Modern Manufacturing: Information Control and Technology

Advanced Manufacturing Series Series editor: D.T. Pham

Other titles in the series:

A Systems Approach to AMT Deployment Eds. D.R. Towill and J. Cherrington

Human-Intelligence-Based Manufacturing Ed. Y. Ito

Intelligent Manufacturing: Programming Environments for CIM Eds. W.A. Gruver and I.C. Boudreaux

Automatic Supervision in Manufacturing Ed. M. Szafarczyk

MODERN MANUFACTURING

INFORMATION CONTROL AND TECHNOLOGY

Edited by

Marek B. Zaremba and Biren Prasad

With 176 Figures

Springer-Verlag London Berlin Heidelberg N ew York

Paris Tokyo Hong Kong Barcelona Budapest

Marek B. Zaremba, PhD, MSc Departement d'Informatique Universite du Quebec a Hull 101 St-Jean-Bosco, Hull, Quebec, Canada J8Y 3G5

Biren Prasad, PhD CERA Institute 5421 South Piccadilly Circle, West Bloomfield, MI 48322, USA

Series Editor

D.T. Pham, PhD University of Wales, College of Cardiff School of Electrical, Electronic and Systems Engineering P.O. Box 917, Cardiff CF2 lXH, UK

ISBN-13: 978-1-4471-2103-9 e-ISBN-13: 978-1-4471-2101-5 DOl: 10.1007/978-1-4471-2101-5

British Library Cataloguing in Publication Data A catalogue record for this book is available from the British Library

Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permitted under the Copyright, Designs and Patents Act 1988, this publication may only be reproduced, stored or transmitted, in any form or by any means, with the prior permission in writing of the publishers, or in the case of reprographic reproduction in accordance with the terms of licences issued by the Copyright Licensing Agency. Enquiries concerning reproduction outside those terms should be sent to the publishers.

41 Springer-Verlag London Limited 1994

Softcover reprint ofthe hardcover 1 st edition 1994

The publisher makes no representation, express or implied, with regard to the accuracy of the information contained in this book and cannot accept any legal responsibility or liability for any errors or omissions that may be made.

Typesetting: Camera ready by contributors

69/3830-543210 Printed on acid-free paper

Preface

Manufacturers worldwide are faced today with important and in many respects unprecedented challenges resulting mainly from international competition, changing production processes and technologies, shorter product life-cycles, market globalization, and environmental requirements. Fundamental to meeting these challenges is the understanding and control of information across all stages of the Computer Integrated Manufacturing (CIM) process. Manufacturing competitiveness is a balancing act. There is no single technical solution that can be copied easily or bought from another successful company. A well-orchestrated process, using the capabilities of information technology to their full extent, is required to achieve corporate goals and objectives.

This book offers a solid tutorial and reviews the state of art in the information oriented aspects of Computer Integrated Manufacturing and Intelligent Manufacturing Systems. The book deals with modern manufacturing knowledge that is sufficiently general to provide at least partial intellectual support for a number of specific CIM cases, applications, and the introduction of new products and systems. Particular emphasis is placed on the impact of new software engineering technologies, object-oriented approach, database design, hierarchical control and intelligent systems. A number of fundamental techniques and methods for achieving manufacturing realization are extracted from modern manufacturing theory and the currently successful practices.

The structure of the presentation reflects four fundamental aspects of manufacturing: planning, modeling, design and control. Thirteen chapters of the book are grouped together in six parts. The first part addresses general issues of modern manufacturing paradigm and enterprise modeling. Chapter 1 begins with an introduction of fundamental notions of modern manufacturing. It lists major elements of Intelligent Information Systems and discusses main barriers hindering the development of a product. Eight areas that determine the performance of enterprise competitiveness are examined. Chapter 2 deals with enterprise modeling. Enterprise modeling system presented in the chapter provides a comprehensive approach to model the business and engineering processes as well as to simulate dynamically the operations within a manufacturing enterprise.

Three next three chapters are focused on object-oriented approach. Chapter 3 discusses object-oriented information modeling paradigms - a description of a distributed information system model that includes both information (data, knowledge, and processes) and functional specifications. Chapter 4 provides a more detailed presentation of database technology - an essential ingredient of a CIM system. Particular emphasis is placed on relational and object-oriented databases, which provide technology responding to the needs of the next generation distributed database systems. Object-oriented approach to design of process parameters is explored in Chapter 5. A framework of a star topology system is described, where the central node is a blackboard and all the surrounding nodes are objects representing different design perspectives.

Hierarchical structures in the context of production management are the topic of the next two chapters. Chapter 6 describes a framework for building a hierarchical system to model large scale production systems and for execution of such a system to effectuate optimal planning, decision and control. Hierarchical control approach to solve complex

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managerial problems is discussed in Chapter 7. First, the problem of production planning for multi-product CIM systems is dealt with for both linear and non-linear cases. Then, the problem of optimizing the operation of an autonomous manufacturing/supply chain and a composite inventory-marketing problem are considered. Finally, an integrated multi-product dynamic model for long-term strategic planning is given.

The next part of the book examines topics relating to modeling and control of Flexible Manufacturing Systems. Chapter 8 addresses the implications of information control and technology in integrated control and management of the shop-floor operations. Heuristic and knowledge based approaches are emphasized. Modeling of manufacturing systems using Petri nets theory is discussed in Chapter 9. The modeling techniques are analyzed from the standpoint of system performance evaluation and optimization, including deadlock handling and efficiency prediction. Automated synthesis of performance­oriented Petri net models is examined. Chapter 10 deals with the problem of fault tolerance in computerized manufacturing systems. Explicit introduction of fault tolerance at the specification and the design stage of modem manufacturing systems is proposed. A case study of the Volvo Uddevalla computerized assembly plant is presented.

Chapters 11 and 12 deal with the issues of Computer-Aided Design in its broad aspects. Chapter 11 presents computer-aided process planning tasks as the link between CAD and CAM (Computer-Aided Manufacturing) systems. Both fully automatic planning and group technology approaches are looked upon based on the results of two BRITE/EURAM projects. In Chapter 12, computer-aided design process based on features is discussed. Features are used as vehicles to introduce functional aspects into CAD techniques.

Finally, Chapter 13 describes advantages and difficulties of implementing Just-In-Time technology in manufacturing systems. Upon a discussion of the JIT environment, three case studies are presented.

The editors wish to thank all the chapter authors for their contributions to the book. Many of the authors are well-known scholars in modem manufacturing and information technology areas. Many of them are respected instructors and long-time colleagues of the editors. Their names are listed in the list of contributors. Our thanks also go to Miss Imke Mowbray and Mr. Nicholas Pinfield, editor at Springer Verlag for their help with the book production. We are thankful to Suchitra Mathur and Dayana Stetco, who helped edit the manuscript, and our family members: Mrs. Pushpa Prasad, Miss Rosalie Prasad, Miss Gunjan Prasad, Miss Palak Prasad, and Janina, Renata and Chris Zaremba for their love and support.

Marek B. Zaremba Biren Prasad

The Contributors

G.M. Acaccia

Industrial Robot Design Research Group University of Genova Via all'Opera Pia 15/A I - 16145 Genova, Italy

A. Adlemo

Department of Computer Engineering Chalmers University of Technology S - 412 96 G6teborg, Sweden

L.A.R. AI-Hakim

School of Management David Syme Faculty of Business Monash University P.O. Box 197 Caulfield East, Victoria 3145 Australia

S.-A. Andreasson

Department of Computing Science Chalmers University of Technology S - 412 96 G6teborg, Sweden

Z. Banaszak

Department of Robotics and Software Engineering Technical University of Zielona Gora 65-246 Zielona Gora, Poland This work was completed when the author was on a leave at: Department of Mathematics Kuwait University, Kuwait

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M. Cal/egari

Industrial Robot Design Research Group University of Genova Via all'Opera Pia 15/A I - 16145 Genova, Italy

A.W. Chan

Institute for Advanced Manufacturing Technology National Research Council Montreal Road, Bldg. M-50 Ottawa, Ontario, Canada K 1 A OR6

Y.-T. Chen

Department of Industrial Engineering The University of Iowa Iowa City, IA 52242-1527, U.S.A.

K.A. Jorgensen

Department of Production University of Aalborg Fibigerstraede 13 DK - 9220 Aalborg 0, Denmark

G. Kapsiotis

Intelligent Robotics and Control Unit Department of Electrical and Computer Engineering National Technical University of Athens Zographou 15773 Athens, Greece

A. Kusiak

Department of Industrial Engineering The University of Iowa Iowa City, IA 52242-1527, U.S.A.

R. C. Michelini

Industrial Robot Design Research Group University of Genova Via all'Opera Pia 15/A I - 16145 Genova, Italy

R. M. Molfino

Industrial Robot Design Research Group University of Genova Via all'Opera Pia 15/A I - 16145 Genova, Italy

R. Nagi

Department of Industrial Engineering State University of New York at Buffalo 342 Bell Hall Buffalo, NY 14260, U.S.A.

H. Nordloh

Bremer Institut fur Betriebstechnik und angewandte Arbeitswissenschaft an der Universitat Bremen, Hochschulring 20 D-28359 Bremen, Germany

B. Prasad

CERA Institute 5421 South Piccadilly Circle West Bloomfield, MI 48322, U.S.A.

J.-M. Proth

INRIA-LORRAINE Technopole de Metz 2000 4 rue Marconi 57070 Metz, France

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M. Schulte

Universitat des Saarlandes Lehrstuhl fUr Konstruktionstechnik/CAD, Postfach 1 511 50 66041 SaarbrOcken, Germany

A.S. Sohal

School of Management David Syme Faculty of Business Monash University P.O. Box 197 Caulfield East, Victoria 3145 Australia

R. Stark

Universitat des Saarlandes Lehrstuhl fOr Konstruktionstechnik/CAD, Postfach 151150 66041 SaarbrOcken, Germany

S. Tzafestas

Intelligent Robotics and Control Unit Department of Electrical and Computer Engineering National Technical University of Athens Zographou 15773 Athens, Greece

F.B. Vernadat

INRIA-LORRAINE Technop61e de Metz 2000 4 rue Marconi 57070 Metz, France

Ch. Weber

Universitat des Saarlandes Lehrstuhl fOr Konstruktionstechnik/CAD, Postfach 151150 66041 SaarbrOcken, Germany

Contents

1. Modern Manufacturing

B. Prasad

2. Enterprise Modelling

A. W. Chan ......................................................................... 26

3. Object-Oriented Information Modelling

K.A. Jergensen ................................................................... 47

4. Databases for CIMS and IMS

F.B. Vernadat ...................................................................... 85

5. An Object-Oriented Approach to Design of Process Parameters

Y.- T. Chen and A. Kusiak ................................................... 115

6. Hierarchical Production Management

R. Nagi and J.-M. Proth ..................................................... 132

7. Hierarchical Control Approach to Managerial Problems for Manufacturing Systems

G. Kapsiotis and S. Tzafestas .............................................. 173

8. Flexible Manufacturing by Integrated Control and Management

R.C. Micheli!?i, G.M. Acaccia, M. Callegari, and R.M. Molfino ... 225

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9. Modeling of Manufacturing Systems

Z. Banaszak 253

10. Fault Tolerance in Flexible Manufacturing Systems Parameters

A. Adlemo and S.-A. Andreasson ........................................ 287

11. Integration of CAD,CAM and Process Planning

H. Nordloh ....................................................................... 327

12. Features as Modeling Entities for Intelligent Design Systems in Mechanical Engineering

M. Schulte, R. Stark, and Ch. Weber ................................... 354

13. Implementation of JIT Technology

A.S. Sohal and L.A.R. AI-Hakim .......................................... 378

Index ............................................................................... 401