13 LABORATORY - VISION SYSTEMS FOR INSPECTION

page 501



1. Complete the Labview vision tutorial.

2. Modify the appropriate test program to read bar codes, and save them to a file

3. Modify the appropriate test program to read a dimension of arbitrary parts and write the

dimension to a serial port.

Submit:

1. Printouts of the modified test programs.



page 502



18. INTEGRATION ISSUES



18.1 CORPORATE STRUCTURES

• First consider the major functions within a company,

- Production

- Materials

- Process Planning

- Design

- Customer Orders / Service

- Marketing

- Accounting

- Management

• All of these functions generate and use common information which must be communicated

between departments.



• Since computers handle information, we must be aware of what we get, and what we produce.



18.2 CORPORATE COMMUNICATIONS

• Previous paper based systems provided support for data transfer between departments, and

provided a good basis for the introduction of computers



• ASIDE: Computers can make a good system better, but they will always make a bad system

worse. This is because a system which is not well defined and poorly understood cannot be programmed, or optimized.



• Characteristics of paper based manufacturing systems,



page 503



- Multiple copies of same information.

- Revising information is hard when multiple copies exist.

- Delays for the transfer of paper.

- Easy to lose paper.

- Paper is not interactive.

- Paper requires bulky storage.

• Computers overcome and reduce the problems above, but introduce some technological

challenges,

- Creating programs to support corporate functions.

- Software to support interdepartmental communication and data sharing.

- Hardware to support the software.



S u p plier

D ata



O rd er



P rodu ction

O rder

P urchase

O rder R eq



O rder



O rder R eq



Incom ing

C o m m un ication



M an ag e

R aw M aterial

an d E n erg y

4



S ched ule



O rd er

S tatu s



K now

H ow



D ata



M eth o d s



S h ip p in g C o st



R e qm ts



Q A R esu lt



In v en to ry



P ack O ut S c he du le



A ssum e

Q u ality

6



C orporate

R& D



O rde r

R eq u est



A ccep ted

O rd er

R e serv atio n



M anage

P rod uct

C o sts

9



W aiv ers



QA

R esults



STDS



P erfo rm an ce

& C o sts



C o st O B J



M anage

P rodu ction

3



A pp ro v als



M a terial an d

E n ergy Inv en to ry



M a terial an d

E n erg y R eq d



P a rts

R M & E n erg y

Inc om ing



S ales

F orecast



S ch edu le

P ro ductio n

2

C ap acity



M ark etin g

P lant F un ctional E ntities and S ales



A nnual

S ales



P ro cess

O rd ers

1



P ro d uc tio n

C o st



Transit

C o m pan y



M ark eting

and S ales



R eq m ts



C u sto m er



M anag e

P ro du ct

S h ippin g

8



T ran sp o rt

O rder



M an age

P rodu ct

In vento ry

7



Inventory B alance



L o n g Te rm

M aterial an d E n erg y

R eq u irem en ts



M anage

P ro cu rem en t

5



P ay m en t

R elea se



A ccoun ting



M FG

R M & E n erg y

C o sts



Invoice and

S h ipp ing

D ocum en ts



E xternal E ntities



P urchasing



S u pp lier

P e rfo rm an ce



In vo ic e



S up plier /

Ven do r



C redit L im it

and O ther P o licy



A cco untin g



R elease

To S h ip



C onfirm

Availability



R elease Invoice

C onfirm

S hip



M arketin g

an d S ales



Invoice



C u sto m er



page 504



• This figure below shows various departments, and the information flow [source - ???



page 505



• Requirements for interfacing corporate management and staff functional entities to the fac-



FA C TO RY L E V E L 0.0



M anpow er

R equirem ents

K now H ow

Vendor

C ontracts



RES



E xternal

E ntities



PURCH



RD&E



M KTG

and

SALES



Policies



CORP

MGMT



H um an



M anufactuing

policies



ACCT



R equirem ents



tory [source - find]



• Assumed functional hierarchy computer system structure for a large manufacturing com-



page 506



Plant Production

Scheduling and

Operational

Management



Level3



Supervisor’s

Console



Inter-area

Coordination

(Shop coordination)



Level2



Supervisor’s

Console



Work Cell

(Direct Numerical

Control)



Operator’s

Console



Work Station

(Computerized

numerical Control)



Level 1

Dedicated

Programmable

Logic Controllers



PROCESS



Communications

with other areas



Operational and

Production

Supervision



Level4



Communications

with other

supervisory systems



Plant

Management

Information



Communications

with other

control systems



Management

Data

Presentation



Sales

Orders



plex [source - find]



[source - find]



raw material, energy

and spare parts

orders



PURCH



External

Entities



Status of

Production

orders



FACTORY LEVEL 0.0



Requests for

information,

plant tests



RD&E



MKTG

and

SALES



operational

performance

Policies



Manpower

performance

data and reqmts



RES



Human



Corporate

Performance reporting



CORP

MGMT



Cost

reporting



ACCT



page 507



• Report interfacing to corporate management and staff functional entities from the factory



page 508



• The Shop Floor Production Model (SFPM):

[ source - find]



Level



Section/



Responsibility



Supervise shop

4



Sub-Activity



Supervising and coordinating



floor production process



Area



the production and supporting the

jobs and obtaining and allocating

resources to the jobs.



Coordinate shop

3



floor production



Cell



Sequencing and supervising

the jobs at the shop floor produc-



process



tion process



Command shop

2



Station



floor production process

Execute shop floor



1



Equipment



production process



Directing and coordinating the

shop floor production process

Executing the job of shop

floor production according to commands



The ISO Reference Model for Factory Automation adds a couple of layers

[ source - find]



Level/

Hierarchy

6/

Enterprise



Area of Con-



Responsibility



Basic Functions



Managing the



Achieving the



Corporate management



trol



corporation



enterprise’s mission



Finance



and managing the



Marketing and sales



corporation



Research and Development



page 509



Level/

Hierarchy

5/

Facility or



Area of Con-



Responsibility



Basic Functions



Planning Pro-



Implementing



Product design and production



trol



duction



plant



the enterprise functions and planning

and scheduling production



engineering

Production management (upper

level)

Resource management (upper

level)

Procurement (upper level)

Maintenance management

(upper level)



4/

Section or



Allocating and



Coordinating



Production management (lower



production and



als and resources



obtaining and allocat-



Procurement (lower level)



ing resources to jobs



area



supervising materi-



Resource management (lower



level)



level)

Maintenance management

(lower level)

Shipping

Waste material treatment

3 / Cell



Coordinating



Sequencing and



multiple machines



supervising shop



and operations



Shop floor production (cell level)



floor jobs and supervising various supporting services



2 / Station



commanding



Directing and



machine sequences



coordinating the



and motion



activity of the shop

floor equipment



Shop floor production (station

level)



page 510



Level/

Hierarchy

1 / Equipment



Area of Con-



Responsibility



Basic Functions



Activating



Taking action on



Shop floor production (equip-



trol



sequences and



commands to the



motion



shop floor equipment



ment level)



page 511



• A LAN (Computer Network) Hierarchy for Shop Floor Control [source - find]

E n te rp rise L A N



L ev e l 6 :

E n terp rise



L ev e l 5 :

F ac ility o r P lan t



F ac to ry B ac k b o n e L A N



S ec tio n

C o n tro lle r A



S e ctio n

C o n tro lle r B



S ec tio n

C o n tro ller C



sim ila r to A

L ev e l 4 :

S ec tio n o r A re a



C ell

C o n tro ller A



L ev e l 3 :

C e ll



L ev e l 2 :

S tatio n



sim ila r to A



S ec tio n A L A N



C e ll A L A N



D e v ic e

C o n tro ller A



C ell

C o n tro lle r B



C ell B L A N



D e v ic e

C o n tro ller B



D e v ice

C o n tro lle r A



D e v ice

D e v ic e

D ev ice



D ev ice

D e v ice

D e v ic e



D e v ice

C o n tro ller B



L ev e l 1 :

E q u ip m en t

D ev ic e

D ev ice

D e v ice



D e v ic e

D ev ic e

D ev ice