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INDEX A Academic research, see University R&D Aerospace industry process design, 104-105 Animation AT&T systems engineering, 32 graphic design system/user interfaces, 178 manufacturing systems design, 135, 137, 140, 146 operator performance, 153-154 production scheduling, 145-146 systems analysis, 122 see also Product design modeling; Solid modeling Artificial intelligence CIM, 30 human interactions with, 154 for IM&M, 150 for manufacturing systems analysis, 121, 128 simulation for design and scheduling, 143 see also Expert systems Assembly processes, see SAPD cost of, at AT&T, 15 Asset management versus technological management, 204 AT&T electronics productivity program, 12-33 automation and robotics, 15-16, 23-24, 29 CIM, 17-18, 20-22, 30 corporate organization, 13-14, 17-18 Denver Works, 24-25 focused factories, 14, 24-29 IM&M, 16) 19-22 location of implementation, 24 numerically controlled machines, 33 Oklahoma City Works, 24-29 process control, 14-15, 22 R&D, 12, 17-18, 22 systems engineering tools, 31-33 Automation for AT&T electronics production, 15-16, 23-24, 29,31 barriers to implementation, 51-52 cost assessment, 205 effects on operators, 192 manufacturing automation protocol, 20, 81, 90 for materials handling, 56-57, 109 replacement of labor, 23-24 simulation, 145-146 software, 51 user-support systems, 163 see also CIM; EMS Automobile industry use of SAPD, 213-215 see also General Motors Corporation; Toyota 233
234 C CAD (Computer-aided design) at AT&T, 12-33 drawing tolerances, 94 effects on operator tasks, 157 via finite difference methods and geometric modeling, 160 IM&M, 61 integrated with CAM, 151, 168-169, 178 integration with numerically controlled machines, 151 materials handling, 55, 58 process determination, 94 product design, 168-169 representation of physical objects, 93-94 see also CIM; FMS; Product design modeling; SAPD; Solid modeling CAE (Computer-aided engineering) via finite difference methods and geometric modeling, 160 status of, 151 CAM (Computer-aided manufacturing) effects on operator tasks, 157 via finite difference methods and geometric modeling, 160 integrated with CAD, 151, 168-169, 178 integration with numerically controlled machines, Data bases 151 via wireframe stream, 169-171 see also CIM; FMS; IMS CAPP (Computer-aided process planning), 108-109, 116 via CAD techniques, 94 via data bases and expert systems, 109 for materials handling, 109 CIM (Computer-integrated manufacturing) architectural framework for, 67-78 attributes of, 47-48 at AT&T, 17-18, 20-22, 30-31 and AT&T systems engineering technology, 31-33 at Digital Equipment Corp., 61 functional model of, 69-78 information management requirements of, 66-78 and materials handling, 46-58 networking for, 65, 72-78 problems in implementation, 151-152 in relation to FMS, 45 Communications, see IM&M; Networks Competition and complexity of products, 204 at international level, 7-11 international status of AT&T Oklahoma City, 28- 29 Constructive solid geometry, and modeling techniques, 160, 171, 173, 180, 186 Corporate R&D, 4-5 INDEX at AT&T, 12, 17-19, 22, 28-29 automated systems and simulation, 145-146 IMS, 5 materials handling, 46, 56, 59 process models, 115 product design modeling, 175-177, 180-184, 188 real time, 79-91, 128, 144-145 in relation to university R&D, 3, 8-9 SAPD, 221 scheduling, 128, 143-147 semiconductors, 10 simulation for scheduling and design, 143-147 solid modeling, 175-177, 180-184 systems analysis, 125-128, 131 systems engineering tools at AT&T, 31-33 Cost/benefit analysis in AT&T manufacturing engineering systems, 32 automation, 205 design phase trade-offs, 94-94, 106-108 feasibility analysis, 124-125 FMS, 35-38, 43, 45, 113-114 IMS, 114 quality products, 60 SAPD, 220-221 D for production scheduling, 142 relational data bases for process planning, 109 for SAPD systems, 217 for simulation in real time analysis, 135 standards for, 20 for systems integration, 65-66 Data flow, see IM&M l:)epartment of Defense semiconductor R&D, 10 Design of advanced manufacturing systems, 50, 110 aggregate analysis, 125-126 for AT&T, 12-33 design for analysis, 129-131 detailed analysis phase, 126-127 via discrete event dynamic systems, 127 feasibility analysis, 124-125 FMS, 110-113, 136 interface of design and manufacturing, 93-96 materials handling, 55, 57 process development and planning, 14-15, 104- 108 simulation techniques and applications, 36, 134- 137, 140-147 systems analysis, 118-132 see also CAD; CAPP; Product design; SAPD; User- support systems Digital Equipment Corp. implementation of CIM, 67-78 systems integration process, 61
INDEX Digital switches production at Oklahoma City AT&T, 24-29 Distribution AT&T organizational structure, 13-14, 17 E Education curricula for design, 205 for SAPD, 221-222 see also University R&D Electronics AT&T electronics productivity program, 12-33 Employee issues middle management roles, 151-152 retraining, 152 worker involvement, 214 workforce reduction during integration, 49 UAW, 214 see also User-support systems Ergonomics, see Human-technology interaction; Operator tasks; User-support systems Expert systems CAD-generated materials handling, 58 design and scheduling simulation, 141, 144 manufacturing systems analysis, 121 on-line intelligent information management, 161 process planning, 109 F FACTOR, 139-140 FMC (Flexible machining cell), 35-45 EMS (Flexible manufacturing systems), 109 cost/benefit analysis of, 113-114 design of, 110-113, 136 development of, 151 human operators, integration with, 152-154, 157- 158 in Japan versus United States, 7-8 in machine tool industry, 34-45 and numerically controlled machines, 38 simulation of, 109 using CAD, 200 see also CIM G General Motors Corporation manufacturing automation protocol, 20 NUMMI, 214-216 use of SAPD, 214-215 Geometric Germany, Federal Republic of industry uses of university R&D, 8 Volkswagen, 54, 213-214 Graphics, see Animation 235 H Human-technology interaction, 148-149 acceptance of technology and innovation, 116- 117, 151-153, 162, 216 in CIM, 67 see also Operator tasks; User-support systems I IM&M (Information movement and management) at AT&T, 13, 16, 19-22, 33 within CIM framework, 68-78 via expert systems, 161 via intelligent systems, 150 at LTV Aircraft Group, 41 simulation for integration, 145 for subsystems integration, 65-66, 69-70 systems data consistency, 66 systems integration criteria, 63-65 systems integration levels, 61, 69 systems integration simulation, 61-62 for systems planning, 66 see also Data bases; Networks IMS (Integrated manufacturing systems) attributes of, 47-48 barriers to, 48-49 cost/risk/performance methodology for, 114 design of, 50 implementation of, 50-51 in machine tool industry, 35, 41-44, 110-111 marketing of, 50 software for real time control of, 79-91 see also AT&T electronics productivity program; CIM; EMS; SAPD Integrated circuits assembly and packaging at AT&T, 24 at Oklahoma City AT&T, 24-29 Inventory control, 4 via buffer stocks, 120 centralized versus distributed storage, 53-54 and materials storage, 53-56 research on, 56 see also Just-in-time Japan in international competition, 7-8 kanban and total quality control, 48, 109, 122- 123, 214 materials handling advances, 46 NUMMI, 214-216 quality control and operator performance, 204 research strategies of, 8 systems analysis of manufacturing, 120-121, 123 Toyota production system and JIT, 52 use of SAPD for shipbuilding, 209-211
236 Ji~loka (quality principle), 214 Just-in-time BIT) production and conveyance system, 48, 52, 109, 120-125, 214 K Kanban at AT&T, 25 in automobile industry, 48, 52, 214 in CIM, 31 feasibility analysis for, 125, 127 in Japan, 120, 122-123 models of, 126 versus traditional/American techniques, 120, 122- 123 L Life cycle concept manufacturing systems, 123-124 model changes, 16 obsolescence, 129 product design, 205-207 product design learning curve, 203-204 product life, 4, 123-124 LTV Aircraft Products Group FMC, 35-45 cost/benefit analysis, 36-38, 43 equipment system and vendors, 38-44 operational phase and system structure, 38-40 planning and implementation, 35-38 second- and third-generation planning, 41-44 software for, 40-41 use of IMS, 35, 41-44 use of simulation in planning, 36 M Machine tool industry economic processes models of, 101-104 FMS, 110-112 IMS, 35, 41-44, 110-111 physical process control in, 96-101 Maintenance, see Product maintenance and repair Management techniques and managers and information needs for complex systems, 149- 150 and innovation, 151 middle management, effects of advanced manufacturing, 151-152 Manufacturing Studies Board report on status of U.S. manufacturing, 2, 7, 216, 222 Materials costs, storage, 54 Materials handling systems advances in Europe and Japan, 46 via automation, 56-57, 109 CIM, 46-59 INDEX computer-assisted planning, 109 development needs of, 57-58 human operator involvement, 53 in integrated manufacturing, 46-47, 52-59 just-in-time inventories, 52 lack of standardization, 53 material control systems, 54-55 research on, 46, 56 simulation of, 55 storage, see Inventory control Mechanical design, see Product design modeling; Solid modeling Military applications of FMS, 151 product design models, 196-197 Modeling, see Product design modeling; Simulations and models; Solid modeling N National Research Council, see Manufacturing Studies Board National Science Foundation role in manufacturing education, 221 role in research, 9 NC (Numerically controlled machines) effects on operators, 152, 157 in evolution of manufacturing, 192-193, 197 within FMS, 38 linkage with CAD/CAM, 150-151 program verification for, 176-177 software systems for, 80-84 Networks and CIM, 48, 65 layered model of CIM network, 72-78 manufacturing automation protocol for, 81 New United Motors Manufacturing, Inc. (NUMMI), 214-216 o Operator tasks effects of automation, 192 effects of CAD/CAM, CNC, and FMS on, 152- 154, 157 for machine operation, 109-110 and task characterization and assessment, 154-158 Optimization strategies, 102-103 Organizational structure of manufacturing, 151-152 at AT&T, 13-14, 17-18, 20-21 as barriers to integration, 48-49 see also IM&M; SAPD p Packaging and containers lack of standardization, 53
INDEX PADL (Part and Assembly Description Language), 186-187 Process control in aerospace industry, 104-105 at AT&T, 14-15, 22, 32 via CAD techniques, 94 design of new processes, 104-108, see also SAPD empirical models of, 100-101, 115 feasibility analysis, 124 models of 92-100, 105-116 operator support, 156-157 phenomenological models of, 99-100, 115 of physical processes, 96-101 process planning, 108-109 product development, 7 quality control, 104 real time software models, 86-87, 89-90 for unit manufacturing, 92, 94-116 see also CAPP; EMS; Inventory control; Materials handling; Production capacity and scheduling; SAPD Process economics constraints on objective function, 102 design of models, 106-108, 113 of EMS, 113 optimization strategies, 102-103 SAPD, 220-221 of unit manufacturing, 101-104, 116 Product design analytical tools for, 196 design for manufacturability, 14, 16 evolution of, 169-172, 189-197 feasibility analysis, 124 information management for, 70-71 levels of strategy, 207-213 for materials cost reduction at AT&T, 28 materials handling, 57-58 versus process improvements, 7 recent examples of, 213-215 for Toyota Production System, 52 and university engineering curricula, 205 see also Product design modeling; SAPD Product design modeling, 167-197, 189 analytical tools for, 196 conditional versus open-loop process planning, 188 evolution of, 169-172, 189-197 geometric control, 186-187 manufacturing processes, 184-185, 189-197 military applications of, 196-197 phenomenological representation, 197 via polygonal graphics, 172 via sculpted surfaces, 172 tolerances, 94, 188, 193-197 user interfaces, 178-180 via wireframe graphics, 169-172, 178 see also Solid modeling Product maintenance and repair 237 manufacturing, 8 SAPD, 220 Production capacity and scheduling of AT&T systems engineering technology, 31, 33 FMS-human integration, 153 modeling versus eliminating constraints, 120-121 operations phase systems analysis, 128-129 via optimized production technology, 121-122 real time simulation, 135, 144-145 simulation of, 134, 137-147 via traditional scheduling, 138 Productivity design phase trade-offs, 94-96 versus product quality, 10, 60 see also AT&T electronics productivity program Q Quality control at AT&T, 14, 32 automation, 204-205 design phase trade-offs, 94-96 in Japan, 204 process control, 104-105 versus productivity, 10, 60 SAPD, 213-214, 218-220 tolerances, 94, 98, 188, 193-197, 218-220 TQC (total quality control) techniques, 14, 109 see also Standardization R Real time animation, 146-147 AT&T process control, 22, 32 within CIM functional systems model, 75-76 and distributed storage systems, 53-53 logical versus Euclidean view of, 84 models for, 86-87, 89-90 scheduling via simulation, 135, 144-145 simulation via data bases, 135 software for, 79-91 systems analysis research on, 128-129 systems/subsystems integration, 64-65 Repairs, see Product maintenance and repair Research, see Corporate R&D; University R&D Robotics at AT&T, 15-16 design for assembly, 202 solid modeling, 177-178 S SAPD (Strategic approach to product design), 201, 205-222 assembly, 200-202, 205, 209, 210-212, 218, 220- 221
238 for automobile industry, 213-216 versus design for fabrication, 202 design learning curve, 203-204 for producibility, 209 product complexity, 208 product function analysis, 210 product life cycle, 205-207 research needs, 221 sequencing and components of, 207-209 for shipbuilding in Japan, 209-211 tolerance assessment, 218-220 Semiconductors and U.S. R&D, 10 Shipbuilding via SAPD in Japan, 209-211 Simulations and models animation, 122, 135, 137 in AT&T systems engineering technology, 31 via CAD/CAM, 168-169 CIM functional information systems, 69-78 in design of manufacturing systems, 134-137 economic and process models, 92-116 FMS, 35-36, 136, 153 graphic animation, 122, 135, 137 languages available for system design, 36, 135 materials handling methods, 55 physical processes, 99-101, 115 process design and planning, 104-109 process economics, 101-104 random system behavior, 136-137 real time, 86-87, 89-90, 135, 144-145 for scheduling and control, 137-143 for systems analysis, 122, 125-127 systems integration, 61-62 see also Product design modeling; Solid modeling Software automation, 51 compilers, 82-83, 85-86, 90 components and assemblages, 81-84 distributed language environment, 85-86, 90 FMS, 40-41 generic components, 87-90 optimized production technology, 121-122 product design modeling language, 186-187 production scheduling (FACTOR), 139-140 program verification for numerically controlled machines, 176-177 real time control in IMS, 79-91 SLAM simulation language, 36 solid modeling (PADL), 130 via UNIX operating system, 22 for user-support systems, 82-84 Solid modeling, 189 applications, 174-178, 182-184 boundary representation and constructive solid geometry, 171-172 INDEX using constructive solid geometry, 160, 171, 173, 180, 186 defined and schemes outlined, 171-172 polygonal modeling, 172-173 research on, 175-177, 180-184 sculptured-surface modeling, 172-173 software for (PADL), 130 system organization and geometric coverage, 172- 174 theory, 180-182 and user interface, 178-180 Standardization via automation protocols, 2O, 81, 90 for data bases, 20 in materials handling and storage, 53 networking, 81 packaging, 53 tolerances, 94, 98, 188, 193-197, 218-220 Systems analysis, 118-132 aggregate analysis, 125-126, 128 design for analysis, 129-131 detailed analysis, 126-127 feasibility analysis, 124-125, 128 implementation, 127 in Japan versus United States, 120-123 ongoing operations, 127-128 simulation, 134-147 system life cycles, 123-124 traditional versus modern motivation for, 119- 120, 122 Systems engineering at AT&T, 18-19, 31-33 for materials handling, 46-59 see also CAD; CAM; CIM; FMS; IM&M T Toyota NUMMI, 214-216 product design (Toyota Production System), 52 use of SAPD, 214-215 U Unit manufacturing physical and economic process models for, 92-116 United Automobile Workers (UAW), 214 University R&D computer-assisted process planning, 108-109, 112 materials handling and inventory, 56, 59 process planning, 99, 115 in relation to industry efforts, 3, 8-9, 115 User-support systems, 148-164 at AT&T, 22, 24 framework for, 154-164 manufacturing systems analysis, 129
INDEX obstacles to, 161-162 product design modeling, 160, 178-180 production schedulers, 140-144 software requirements for, 82-83 task characterization and assessment, 154-158 V Volkswagen, 54, 213-214 239 W Wireframes, 169-172 user interfaces, 178 X Xerox survey on part geometry, 186-187
