E-Manufacturing: A Technology Review

carry ons of the World coition on introduction 2008 Vol II WCE 2008, July 2 4, 2008, London, U. K. E Manufacturing a Technology Review Dr. H. K. Shivanand, Nanjundaradhya N. V, Prabhakar Kammar, Divya shree S, Keshavamurthy YC. Abstract With a rapid change in technology especi bothy in the manufacturing sector, nodes ar demanding much(prenominal) value, less risk, and better desegregation of products, hence thither is a need to change the manufacturing strategies, which set up result in improved transaction thereby meeting the customer demands.This paper critic onlyy reviews a bracing bea to overcome the above puzzle called E Manufacturing which brook commingle customers, products and bequeathrs with the overhaul of profits Technology. The concept of E Manufacturing, its development, motherfuckers and potential benefits are discussed along with application casefuls on Automobiles. Areas analogous E Maintenance, E nosology, E craft related to E Manufact uring is also discussed. By adopting such a manufacturing proficiency zero downtime, reduced product error, customer satisfaction, quick manufacturing changes can be accomplished.In addition the concept of E-Manufacturing applied to the manufacture of flips is also discussed there by providing better chthonicstanding of this march. like ERP, MES, SCADA, and even wiseer acronyms like go-ahead As sort out Management (EAM) and Product Lifecycle Management (PLM) are communicating with each other, and sharing data done network connections. II. EVOLUTION OF E MANUFACTURING For decades, the predominate manufacturing model was based on principles of mass output 2.Standardized part and processes made economies of scale achievable, but limited design flexibility and customization. The outsourcing and flow manufacturing gallerys of the 1980s and 1990s drove the emergence of a freshly paradigm, termed the character Management era. Manufacturing companies, particularly large Origi nal Equipment Manufacturers (OEM) outsourcing shifts critical elements of the design and production process onto a manufacturers supply chain. The lean manufacturing movement places a premium on time and inventory reduction.Combining the attributes of the tone of voice era suggests a very antithetical descent model for manufacturing green light integration or E-Manufacturing. In the E-Manufacturing era, companies will be able to substitute knowledge of all types with their providers at the speed of light. III. E MANUFACTURING E-Manufacturing can be most cogently and generally described as the application of the Internet to Manufacturing 3, come on E-Manufacturing is becoming popular with the increased mapping of the net income.Due the widespread availableness of the Internet large-scale distributed projects in manufacturing are becoming popular. It is the methodology and material for collaborative Virtual Manufacturing. The ability to exchange randomness and automate man ufacturing processes manikins the building blocks of the virtual manufacturing companies of the near in store(predicate). It covers all aspects of manufacturing sales, marketing, customer wait on, spic-and-span product development, procurement, supplier relationships and logistics manufacturing strategy development and so on.As a result, it is to sidereal day so much easier to entrust current people gain access to definite sections of the ashes, according to whatever criteria they like living people need indisputable parts of the data, but not others operators would be able to access a limited number of thingmajigs managers would be allowed to monitor, but not change anything, and so forth New technologies such as the Extensible Markup Language (XML) are now making it easier to share data betwixt different application programs, and to set up computers to take actions based on criteria for instance, to gild supplies when inventories reach a critical low point.The E-M anufacturing WCE 2008 Index Terms E Manufacturing, E Maintenance, E Diagnostics, Automobile, Gears. I. INTRODUCTION F manufacturing companies what matters more is that how efficiently their company can compete globally with others as an organization followed by meeting the day to day requirements of the customer and exchange of hassle free information while not foc utilize just now on sales of the company 1. Todays customers provide top priority for money, better quality and less risk.In order to cater to the needs of the customer, manufacturing companies eat up adopted a new technique called E Manufacturing. It is concerned with the use of the Internet and E-Business technologies in manufacturing industries wherein a network can be established between the customer, the manufacturer and the product. The internet offers a frictionless path for exchange of information. The concepts of E-Maintenance, E-Business, E Diagnostics and ECare father led to the formation of an E-Factory which can produce quality products at odd speeds.In short, the customer is just a click a behavior from a business deal. Within manufacturing concerns, the sundry(a) enterprise-wide dusts OR todays mul latch onle sclerosis received October 11, 2007. H. K. Shivanand is with the University Visvesvaraya College of Engineering , Bangalore, Karnataka, INDIA 560001 phone 918022961887 e-mail Shivanand. emailprotected gmail. com Prabhakar Kammar, is working at MVJ College of Engineering, Bangalore Nanjundaradhya N. V is working at RV College of Engineering, Bangalore Divya shree S is working at BEL, Bangalore.Keshavamurthy YC, ME (Manufacturing Sc &Engg), UVCE, Bangalore. ISBN978-988-17012-3-7 Proceedings of the World Congress on Engineering 2008 Vol II WCE 2008, July 2 4, 2008, London, U. K. technique also affects products as well since it is possible to use Internet technologies to add new product functions and to provide new wait ons. The Internet is be used even at the shop floo r level. For instance, computer numerical bidding devices (CNCs) can be connected via intranets or the Internet to ERP ( opening move election Planning), production cookery, or alimentation systems.As such, the E-Manufacturing project aims to develop an charm framework for a common platform to enable distributed planning and control in manufacturing for quicker, easier, secure and cost- useful collaborations. The developed system will allow dispersed engineering team members to work together productively, as if they were under one roof. This transformation of the enterprise coincides with the increasing content of information contained in products and processes. This new production enterprise is information-rich.The major functions and objectives of e-manufacturing are (a) provide a tran pointlessnt, seamless and automated information exchange process to enable an only handle information once (OHIO) environment (b) improve the utilization of set out floor assets using a holi stic approach combining the tools of prognostic maintenance techniques (c) links entire SCM operation and asset optimization and (d) drive home customer services utilizing the latest bidive intelligence methods and Tether-free technologies 4 physical body 2 Before Implementing E Manufacturing Fig 3 After Implementing E Manufacturing IV.E MANUFACTURING TOOLS Implementation of the E-Manufacturing tools results in cost saving, regardless of the company size. E-Manufacturing tools enable connectivity among the confused modules of the manufacturing process. Areas where the E-Manufacturing tools need to be developed are listed below 5 9. Data and information transformation tool The large amounts of raw data collected during a manufacturing process are rendered useless, unless the data is gathered and transformed into some profitable information which whitethorn be used to monitor a system. To generalise this better a simple example is taken below.Consider a CNC machine hooked to t he Internet as shown in Figure 4. It shows the way data and information are transformed from the machine to the internet. Here the root word is to monitor the health of the tool life of the tool fixed in the CNC machine. This technique can also be used to calibrate a machine from the Internet. Fig 1 Evolution of E Manufacturing (Source NACFAM) The contrast between the traditional system and the system with E-Manufacturing is indicated below 3 ISBN978-988-17012-3-7 WCE 2008 Proceedings of the World Congress on Engineering 2008 Vol II WCE 2008, July 2 4, 2008, London, U.K. Fig 4 Tool Monitoring in a CNC Machine Using Internet. Prediction Tools Apart from data organism gathered, certain tools need to be developed, which can predict or find out the degradation of various parts of the machine, transaction loss and trend of failure. ontogenesis a tool which monitors these aspects could set the trend for an advanced diagnostic system. optimisation Tools As far as E-Manufacturing is co ncerned data can be accessed from any part of the globe at any time. Hence certain tools need to be developed which can optimize the data and provide easy to read results.For example, these tools should be able to provide the performance of a drill bit for various drilling operation verses time, temperature, tool tip failure with various materials and so forth Synchronization Tools This is an important tool in the E-Manufacturing environment, which can associate various groups such as customers suppliers and manufacturers, where first hand information needs to be sent to these groups during emergencies, for example if tool needs a replacement or tool has exhausted out and then the information is sent from first the manufacturer to the supplier and tool maker where the tool can be assessed for performance.The new connectivity and communication theory tools will boost productivity, profits, speed to market, and flexibility for those manufactures who are willing to upgrade. some(a) of the common E-manufacturing tools are SMS, E Mail, Bluetooth, Wi-Fi, Fax and Infrared Connectivity. V. E maintenance Progressive plant executives, maintenance managers, and work planners have always cute to have information about the condition of equipment assets at their fingertips when they need it. Unfortunately, it typically is scattered among separate information systems.It is difficult to view, compile and synchronize the different information types on the same computer terminal. If one wants to maximize business continuity by increasing device up-time and minimize the time, costs and headaches associated with device brass he must adopt the E-Maintenance strategy. It is a network that integrates and synchronizes the various maintenance and reliability applications to gather and deliver asset information where it is needed, when it is needed. Interconnectivity of the islands of maintenance and reliability information is embodied in E-Maintenance.The EMaintenance network c an be developed from a collection of information islands by using a single proprietary system, a custom bridge, or by using an open systems bridge. EMaintenance also removes the need for manual meter exercises that is your device administration is virtually reduced to nil. It is estimated that 15- 40% of indirect costs of manufacturing is maintenance related. roughly 50% are unnecessary corrective maintenance, which costs 10-15 times more than predictive maintenance. Furthermore, 25% of maintenance is interdictive, which is 3-5 times more expensive then predictive.An effective E-Manufacturing strategy uses predictive maintenance techniques to forecast equipment wear and predict failure. Apart from this, it also alerts MRO managers to unexpected problems. This allows managers to proactively correct problems, thus maximizing the use of machinery and personnel while minimizing preventive maintenance expenses. Predicting the reliability of plant-floor equipment can be the difference between a few minutes of preventive maintenance and hours or days of downtime for corrective maintenance.Ultimately, predictive maintenance, computerized maintenance management systems or CMMS, and effective utilization of maintenance specialists make E Manufacturing work. VI. E nosology E-Diagnostics is the reactive and proactive remote diagnosis, maintenance and repair of equipment by service personnel. EDiagnostics offers many businesses the promise of better equipment reliability and performance at a much lower cost. It is the hardened, reliable acquisition of time-stamped, highspeed information from the tool registers and adjuvant data points, database retention and management, parsing and analysis.A complete E-Diagnostics source would include the undermentioned (a) Remote capture, transmission, analysis and dissemination of equipment performance data. (b) Remote takeover of equipment to fudge equipment settings during and after repair. (c) A trigger for replenishing spare parts. (d) Faster and more effective response to field service engineering requests, bringing the experts remotely to the problem. (e) cut down equipment and process variation, through better visibility and response to differences in equipment performance among machines. ISBN978-988-17012-3-7 WCE 2008Proceedings of the World Congress on Engineering 2008 Vol II WCE 2008, July 2 4, 2008, London, U. K. (f) Preventive response to pending equipment failures through the use of advanced process control (real-time multivariate statistical analysis). (g) Enhanced next-generation tool development through improved awareness of deficiencies in current equipment designs. Traditional E-Diagnostics systems monitor tool performance and provide maintenance needed alerts to service and engineering personnel. much(prenominal) more can be derived from the rich sensor data generated as wafers pass through process chambers.This step in E-Diagnostics is to employ proven enterprise data mining (EDM) te chniques to correlate device turn in and performance with the vast amount of tool-level and wafer-level chamber sensor data. With this new approach, yield and process-level issues can be uncovered down to a particular sensor reading on a specific tool process chamber. Once a specific tool issue can be identified to have an impact on process results, specific E-Diagnostics monitors can be targeted to prevent future yield and process excursions, completing a closed curl up process learning effort.The steps to be followed to implement the E Diagnostics strategy in an industry are as shown below. maintenance programme. information processing systemized maintenance management systems optimize the deployment of all maintenance, repair, and operating (MRO) resources, such as people, spare parts, tools and facilities, and allow the creation of a planned maintenance programme for all assets. EProcurement allows the replacement of stock with information and offers direct access to spares a t net cost. For the successful application of E-Manufacturing there must exist a federation between the supplier and the customer.The goal is to deploy stovepipe practices in e-business processes as quickly and effectively as possible while ensuring a quantifiable return on investment (ROI). The benefits of adopting E business strategy are (a) Quick installation of software updates with no need for expensive integration projects. (b) One enterprise wide view of the customer, product or process. (c) orbicular deployment from one instance of the software, making all applications accessible globally via a standard Web browser. (d) Simplified systems and maintenance for IT staff due to the one-vendor approach. e) streamline business processes. (f) Better decision-making and business intelligence because of the single-database architecture and preintegrated applications and rapid deployment at lower cost. VIII. AUTOMOBILE INDUSTRY AND GEARS Every automobile industry has an many num ber of divisions, each division manufacturing a particular system of the automobile- like the steering system, brake system, engine, suspension, chassis and body, interiors, safety division, quality control division, etc.With so many departments working towards the creation of the same end product, a lot of time and money is spent in redesigning and related cases which may arise due to inefficient data transfer or delay transfer of important information between the departments. Such a problem can be sorted out by implementing the EManufacturing strategy into the industry. The internet can be used to share data and information between various departments and between manufacturers servicemanwide.Data sharing can be extensively used between the head office and the various branches and service centers of a company which may be located at different locations well-nigh the globe. For example, if a component is found defective in one of the branches the information is relayed immediately to the other branches warning them to arrest the production of that component immediately. As a result of this, huge amounts of time, material and money are saved. The internet is a means of communication between production engineers, the manufacturing engineers, and the design engineers.Adopting this new technique can reduce the complexity of the part, without jeopardizing performance. Using CAE tools in the design process may have a profound impact on savings. In many cases, the virtual prototype is a much more accurate representation of what we designed than the physical Fig 5 E Diagnostics VII. E BUSINESS In todays world its the Time Factor that can make or train an industry. Gone are the days of buying different applications from a master of ceremonies of technology vendors and spending countless months and dollars integrating them.Increasingly, the customers are demanding more customized products, swift delivery schedules, and instant access to order status. Results have t o be assessed in financial terms, with return on net assets or return on capital employed, the key measure. EBusiness promises a solution to this customer demanding market. Automated schedule provides a better method of managing production orders and increases the visibility of current and future scheduling activities. Tracking involves the collection, analysis, viewing and reporting of production data.To get the best productivity from the assets deployed, three main areas need to be addressed assure based maintenance computerized maintenance management EProcurement. Condition-based maintenance predicts the deterioration of assets that allows the planning of maintenance actions more effectively and monitors the effectiveness of the ISBN978-988-17012-3-7 WCE 2008 Proceedings of the World Congress on Engineering 2008 Vol II WCE 2008, July 2 4, 2008, London, U. K. prototype. Apart from adopting this strategy in the production line it can also be used in the maintenance program of an automobile.For example, if you only repair your elevator car when it breaks down, you face expensive corrective maintenance. A preventive maintenance schedule, based on the manufacturers recommendations, may prevent breakdowns. Preventive maintenance is possible using E-Diagnostics. When a car is taken in for servicing, it is hooked onto the diagnostic computer which indicates existing problems. provided the service centers are constantly hooked up to the internet and are updated on availability of spares, latest trends in servicing and solutions to commonly occurring problems. each(prenominal) this information is made available from their counterparts from around the world. To add to this the entire service history of the vehicle is uploaded to the net so that it is made available to all of the companys service centers around the globe which will help identify the status of the vehicle wherever and whenever one wants to service it. Gears form an important component in most mach ines as well as in automobiles. Todays Customers demand a multitude of gears in a short span of time, without any compromise on quality.The solution to this challenge is E Manufacturing. One can hook up the gear manufacturing machine to the net. It offers fully integrated production control software for estimating, order and job control, job travelers, scheduling, data collection, inventory control, purchasing, work center warhead and cost accounting. Various design parameters can be entered by the customer and modifications may also be made until the last minute. Once the system is in place economic and efficient manufacture of gears is imminent. 1. Synchronize proceeds Processes with Business Processes. . Orchestrate Upstream Flows of Work, Information, and Material. 3. Automate Business Processes & Workflows within the Enterprise 4. Give Control to Managers with Plant Information & Analysis Tools. 5. Integrate the fig Process among All Collaborating Parties. 6. Leverage Bi-dir ectional Down-stream Information. 7. Enable Collaborative Maintenance and Manufacturing Support. X. terminus This paper discussed certain key areas and subsets of the E-Manufacturing strategy which when implemented will yield priceless benefits to an industry that implements it.Further the concept of an E-Factory promises greater increase in productivity and performance, while at the same time decreases production costs. However, for E-Manufacturing to be a success, co-operation between various public and private sector organizations is mandatory. This new thinking paradigm to integrate web-enabled and predictive intelligence for manufacturing systems is becoming a new benchmark strategy for manufacturing companies to compete in the twenty-first century. 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Proceeding of Sixth International Manufacturing Technology in Hong Kong, celestial latitude 2001 Lee J, Ni J. E-manufacturing and e-business integration a case study. Proceeding of the International Manufacturing Leaders Forum (IMLF), Adelaide, Australia, February 810, 2002. Lee J, Ni J. Infotronics agent for tether-free prognostics.Proceeding of the AAAI Spring Symposium on Information Refinement and Revision for Decision Making Modeling for Diagnostics, Prognostics, and Prediction, Stanford University, Palo Alto, CA, March 2527, 2002. 3 4 5 6 7 Figure 6 Application of E Manufacturing to Automobile Industry 8 9 IX. BENEFITS OF E-MANUFACTURING E-Manufacturing is a fundamental change in the strategical value proposition for manufacturers. Its collection of systems, processes, and technologies that support and enable manufacturers to compete in collaboration with others has seven fundamental jobs ISBN978-988-17012-3-7 WCE 2008