Computer integrated manufacturing control

Many manufacturing companies have long endured the problems associated with the presence of `islands of automation'. Due to rapid computerisation, `islands' such as Computer-Aided Design (CAD), Computer-Aided Manufacturing (CAM), Flexible Manufacturing Systems (FMS) and Material Requirement Planning (MRP), have emerged, and with a lack of co-ordination, often lead to inefficient performance of the overall system. The main objective of Computer-Integrated Manufacturing (CIM) technology is to form a cohesive network between these islands. Unfortunately, a commonly used approach - the centralised system approach, has imposed major technical constraints and design complication on development strategies. As a consequence, small companies have experienced difficulties in participating in CIM technology. The research described in this thesis has aimed to examine alternative approaches to CIM system design. Through research and experimentation, the cellular system approach, which has existed in the form of manufacturing layouts, has been found to simplify the complexity of an integrated manufacturing system, leading to better control and far higher system flexibility. Based on the cellular principle, some central management functions have also been distributed to smaller cells within the system. This concept is known, specifically, as distributed planning and control. Through the development of an embryo cellular CIM system, the influence of both the cellular principle and the distribution methodology have been evaluated. Based on the evidence obtained, it has been concluded that distributed planning and control methodology can greatly enhance cellular features within an integrated system. Both the cellular system approach and the distributed control concept will therefore make significant contributions to the design of future CIM systems, particularly systems designed with respect to small company requirements.

Computer integrated manufacturing (CIM) and the principle of business control

In response to the increasing international competitiveness, many manufacturing businesses are rethinking their management strategies and philosophies towards achieving a computer integrated environment. The explosive growth in Advanced Manufacturing Technology (AMI) has resulted in the formation of functional "Islands of Automation" such as Computer Aided Design (CAD), Computer Aided Manufacturing (CAM), Computer Aided Process Planning (CAPP) and Manufacturing Resources Planning (MRPII). This has resulted in an environment which has focussed areas of excellence and poor overall efficiency, co-ordination and control. The main role of Computer Integrated Manufacturing (CIM) is to integrate these islands of automation and develop a totally integrated and controlled environment. However, the various perceptions of CIM, although developing, remain focussed on a very narrow integration scope and have consequently resulted in mere linked islands of automation with little improvement in overall co-ordination and control. This thesis, that is the research described within, develops and examines a more holistic view of CIM, which is based on the integration of various business elements. One particular business element, namely control, has been shown to have a multi-facetted and underpinning relationship with the CIM philosophy. This relationship impacts various CIM system design aspects including the CIM business analysis and modelling technique, the specification of systems integration requirements, the CIM system architectural form and the degree of business redesign. The research findings show that fundamental changes to CIM system design are required; these are incorporated in a generic CIM design methodology. The affect and influence of this holistic view of CIM on a manufacturing business has been evaluated through various industrial case study applications. Based on the evidence obtained, it has been concluded that this holistic, control based approach to CIM can provide a greatly improved means of achieving a totally integrated and controlled business environment. This generic CIM methodology will therefore make a significant contribution to the planning, modelling, design and development of future CIM systems.

An investigation into the use of knowledge representation in computer-integrated manufacturing

In a certain automobile factory, batch-painting of the body types in colours is controlled by an allocation system. This tries to balance production with orders, whilst making optimally-sized batches of colours. Sequences of cars entering painting cannot be optimised for easy selection of colour and batch size. `Over-production' is not allowed, in order to reduce buffer stocks of unsold vehicles. Paint quality is degraded by random effects. This thesis describes a toolkit which supports IKBS in an object-centred formalism. The intended domain of use for the toolkit is flexible manufacturing. A sizeable application program was developed, using the toolkit, to test the validity of the IKBS approach in solving the real manufacturing problem above, for which an existing conventional program was already being used. A detailed statistical analysis of the operating circumstances of the program was made to evaluate the likely need for the more flexible type of program for which the toolkit was intended. The IKBS program captures the many disparate and conflicting constraints in the scheduling knowledge and emulates the behaviour of the program installed in the factory. In the factory system, many possible, newly-discovered, heuristics would be awkward to represent and it would be impossible to make many new extensions. The representation scheme is capable of admitting changes to the knowledge, relying on the inherent encapsulating properties of object-centres programming to protect and isolate data. The object-centred scheme is supported by an enhancement of the `C' programming language and runs under BSD 4.2 UNIX. The structuring technique, using objects, provides a mechanism for separating control of expression of rule-based knowledge from the knowledge itself and allowing explicit `contexts', within which appropriate expression of knowledge can be done. Facilities are provided for acquisition of knowledge in a consistent manner.

Integrated manufacturing systems design in a multi-product company

Using a hydraulic equipment manufacturing plant as the case study, this work explores the problems of systems integration in manufacturing systems design, stressing the behavioural aspects of motivation and participation, and the constraints involved in the proper consideration of the human sub-system. The need for a simple manageable modular organisation structure is illustrated, where it is shown, by reference to systems theory, how a business can be split into semi-autonomous operating units. The theme is the development of a manufacturing system based on an analysis of the business, its market, product, technology and constraints, coupled with a critical survey of modern management literature to develop an integrated systems design to suit a specific company in the current social environment. Society currently moves through a socio-technical revolution with man seeking higher levels of motivation. The transitory environment from an autocratic/paternalistic to a participative operating mode demands systems parameters only found to a limited extent in manufacturing systems today. It is claimed, that modern manufacturing systems design needs to be based on group working, job enrichment, delegation of decision making and reduced job monotony. The analysis shows how negative aspects of cellular manufacture such as lack of flexibility and poor fixed asset utilisation are relatively irrelevant and misleading in the broader context of the need to come to terms with the social stresses imposed on a company operating in the industrial environment of the present and the immediate future.

Aspects of the design and control of manufacturing systems subject to demand uncertainty

The recent explosive growth in advanced manufacturing technology (AMT) and continued development of sophisticated information technologies (IT) is expected to have a profound effect on the way we design and operate manufacturing businesses. Furthermore, the escalating capital requirements associated with these developments have significantly increased the level of risk associated with initial design, ongoing development and operation. This dissertation has examined the integration of two key sub-elements of the Computer Integrated Manufacturing (CIM) system, namely the manufacturing facility and the production control system. This research has concentrated on the interactions between production control (MRP) and an AMT based production facility. The disappointing performance of such systems has been discussed in the context of a number of potential technological and performance incompatibilities between these two elements. It was argued that the design and selection of operating policies for both is the key to successful integration. Furthermore, policy decisions are shown to play an important role in matching the performance of the total system to the demands of the marketplace. It is demonstrated that a holistic approach to policy design must be adopted if successful integration is to be achieved. It is shown that the complexity of the issues resulting from such an approach required the formulation of a structured design methodology. Such a methodology was subsequently developed and discussed. This combined a first principles approach to the behaviour of system elements with the specification of a detailed holistic model for use in the policy design environment. The methodology aimed to make full use of the `low inertia' characteristics of AMT, whilst adopting a JIT configuration of MRP and re-coupling the total system to the market demands. This dissertation discussed the application of the methodology to an industrial case study and the subsequent design of operational policies. Consequently a novel approach to production control resulted. A central feature of which was a move toward reduced manual intervention in the MRP processing and scheduling logic with increased human involvement and motivation in the management of work-flow on the shopfloor. Experimental results indicated that significant performance advantages would result from the adoption of the recommended policy set.

Computer Integrated Business: Theoretische und empirische Analyse der bisherigen Ansätze und zukünftigen Perspektiven

Die Arbeit stellt einen strukturellen Rahmen zur Einordnung sowohl bisheriger als auch zukünftiger organisationstheoretischer und DV-technologischer Entwicklungen zur Umsetzung eines Computer Integrated Business (CIB) bereit. Dazu analysiert sie bisherige Ansätze und zukünftige Perspektiven eines CIB mittels theoretischer und empirischer Bearbeitungsverfahren. Die Notwendigkeit zur Unternehmensintegration ergibt sich aus dem betriebswirtschaftlichen Konzept der Arbeitsteilung, über die das Phänomen der Economies of Scale erschlossen wird. Die Arbeitsteilung wurde zum Gestaltungskonzept in den Fabriken der industriellen Revolution. Komplexe Arbeitsgänge wurden in spezialisierte Teilaufgaben zerlegt und nach Möglichkeit auf maschinelle bzw. technologische Potentiale übertragen. Die Zielsetzung lag zunächst in der Automatisierung des Materialflusses, während der Informationsfluss noch lange Zeit im Hintergrund stand. Mittlerweile ermöglichen leistungsfähige DV-Systeme auch die Automatisierung des Informationsflusses und damit die DV-gestützte Integration des Unternehmens, die den Kern des CIB-Konzeptes darstellt. Das CIB-Konzept wurde Ende der achtziger Jahre am Fraunhofer-Institut für Arbeitswirtschaft und Organisation als Erweiterung des Computer Integrated Manufacturing (CIM) für Industrieunternehmen von Bullinger geprägt, jedoch in seiner Zielsetzung als Modell zur Totalintegration von Unternehmen danach nicht maßgeblich weiterentwickelt. Vielmehr wurden in der Folgezeit überwiegend Teilintegrationslösungen diskutiert, wie z. B. Konzepte zur Integration der Fertigung oder zur Unterstützung der Teamarbeit. Der Aspekt der umfassenden, unternehmensinternen Integration rückte Mitte der neunziger Jahre durch die an Popularität gewinnende Internet-Technologie an den Rand der wissenschaftlichen Diskussion. Erst nach dem Zusammenbruch der ersten Internet-Euphorie und der anschließenden wirtschaftlichen Rezession gewann das Integrationsthema am Anfang dieses Jahrzehnts mit Hinblick auf dadurch mögliche Kostenvorteile wieder an Bedeutung. Die Diskussion wurde jedoch mit starkem technologischem Fokus geführt (z. B. zum Thema Enterprise Application Integration) und Aspekte der Unternehmensorganisation wurden bestenfalls grob, jedoch nicht im Detail diskutiert. Die vorliegende Arbeit bearbeitet die CIB-Thematik umfassend sowohl aus unternehmensorganisatorischer als auch DV-technologischer Sicht und bewegt sich deshalb interdisziplinär zwischen den Wissenschaftsbereichen der Betriebswirtschaft und der Informatik. Die Untersuchung wird vor dem Hintergrund einer sozio-technologischen Unternehmensorganisation geführt, in der DV-technologische Potentiale neben humanen Potentialen zur Erreichung der Unternehmensziele eingesetzt werden. DV-technologische Potentiale übernehmen darin einerseits Integrationsaufgaben und werden andererseits aber selbst zum Integrationsziel. Die Herausforderung für die Unternehmensführung besteht in der Konfiguration des CIB und im Finden eines Gleichgewichts zwischen Arbeitsteilung und Integration auf der einen sowie humanen und technologischen Potentialen auf der anderen Seite, letztendlich aber auch in der Automatisierung der Integration. Die Automatisierung der Integration stellt mit Hinblick auf die durch Umweltveränderungen bedingte Konfigurationsanpassung ein bisher konzeptionell nur ansatzweise gelöstes Problem dar. Der technologischen Integrationsarchitektur sowie den verwendeten Methoden des Prozessdesigns und der Software-Entwicklung kommt bei der Lösung dieses Problems eine hohe Bedeutung zu. Über sie bestimmt sich die Anpassungsfähigkeit und geschwindigkeit des CIB. Es kann vermutet werden, dass eine Lösung jedoch erst erreicht wird, wenn sich die Unternehmensorganisation vom Konzept der zentralen Koordination abwendet und stattdessen an dezentralen Koordinationsmechanismen unter Verwendung ultrastabiler Anpassungsprogramme orientiert, wie sie z. B. in der Biologie bei Insektenkulturen untersucht wurden.

Automated support for versioning compliance checking between workflow management and product lifecycle management (in Chinese)

With the development of enterprise informatisation, Product Lifecycle Management (PLM) systems have been widely deployed and applied in enterprises. This paper analyzes the requirement that conducting version operations on business objects as specified in process models should be compliant with the versioning policies imposed by product lifecycles. This leads to the introduction of the concept of versioning compliance, and the approach of compliance checking that we proposed in our earlier work, which comprises both syntactical compatibility and behavioural compatibility checking. The paper then focuses on the tool implementation for providing automated support to the versioning compliance checking. An empirical evaluation of the tool was also performed with industrial partners using the well-known questionnaire-based method. The evaluation and feedback from practitioners further evidence the practical significance of this research question in the PLM field and demonstrate that the proposed solution with its automated tool support possesses a high application potential.

Solving problems in production scheduling

Traditionally, production scheduling has been viewed as a problem-solving task that involves a single problem - generation of a suitable schedule. This paper presents an alternative model in which individual difficulties are viewed as problems, and the task is to maintain a suitable schedule by resolving as many of these problems as possible. Decision support software is described that has facilities for defining policies to handle numerous minor problems and complete problem-solving strategies to deal with major problems. The paper then discusses the potential for this style of decision support to improve the performance of human schedulers. © 1995.