26 1-8 Summary 33 Reterences 33 Questions 34 ProhIems 35 Projects 36 Appendix 1-1: The Benefits of a ClM Implementation 37 Appendix 1-2: The Parable of the TWo Farmers 38 2 Manufacturing Systems 2-1 Manufacturing Classifications 45 2-2 Product Development Cycle 52 2-3 Enterprise Organization 53 2-4 Manual Production Operations 60 2-5 Summary 62 References 63 Questions 63 Projects 64 Appendix 2-1: ClM as a Competitive Weapon 64 Case Study : Evolution and Progress-0ne WorId-Class Company's Measurement System 65 PART 2 THE DESIGN ELEMENTS AND PRDDUCTION ENGINEERING 3 Product Design and Production Engineering 3-1 Product Design and Production Engineering 70 3-2 Or Organization Model 71 3-3 The Design Process: A Model 74 3-4 Concurrent Engineering 82 3-5 Production Engineering 88 3-6 Summary 98 References 98 Questions 99 Projects 99 Case Study: Repetitive Design 100 4 Design Automation: CAD 4-1 lntroduction to CAD Systems 101 4-2 General System Operation 108 4-3 CAD Classification: Hardware Platforms 110 4-4 CAD Classification: Software 115 4-5 Application of CAD to Manufacturing Systems 125 4-6 Summary 129 References 131 Questions 132 ProhIems 132 Projects 133 Appendix 4-1: B-Splines to Nurhs 133 Appendix 4-2t Web Sites for CAD Vendors 135 Appendix 4-3t Web Sites for Computer Systems 136 5 Design Automation : Computer-Aided Engineering 5-1 Design for Manufacturing and Assembly 139 5-2 Computer-Aided Engineering Analysjs 144 5-3 Computer-Aided Engineering Evaluation 154 5-4 Group Technology 160 5-5 Production Engineering Strategies 165 5-6 Design and Production Engineering Network 185 5-7 Summary 188 Reterences 189 Questions 189 Problems 190 ProJects 191 Appendix 5-1: Ten Guidelines for Design for Assembly 192 Appendix 5-2: Weh Sites for CAE Vendors 193 Appendix 5-3: Weh Sites for Rapid Prototyping Vendors 194 PART 3 MANAGING THE ENTERPRISE RESOURCES 6 Introduction to Production/Operations Planning 6-1 Operations Management 199 6-2 Manufacturing Planning and Control 200 6-3 Manufacturing Planning and ControI ModeI- Manutacturing Resource PIanning (MRP2) 205 6-4 Material Requirements PIanning 207 6-5 lntroduction to Production Activity ControI 211 6-6 Gantt Charts and Schedule Boards 212 6-7 Priority Control and Dispatching Techniques 213 6-8 Shop Loading 219 6-9 Input/Output ControI 221 6-10 Automating the MPC Function 221 6-11 Summary 223 References 224 Questjons 225 Prohlems 225 Projects 226 7 Introduction to Manufacturing Planning and ControI 228 7-1 PIanning in the MPC System 228 7-2 Production Planning 232 7-3 Master Production ScheduIe 238 7-4 lnventory Management 243 7-5 Product Data Management 247 7-6 Summary 249 References 251 Questions 251 Prohlems 252 Projects 255 Case Study 7-1: Production System at New United Motor Manufacturing, Part 1 256 8 Material PIanning, Production Scheduling, and Operating Systems 258 8-1 MateriaI Requirements Planning 258 8-2 Capacity Reguirements Planning 268 8-3 From Reorder-Point Systems to Manufacturing Resource PIanning (MRP ll) 270 8-4 Just-in-Time Manufacturing 281 8-5 Synchronized Production 293 8-6 The Emergence ot Lean Froduction 295 8-7 Summary 298 References 299 Questions 300 ProhIems 301 Projects 302 Case Studyt Production System at New United Motor Manufacturing, Part 2 303 Appendix 8-1: Wight's BicycIe ExampIe 307 Appendix 8-2: ABCD Checklist 309 9 Enterprise Resource Planning, and Beyond 9-1 MRP ll: A Driver of Effective ERP Systems 321 9-2 lnformation TechnoIogy 322 9-3 The Decision to Implement an ERP System 325 9-4 Features of Modern MP&C Systems 326 9-5 Developing TechnoIogies; Converging and Enahling 330 9-6 Identitying ERP System SuppIiers 335 9-7 Summary 337 References 338 Projects 338 Appendix 9-1: Identifying the Ahhreviations lncIuded in Figure 9-1 339 Appendix 9-2: lmportant ERP-Related Sites on the lnternet 339 Appendix 9-3: An ERP Example Using WinMan 340 PART 4 ENABLlNG PR0CESSES AND SYSTEMS F0R MODERN MANUFACTURlNG 10 Production Process Machines and Systems 10-1 MateriaI and Machine Processes 347 10-2 FIexible Manufacturing 367 10-3 Fixed High-Volume Automation 376 10-4 Summary 379 References 381 Questions 382 Projects 383 APPendix 10-1: History of Computer-Controlled Machines 383 11 Production Support Machines and Systems 11-1 lndustrial Rohots 386 11-2 Automated MateriaI Handling 403 11-3 Automatic Guided VehicIes 409 11-4 Automated Storage and Retrieval 419 11-5 Summary 423 References 424 Questions 424 Projects 425 Case Study: AGV Applications at GeneraI Motors 426 12 Machine and System ControI 12-1 System Overview 427 12-2 CelI ControI 430 12-3 Proprietary Versus Open System lnterconnect Software 434 12-4 Device Control 437 12-5 Programmahle Logic Controllers 438 12-6 Computer Numerical Control 449 12-7 Automatic Tracking 453 12-8 Network Communications 458 12-9 Summary 459 References 460 Questions 461 Projects 462 Appendix 12-1: Turning G Codes 462 13 QuaIity and Human Resource Issues in Manufacturing 13-1 Quality 464 13-2 TotaI QuaIity Management 465 13-3 Quality Tools and Processes 469 13-4 Defect-Free Design Philosophy 479 13-5 The Changing Workforce 483 13-6 SeIf-Directed Work Teams 484 13-7 Summary 489 References 490 Questions 491 Projects 492 Appendix 13-1: Deming's Fourteen Points 492 Index
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