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DESIGN AND ANALYSIS OF INTEGRATED MANUFACTURING SYSTEMS W. Dale Compton, Editor NATIONAL ACADEMY OF ENGINEERING NATIONAL ACADEMY PRESS Washington, D.C. 1988
NATIONAL ACADEMY PRESS 2101 CONSTITUTION AVENUE, NW WASHINGTON, DC 20418 The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its adminis- tration and in the selection of its members, sharing with the National Academy of Sciences the responsibil- ity for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. Robert M. White is president of the National Academy of Engineering. This publication has been reviewed by a group other than the authors according to procedures approved by a Report Review Committee. The interpretations and conclusions in this publication are those of the authors and do not purport to represent the views of the council, officers, or staff of the National Academy of Engineering. Funds for the National Academy of Engineering's Conference "Design and Analysis of Integrated Manufacturing Systems: Status, Issues, and Opportunities" were provided by the Academy's Technology Agenda Program. Library of Congress Catalog~ng-~n-Publication Data Design and analysis of integrated manufacturing systems. Papers presented, in part, at a conference held Feb. 25-27, 1987. Includes index. 1. Computer integrated manufacturing systems Congresses. 2. Flexible manufacturing systems Congresses. I. Compton, W. Dale. II. National Academy of Engineering. TS155.6.D47 1988 670.42'7 88-1766 ISBN 0-309-03844-8 Copyright (D 1988 by the National Academy of Sciences No part of this book may be reproduced by any mechanical, photographic, or electronic process, or in the form of a phonographic recording, nor may it be stored in a retrieval system, transmitted, or otherwise copied for public or private use, without written permission from the publisher, except for the purpose of official use by the United States government. Printed in the United States of America
CONTENTS Preface Integrated Manufacturing Systems: An Overview James J. Solberg ..................................... Manufacturing Systems: Meeting the Competitive Challenge Erich Bloch and Kathy Prager Conrad ........... 7 Design and Analysis of Integrated Electronics Manufacturing Systems Laurence C. Seifert .................................... Flexible Machining in an Integrated System Arthur J. Roch, Jr. Material Handling in Integrated Manufacturing Systems John A. White 46 Designing an Information System for Integrated Manufacturing Systems Ulri~h Flatau 60 · · ~
By CONTENTS Integration and Flexibility of Software for Integrated Manufacturing Systems Arch ~ Naylor and Richard A. Volz 79 Process and Economic Models for Manufacturing Operations Vijay A. Tipnis ........................................................................... A New Perspective on Manufacturing Systems Analysis Rajan Suri ............................................................................... Simulation in Designing and Scheduling Manufacturing Systems F. Hank Grant .......................................................................... The Human Role in Advanced Manufacturing Systems William B. Rouse ............................ Modeling in the Design Process Herbert B. Worker .... .92 118 134 148 . 167 The Strategic Approach to Product Design Daniel E. Whitney, lames L. Nevins, Thomas L. De Fazio, Richard E. Gustavson, Richard ~ Metzinger, Jonathan M. Rourke, and Donald S. Seltzer Advisory Committee for the Conference Contributors Glossary ...................................................................... Index 200 226 230 ... 233
PREFACE The manufacturing sector has been a strong and consistent contributor to the economic vitality of the United States. With the onslaught of imports from foreign manufacturers who have a cost advantage in either labor or natural resources, it is increasingly difficult for U.S.-basec] manufacturers to maintain their market share and sustain current levels of employment. It is apparent that the advantages of the overseas suppliers wiD be overcome only through a concerted effort that improves the efficiency of U.S. operations while providing high-quality products at a com- parable price. This need to increase productivity, improve quality, and reduce costs has led many companies to search for new ways of achieving the conversion of a product idea into a manufactured product. Recognizing that all participants in the enterprise- the product designer, the material hanger, the material processor, the assembler, the service personnel, and the corporate managementcontribute to the success of the operation, the search for improved ways to create competitive products must affect them all. We can improve the competitiveness of U.S. manufacturing only when we have come to understand the factors that affect the productivity of each of the segments of the manufacturing enterprise as well as the interaction among them. This search for new understanding implies a special need to improve the tools that are used to analyze and design systems of the complexity of a manufacturing enterprise. It was recognition of the challenges in meeting this need that led the National v
al PREFACE Academy of Engineering to hoist a conference entitled "Design and Analysis of Integratecl Manufacturing Systems: Status, Issues, and Opportunities" on February 25-27, 1987. The papers contained in this volume were presented, in part, at that conference. In this volume the authors, as experts in key areas of the field, explore the status of the tools that are used to design and analyze integrated manufacturing systems, and they identify many issues that arise in the use of these tools in designing and later in controlling these systems. Finally, each author has identified a series of research opportunities that should be explored as we search for better and more powerful tools for handling the problems posed by systems of this complexity. Although each of the conference presentations generated intense discussion, the central theme of discussions throughout the conference was that U.S. firms and researchers interested in manufacturing must abandon the narrow view of manu- facturing the view from the perspective of a single element of the enterprise. They must learn to treat the entire system as an interacting set of elements that cannot be optimized in a narrow context. There is a corresponding need to abandon compartmentalization in manufacturing and to break down the barriers between design and its realization. Old patterns of limited interaction between elements of the manufacturing enterprise must give way to new patterns emphasizing commu- nication and teamwork. We can no longer afford the disruptions and the inefficien- cies that result when one unit throws a design, analysis, or test "over-the-wall" to another unit. In addition to the topics that are presented in the papers included in this volume, it should be noted that discussions in small workshops led to a consensus that a more intensive search shouIcI be undertaken for the elements of a manufacturing system discipline. It was felt that both the practitioner and the educator would benefit from this the practitioner from the generic tools that would assist him in analyzing, designing, and controlling systems and the educator from the availability of a systematic body of knowledge for presentation in the classroom. On behalf of the National Academy of Engineering, ~ would like to thank especially the conference advisory committee (listed on page 225) that designed the conference, and the speakers at the conference and the individuals who attended and participated so actively in the discussions. With regard to the preparation of the manuscript for publication, ~ am especially grateful to H. Dale Langford, the National Academy of Engineering's editor, and Mary I. Ball, administrative secre- tary in the National Academy of Engineering Program Office. W. DA LE COMPTON Senior Fellow National Acaclemy of Engineering i.
DESIGN AND ANALYSIS OF INTEGRATED MANUFACTURING SYSTEMS