Design and Analysis of Integrated Manufacturing Systems (1988) / Chapter Skim
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Design and Analysis of Integrated Electronics Manufacturing Systems
Design and Analysis of Integrated Electronics Manufacturing Systems
Pages 12-33
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From page 12... ...
AT&T has conducted productivity improvement programs at various manufacturing facilities. This experience is the base from which we have established new directions for further advances in manufacturing productivity.
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The following functions are contained under the heading of manufacturing: · Process design and engineering · Translation of product design information into manufacturing information · Production planning, scheduling, and control · Incoming material control · Material ordering and stocking · Product fabrication, assembly, and testing · Product repair · Quality control · Product and process productivity improvement · Manufacturing information management We consider manufacturing and distribution as a single business activity. This approach integrates the following functions with those listed above: Components \ j/ Products - - - Dlstrlbutlon \ Systems, Subsystems, Power, (Repair: /Stocking, Installation, Clrcult Packs \ / ~ Staging _ ~ Network Systems r Semiconductors ~ ~ Equipment etwork Sys ma Dlscretes I ~ ~ Media HlCs | | | Data Systems | _ Large Business | Systems | _ General Business _ Systems consumer Products T Underlying Technologles Manufacturing Technology -Systems Engin~rlng -CIM -Physical Sciences Network Systems r (OTC)
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From page 14... ...
They will eventually result in a merger of manufacturing and distribution operations into product family operations that are singularly managed. The balance of this paper deals with our experiences with productivity improvement programs and the directions we have set for design of manufacturing processes and for related R&D programs.
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Preferred component use offers not only improvements in assembly costs but also additional benefits realized from material management, parts stocking, volume purchasing, test program reuse, and fewer quality and reliability engineering activities. A strong DFM effort between product designers and manufacturing engineers, especially for component engineering in the manufacture of electronic circuit packs, has greater leverage in reducing overall costs than does automation aimed at simply reducing assembly labor cost.
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Organizations supporting this office consist of functional planning groups for various aspects of manufacturing operations, the manufacturing R&D operations, and the environmental control staff. A Manufacturing and Distribution Council A manufacturing and distribution council, consisting of all corporate officers who have direct manufacturing or distribution responsibilities and chaired by the corporate manufacturing executive, has been established.
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| Flow Control =1/ Matorlal Handling, Queue Control Labor Productivity FIGURE 3 Manufacturing productivity realization model. High-V=bility Projects Specific high-visibility projects have been established in each business group.
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Quality Reliability Sched. 2 2 1 2 2 2 FIGURE 4 Implementation of process engineering software tools at AT&T manufacturing facilities.
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Since mechanization equals automation plus integration, the major benefits of information mechanization come from the integration component of that relation. Providing a customized information system for each operation can be expensive, both for initial implementation and ongoing enhancements.
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& T - t i//// Clrcult pack store room ~/////////~ i//////// ~////////~ | Malntenan~ | Quallty 1 L Warranty 1 Equipment I Assy. & Test | Shipping | Customer ~ Dlstrlbutlon Shop Floor Control Synchronized Production Engineering Control System Materials Operations Velocity System Manufacturing Process Control System Circuit Packs MPCS-EQ Manufacturing Process Control System Equipment MPCS-LOT Manufacturing Process Control System Lot Processing Accounting Receiving Executive System Planning Procurement System Integrated Manufactur ing Planning and Control AMAPS MRP-II UNICAD Advanced Manufacturing Accounting Production System Manufacturing Resource Planning Unified Computer-Aided Design For those functions shown without an information system title, local systems are currently in use.
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We have already built and installed workstations that include all elements of the process control model shown in Figure 9 and are connecting these workstations to PRISM systems. In one example of this procedure, a modification developed for photolithography
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1. Equipment t CIMA levels FIGURE 9 Process control model.
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In this situation, the handoff of the new process designs and technology is evolutionary, and the technology transfer to the operating personnel is continuous. SUCCESSES Projects that followed AT&T's manufacturing productivity realization model (Figure 3)
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100 OutpuVEmployee Product velocity Process time In-shop time 64% 1 61%= Increase (%) 200 400 600 800 1 1 1 1 233% Work In process Inventory Process down time Process analyals and enginoorlng time: 1 Month Initial Implementation Interval: 1 Month FIGURE 1 1 Denver Works productivity improvement initiative.
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SEIFER T Shipments Mlillons Un" ~ U tD _ _ _ FIGURE 12 Oklahoma City Works productivity improvements, SESS systems.
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We consider these results for complex circuit packs, using state-of-the-art devices, to be remarkable. A study was conducted in 1986 to try to evaluate the elements needed for worldcIass manufacturing productivity.
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Figure 17 shows the results achieved in a silicon wafer fabrication process using this technique. CONCLUSION These successes are an "existence proof' of the value of first applying systems engineering disciplines to manufacturing projects, followed by information mechanization (automation plus integration)
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· Opportunities exist for advancing the capabilities of production processes by applying new real-time computing technology capabilities to the following: process control; embedding software tools into CIM platforms, using system performance analysis, with "knowledge-based" and artificial intelligence techniques, and including advanced routing, scheduling, and comput
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From page 31... ...
DCM DETERMINISTIC CAPACITY MODEL LB/L QNA Simulation Models GSM Estimates the production capacity and machine utilization in a clean room as a function of the product mix. LINE BALANCE/LAYOUT Determines the minimum number of workstations and balances the workload among the stations to meet throughput requirements in assembly lines.
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REAL-TIME ANALYSIS SYSTEM Uses statistical techniques to monitor and analyze a manufacturing process in real time and improve efficiency and output by identifying problems as they occur. AGDAT ADVANCED GRAPHIC DATA ANALYSIS TOOL Displays and analyzes defect data using control charts.
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From page 33... ...
FINAL ASSEMBLY SCHEDULER Sequences final assembly in an attempt to smooth the demand on feeder shops. LOADING, BUFFER SIZE, SEQUENCING Quickly estimates production rate and machine use on circuit pack assembly lines and estimates effect of loading, lot sizes, and buffers on those rates.
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