World Class Technologies for
Manufacturing
World Class Technologies for Manufacturing
Patrick J. Delaney, CFPIM, CIRM, CPM
World Class Technologies for
Manufacturing
National Manufacturing Week
Chicago
McCormick Place
February 23-26, 2004
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Manufacturing Enterprise Automation
Manufacturing Process Automation
Product Design Automation
Facility Security & Automation
Data Capture and Data Tracking Automation
World Class Technologies for
Manufacturing
Computer-Integrated Manufacturing
Rehg & Kraebber, Prentice
Hall, 3rd Ed. 2004
Purdue University
 30 Engineering
Schools
 Manufacturing
Technology
Program
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World Class Technologies for
Manufacturing
Are You Ready To Go ?
World Class Technologies for
Manufacturing
The Untouched Processes
World Class Technologies for
Manufacturing
World Class
Technologies
for
Manufacturing
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Electronic Commerce [www.com+EDI]
Internet Supply Chain Systems Suite
Enterprise Resource Planning Systems
Advanced Planning & Scheduling Systems
Integrated ERP/CRM/SRM
Wireless WANs [over 30 miles]
RFID Tracking Technology
Global Tracking Systems
Internet B2B Server Applications
Sales & Field Force Automation [SFA]
Mobile Connectivity [MC]
Computer Aided Design CAD/PLM
Computer Aided Manufacturing [CAM]
Manufacturing Automation Controllers
Device and cell controllers
World Class Technologies for
Manufacturing
DuPont Innovation
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Automotive Coatings
Technology
Wet on Wet Paint Systems
 Rust coating
 Primer coat
 Color coat
 Clear coat
Final stage oven dry
World Class Technologies for
Manufacturing
Robotic Evolution
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Betty Boop
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Hydraulic in early 1980s
Electric/electronic today
Newer vision systems
Higher accuracy & repeatability
Proprietary controllers
[Motorola]
Advanced CAD/CAM
Simulation
Greater path accuracy [0.05mm]
Dual robotic cells
Jig-less manufacturing
World Class Technologies for
Manufacturing
Manufacturing Software
Development Path
APS
MES
SFC
Inventory
control
ERP/ERO
MRP II
MRP
Order Entry
Forecasting
SFA
CRM
DRP
SCM
World Class Technologies for
Manufacturing
Supply Chain Suite
Customer Relationship Management
CRM
Order Management Systems
OMS
Enterprise Resource Planning
ERP
Warehouse Management System
WMS
Advanced Planning & Scheduling
APS
Transportation Management System
TMS
Supplier Relationship Management
SRM/SCOR
Design Engineering/ CAD
G2G
Electronic Commerce Suite
B2B
World Class Technologies for
Manufacturing
Supply Chain Event Managers
[SCEM]
i2 Global
Logistics Monitor
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Computer
Associates
BizWorks
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Monitor all E-commerce
transactions
Business rule based
Create action messages
and flags
Check each event for
validity and accuracy
Accommodates all trading
partners
Order status, shipping,
inventory, billing, etc.
World Class Technologies for
Manufacturing
Internet CAD
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E-commerce graphics
application
Internet transfer of
engineering documents &
graphics
Utilizing a translation software
to interface with incompatible
supplier applications
Ford Case
World Class Technologies for
Manufacturing
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Laser based 100% inspection
Automatic collection of SPC
data
Line stopping feedback
Machine analysis and
preventive maintenance
warnings
Bi-lingual inspection
instructions
Automated display of ISO
9000 procedures
Intranet sharing of QA data
across plant sites
Daimler-Chrysler Case
World Class Technologies for
Manufacturing
Honda Supplier
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Inbound items are bar-coded
Outbound items are bar-coded
WIP isn’t bar-coded
Warehouse isn’t bar-coded
Cycle counts daily
Physical inventory every 30
days
World Class Technologies for
Manufacturing
Old Rand-McNally Publishing Co. Case
Cycle Counting
Approach
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Largest printing plant in the U. S.
Very large warehouses
F.G. Four racks high
Lose signatures
Cycle counters
 Flashlights
 Binoculars
 Computer print out
World Class Technologies for
Manufacturing
Data Capture Devices
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Hand held devices
Pen based devices
Scanner/data input devices
RFID tracking
ERP integrated
Windows CE - OS
Finger size point & scan
Micro-chip theft control
Electronic asset tracking [EAT]
Rackrunners
MicroStamp RFID Technology
World Class Technologies for
Manufacturing
Voice Recognition Technology
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InfoWorld 100
Technology Winner 2003
Warehouse picking application
Headset communications
Belt clip display system
Two-way communications
Improved pick accuracy to one error
in 3,000 picks
World Class Technologies for
Manufacturing
Technology Assessment Team
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Technology Assessment
Investment priorities
Integration issues
Benchmarking study
New employee profiles
Technology training
Payback measurements
University relationships
Technology Vision
World Class Technologies for
Manufacturing
Today’s Typical Systems Environment
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Most technologies are only partially
implemented or interfaced
Budget constraints constantly cut back
deployments
Acquisitions & divestments force major steps
backward
E-commerce skill sets are weak
Short term needs interfere with obtaining
quality deliverables
End to end supply chain initiatives have
overwhelmed the development queue
Outsourcing has built more islands of
automation
World Class Technologies for
Manufacturing
World Class Technologies Assessment
INTEGRATION
World Class Technologies for
Manufacturing
Today’s Purdue Graduates
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Database structuring and administration [Quick BASIC, C+]
Design techniques of Expert Systems [PC Easy & EXSYS]
PC based ERP
Distributed system design & networking
Hands-on PLC programming [programmable controllers]
Apply CAD and CAE software tools
Work in a $10 million CIM laboratory
 CIM software
 CNC workstations
 automated materials handling with robots
 automated data capture [RFID]
 vision systems
World Class Technologies for
Manufacturing
PPR Hub
Production System
Efficiency
Cost
Analysis
Process Planning
Robotics
Ergonomics
Product
Process
HUB
Resource
Scheduling & Control
QA
Factory Flow Simulation
System Integrators: Rockwell/ IBM/ Dassault/ ABB/ EDS/ MIT
World Class Technologies for
Manufacturing
National Manufacturing Week
Chicago McCormick Place
February 23-26, 2004
www.manufacturingweek.com
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What industries are using your product?
What new features have been added to your product since
last year?
What are the integration features of your product?
World Class Technologies for
Manufacturing
Speaker Contact Data
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Patrick J. Delaney
NWU Research Park
E:mail:
SIBCCorp@aol.com
Phone:
1-800-806-5177