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Contents Preface xi PART 1 INTRODUCTION TO CIM AND THE MANUFACTURING ENTERRPRISE 1 1 The Manufacturing Enterprise 2 1-1 Introduction 2 1-2 External Challenges 5 1-3 Internal Challenges 8 1-4 World-Class Order-Winning Criteria 14 1-5 The Problem and a Solution 21 1-6 Learning CIM Concepts 24 1-7 Going for the Globe 26 1-8 Summary 33 Bibliography 33 Questions 34 Problems 35 Projects 36 Appendix 1-1: The Benefits of a CIM Implementation 37 Appendix 1-2: Technology and the Fundamentals of an Operation---Authors' Commentary 38 2 Manufacturing Systems 44 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 Bibliography 63 Questions 63 Projects 64 Case Study: Evolution and Progress-One World-Class Company's Measurement System 64 Appendix 2-1: CIM as a Competitive Weapon 65 PART 2 THE DESIGN ELEMENTS AND PRODUCTION ENGINEERING 69 3 Product Design and Production Engineering 70 3-1 Product Design and Production Engineering 70 3-2 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 Bibliography 98 Questions 99 Projects 99 Case Study: Repetitive Design 100 4 Design Automation: CAD and PDM 101 4-1 Introduction to CAD 101 4-2 The Cost of Paper-Based Design Data 108 4-3 CAD Software 110 4-4 CAD: Yesterday, Today, and Tomorrow 115 4-5 Application of CAD to Manufacturing Systems 125 4-6 Selecting CAD Software for an Enterprise 127 4-7 Product Data Managent 128 4-8 Summary 129 Bibliography 131 Questions 132 Problems 132 Projects 133 Appendix 4-1: Web Sites for CAD Vendors 133 Appendix 4-2: B-Splines to NURBSs 135 Appendix 4-3: Web Sites for Computer Companies 136 5 Design Automation: CAE 138 5-1 Design for Manufacturing and Assembly 139 5-2 CAE bAnalysis 144 5-3 CAE 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 Bibliography 189 Questions 189 Problems 190 Projects 191 Appendix 5-1: Ten Guidelines for DFA 192 Appendix 5-2: Web Sites for CAE Vendors 193 Appendix 5-3: Web Sites for Rapid Prototyping Vendors 194 PART 3 CONTROLLING THE ENTERPRISE RESOURCES 197 6 Introduction to Production and Operations Planning 198 6-1 Operations Management 199 6-2 Planning for Manufacturing 200 6-3 MPC Model-- Manufacturing Resource Planning (MRP II) 205 6-4 Production Planning 207 6-5 Master Production Schedule 211 6-6 Inventory Management 212 6-7 Planning for Material and Capacity Resources 213 6-8 Introduction to Production Activity Control 215 6-9 Shop Loading 219 6-10 Input-Output Control 221 6-11 Automating the Planning and Control Functions 221 6-12 Summary 223 Bibliography 224 Questions 225 Problems 225 Projects 226 Appendix 6-1: Priority Rule Systems 226 7 Detailed Planning and Production-Scheduling Systems 228 7-1 From Reorder-Point Systems to Manufacturing Resource Planning (MRP II) 257 7-2 Material Requirements Planning 258 7-3 Capacity Requirements Planning 268 7-4 Manufacturing Resource Planning 281 7-5 Features of Modern Manufacturing Planning and Control Systems 291 7-6 Summary 298 Bibliography 299 Questions 300 Problems 301 Projects 302 Appendix 7-1: Wight's Bicycle Example 307 Appendix 7-2: ABCD Checklist 309 Appendix 7-3: An ERP Example Using WinMan 310 8 Enterprise Resource Planning, and Beyond 319 8-1 MRP II: A Driver of Effective ERP Systems 321 8-2 Information Technology 322 8-3 The Decision to Implement an ERP System 325 8-4 Identifying ERP System Suppliers 326 8-5 Developing Technologies: Converging and Enabling 330 8-6 Integrating Systems to Manage Design Data 335 8-7 Summary 337 Bibliography 338 Questions 338 Projects 338 9 The Revolution in Manufacturing 352 9-1 Just-in-Time Manufacturing 353 9-2 Synchronized Production 364 9-3 The Emergence of Lean Production 366 9-4 Modern Manufacturing Systems in a Lean Environment 369 9-5 Summary 374 Bibliography 37 Questions 375 Projects 376 Case Study: Production System at New United Motor Manufacturing, Part 1 376 Case Study: Production System at New United Motor Manufacturing, Part 2 378 PART 4 ENABLING PROCESSES AND SYSTEMS FOR MODERN MANUFACTURING 383 10 Production Process Machines and Systems 385 10-1 Material and Machine Processes 387 10-2 Flexible Manufacturing 405 10-3 Fixed High-Volume Automation 413 10-4 Summary 417 Bibliography 419 Questions 420 Projects 421 Appendix 10-1: History of Computer-Controlled Machines 422 11 Production Support Machines and Systems 425 11-1 Industrial Robots 426 11-2 Program Statements for Servo Robots 448 11-3 Programming a Servo Robot 454 11-4 Automated Material Handling 461 11-5 Automatic Guided Vehicles 465 11-6 Automated Storage and Retrieval 476 11-7 Summary 480 Bibliography 481 Questions 481 Projects 483 Case Study: AGV Applications at General Motors 484 12 Machine and System Control 486 12-1 System Overview 487 12-2 Cell Control 493 12-3 Proprietary Versus Open System Interconnect Software 497 12-4 Device Control 499 12-5 Programmable Logic Controllers 500 12-6 Relay Ladder Logic 502 12-7 PLC System and Components 506 12-8 PLC Types 511 12-9 Relay Logic Versus Ladder Logic 513 12-10 Computer Numerical Control 521 12-11 Automatic Tracking 525 12-12 Network Communications 529 12-13 Summary 531 Bibliography 532 Questions 533 Projects 534 Appendix 12-1: Turning G Codes 535 13 Quality and Human Resource Issues in Manufacturing 537 13-1 Quality Foundations 538 13-2 Total Quality Management 543 13-3 Quality Tools and Processes 547 13-4 Defect-Free Design Philosophy 557 13-5 The Changing Workforce 561 13-6 Self-Directed Work Teams 562 13-7 Summary 567 Bibliography 569 Questions 569 Projects 570 Index 571