Transcript Document

HOW CIM
CIM IMPROVES
IMPROVES
HOW
Alev
INVENTORY?
INVENTORY?
Eminoglu
Birsen
Kayhan
Derya
Delibaş
Selcan
Babur
Z. Merve Alptekin Alev Eminoğlu
Derya Delibaş
Birsen Kayhan
Selcan Babür
Mehtap Altuntaş
Merve
Alptekin
Mehtap
Altuntas
What is CIM?
 Computer-integrated
manufacturing
(CIM) is the use of computer
techniques to integrate
manufacturing activities. These
activities encompass all functions
necessary to translate customer
needs into a final product. CIM
should not mix with FMS.
What is FMS?
The flexible manufacturing system
(FMS) is a configuration of computermanaged numerical work stations
where materials are automatically
handled and machine loaded. It
consists of CNC machines, a cell
computer and a robot.
The Cell Controller
The cell computer (typically a
programmable logic controller) is
interfaced with the microprocessors
of the robot and the CNCs. The
supervision and coordination among
the various operations in a
manufacturing cell is also performed
by the cell computer.
The Cell Robot
 In
many applications, the cell robot
also performs tool changing, staging
of tools in the tool changer, and
inspection of tools for breakage or
expressive wear. When necessary,
the robot can also initiate emergency
procedures such as system shutdown.
CIM vs FMS
CIM vs FMS
 In
order to achive CIM, there must
be many connected FMS’s and used
computer softwares and hardwares
must be integrated to each other.
Because of that, our lab is NOT CIM
lab. It includes only two flexible
manufacturing cell which are CNC
machine and assembly unit. In
assembly unit there are two
processes; ball filling unit and gluing.
WHAT IS INVENTORY?
Inventory is a list for goods and
materials, or those goods and
materials themselves, held available
in stock by a business.
Keeping inventory for meeting
customer demand is essential.
However balancing the amount
required for keeping in inventory and
its related cost needs a control
system.
Types of Inventory
Raw materials are inventory items that are
used in the manufacturer's conversion
process to produce components,
subassemblies, or finished products.
Work-in-process (WIP) is made up of all the
materials, parts (components),
assemblies, and subassemblies that are
being processed or are waiting to be
processed within the system.
A finished good is a completed part that is
ready for a customer order. Therefore,
finished goods inventory is the stock of
completed products.
AUTOMATIC INVENTORY
Automatic Identification and Data
Capture (AIDC) refers to the methods of
recognizing objects, getting information
about them and entering that data or
feeding it directly into computer systems
without any human involvement.
Automatic identification and data capture
technologies include barcodes, RFID, OCR,
magnetic stripes, smart cards and
biometrics.
BARCODING IN TOFAS/FIAT
The versions change according to their
accessories, the country that the car is being
produced, and the type of the car, the
description of the car and the picture list of the
car. After this selection we select the desired
Doblo version. There are a lot of types of Doblo
but in the example below you will see that the
type Combi has 28 different versions in itself.
When we select the parts that are used in the
assembling line of Doblo are shown. If we select
a part from these we see the details that are
required for the parts installation.
BODY
ENGINE
Fergone
Panoroma
Cambo
Malibu
Connect
1242cc 8V
1596cc 16 V
1910 DS Asp
1910 DS JTD
LUX
LL0 BASE
LL1 ELEGANCE
LL2
STANDARD ACCESSORIES
Floor
VERSION
Body Lux
Engine
010,011,012,013,1
10,112,113,132,13
3,210,212,213,331
,332,333,411,412,
413,511,512,513,6
11,612,613,411,71
1,712,713,811,813
Immobilizer(With varying
codes)
Follow me home
Heater
Front seat belts
Rear seat belts
Torpedo
Passenger seat
compartment
Benefits of Inventory Software
Some of the benefits that the best software
incorporates include:






Reduce unnecessary raw materials by with MRP
(Material Requirements Planning)
Eliminate excess stored finished goods through
JIT (Just-In-Time) planning
Connect directly to suppliers via EDI (Electronic
Data Interface) to ensure supplies are ordered
when needed
Reduce hours spent counting inventory through
barcode/RFID accountability
Spend less time locating inventory with locationbased tracking
Lot tracking and FIFO (First-In-First-Out)
capabilities
INVENTORY MANAGEMENT
TECHNIQUES
 MRP
AND MRP II.
MRP and MRP II are computer-based
resource management systems
designed for items that have
dependent demand. MRP and MRP II
look at order quantities period by
period and, as such, allow discrete
ordering (ordering only what is
currently needed).
INVENTORY MANAGEMENT
TECHNIQUES
 JUST-IN-TIME
(JIT)
Just-in-time (JIT) is a philosophy that
advocates the lowest possible levels
of inventory. JIT espouses that firms
need only keep inventory in the right
quantity at the right time with the
right quality. The ideal for JIT is one,
even though one hears lot size the
term "zero inventory" used.
LEAN MANUFACTURING
Lean Production is defined as a production
type that consists no unnecessary
component and failure, cost, inventory,
production area, loss and customer
displeasure are at minimum level in its
structure. In production and management,
lean production uses “no mistake”,
“continuos improvement”, “perfection”,
“attendance of workers” and “ just in
time” for describing its production style.
Properties of Lean
Manufacturing
It is a sum because:
In every level of organization, it consists of the
attendance of all workers and the union of ideas and
aims.
It is implemented on all of the regions and activities of
the firm.
 It is quality because:
It consists of the quality of managers’ and workers’works.
It consists of product and service quality.
 It is control because:
Error creators are determined instead of picking out
errors and Main points are controlled
Some systems are developed to prevent repetition of
errors.

Lean Provides Better Inventory
Control
Lean manufacturing eliminates
unnecessary processes, arranges the
stages of continuous processes and
uses continuous improvement
techniques. These improvements
provides better inventory control.
Inventory Cutting
 In
order to achieve lean production
improvement starts in small work
teams. By these improvements,
setup-time is reduced. By using
small lot production system, lead
time is reduced. Application of
Kanban and JIT production provides
Inventory cutting. In order to reduce
inventory , CIM must be
implemented.
LEAN VS TRADITIONAL
Lean Manufacturing
Simple and Visual
Build to Demand
Minimal Inventory
Focus on Non-Value Added
Minimum Size
Minimal Lead Times
Quality Through Process
Value Stream Owners
Traditional Manufacturing
Complex
Build to Forecast
Excessive Inventory
Focus on Value Added Work
Batch Processes
Long Lead Times
Quality Through Inspection
Departmental Supervision
Lean Production Methods
1.
2.
3.
4.
5.
6.
7.
8.
Kanban
Mix Loading and Production
Smoothing
One-piece Flow
Synchronization between machines
U-lines, Shojinka, Work Rotations
Poka-Yoke and Autonomation
Total Productive Maintenance(TPM)
Single Minute Exchange of
Dies(SMED)
1. KANBAN
One of the principles of the lean
manufacturing is to produce a
product at the required time and
required amount. The aim is to
prevent the factory from producing
unnecessary products. To achieve
this every production station should
produce the amount that the next
station can insert into its process.
This production style can be called as
pulling system.
Pull System
In the pull system, the production
schedule is given to the station 1.
The station 1 accordingly makes the
first component and pushes it to the
station 2 and so on. In this way,
along with the material flow station 1
is giving the information target also
to the station 2, that how many
components it needs to make.
Push System
In the push system, the production
schedule is given to the station 4.
the station 4 demands the number of
components required from station 3
and so on. In this way the
information is passed on from station
4 to station 3, that how many
components it needs to make.
TOFAS WAREHOUSE
AUTOMATION SYSTEM
TOFAS main production database is
called NPRC. According to include
datas, orders are given with 2 ways:
internal and external. Internal orders
are made within departments.
External orders are given to supplier
automatically with the amount of
recorded data.
TOFAS WAREHOUSE
AUTOMATION SYSTEM
When orders come to TOFAS entrance
some of the supplied parts goes
quality control to inspection others
go directly to warehouse. After
inspection process non-conformity
parts send to shipping zone for
giving back to supplier. However, the
conforming parts are used in
workshop for production.
INFORMATION FLOW at
TOFAS
Information Flow Databases
POINT: ( CAR PRODUCTION SYSTEM )
 WMF ( WORLD MATTERIAL FLOW )
 MPM ( COST SYSTEM )
 IQF ( INDICATORI QUALITA FORNITORI )
 SGV ( SISTEMI GESTIONE VELOCE )
 DBP ( DISTINTA-BASE PRODUZIONE )
 NPRC ( SUPPLIERS PROGRAMS )
 PDP ( PROGRAMMA DALLA PRODUZIONE )

Information Flow Aplications
The core car production system is
called POINT and the production
tree management application is
called DBP, the supplier
determination application is
called SGV and export parts
orders management is called
WMF.
Information Flow
The information flow within
departments is managed via the
integrated computer systems.
As an example of the information flow
within a department, the information
flow of the production planning and
MRP department is provided.
Production Planning
Department Information Flow
The production planning department enters
the 6 month’s production plans to FIAT
system (PDP) by evaluating the production
parameters entered to FIAT system
(POINT).
The
department
performs
specific simulations on the production
plans and decides on a production plan.
During the simulations, the working
calendar, production capacity and type
details for each brand is taken into
account.
INFORMATION FLOW at
TOFAS
Production Planning
Department Information Flow
The production planning department uses
the order estimations entered to the
system by the commercial channel
logistics services. The decided production
plan (DPD) is sent to the NPRC supplier
system weekly. By this flow each car is
only produced within the production plan
and order number. The production
planning and MRP department performs
these operations by using the PDP system
and the information is used and shared
among the department via this system.
TOFAS SYSTEM
All these production related
systems integrate on an
application called NPRC in TOFAS
to structure master production
plan data. This information is
transferred from production
departments both to FIAT Italy
and to TOFAŞ local systems.
Market
Demand
Finance
Manufacturing
Master
production
schedule
Marketing
Production
plan
MRP
Rough-cut
capacity planning
Capacity
planning
Adjust
production plan
Yes
Problems?
No Requirements No
schedules
Problems?
Adjust master schedule
HOW CIM IMPROVES
INVENTORY?
Yes
CONCLUSION
As can be seen in figure CIM
integrates all business functions
(MRP, MPS, Capacity Planning
etc.) with other departments
(Finance, Marketing,
Manufacturing etc.) within
organization.
Thank you for
listening…