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20 views11 pagesUnit III I FMS Data Base Systems
FMS Data Base Systems
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© © All Rights Reserved
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/ 11
5, Databases in Fesble Mansfocaring Systems 131
robot language; some manual fix-up of the robot program will probably be
necessary
+ Even though most program problems will have been cleared from robot
software prior to use (by way of the simulation) there will still be discrepancies.
Most notable of these are destination errors, because a manufacturing work cell
is usually built with slight errors. The program and robot must now be calibrated
against the actual work cell
Preparing robot programs by simulation reduces the amount of time the expensive
robot must be tied up for enginecring debugging, as well as reducing the danger
to personnel and fixturing due to testing new robot software. It also simplifies
the creation of high-precision robot activities,
VI. The Flexible Manufacturing System
Database System
‘The typical FMS will require a combination of databases and complementary
software systems which manipulate them. This section discusses commonly
needed system areas and design methods for customizing a system for a specific
FMS. Additionally, it is important to plan data exchange with other MDSs and
treatment of specialty areas unique to a particular business,
A. MAJOR SOFTWARE/DATABASE SUBSYSTEMS
Since software to control the FMS and FMS databases are tightly linked,
they must be considered together. It will also often be found that specific da-
tabases have data interactions with multiple applications. An application may
also access and update several databases. Because of this, it is vital to consider
areas of required functionality rather than considering databases or software in
isolation, A high level of automation in FMS control requires a fairly complete
complement of “upstream” manufacturing database subsystems, Refer to Figure
10, Major software/database functions which may be required for the operation
of an FMS include the following:
+ Computer-aided process planning (CAPP)iwork scheduling includes ac-
cepting order information from the MIS, planning production, scheduling ma-
chines, possibly optimizing the schedule. A machine capacity database is a vital
pat of this application area, as is a calendar system to allow rational scheduling
of operations. 2 Willan D. Engelbe
Engneareg
777
‘CAM Lary ot
wert
Fi Con
inspection &
ad
ror Recovery
ss
Mata Handing
Figure 10. An example ofthe typeof database layout that is developed to support FMSs. (Many
ata eaionhips and subsystem databases are omited for simplicity) 5. Detahases in Flexible Manufacturing Stems 133
* Component and process databases are used by CAD and CAM groups
for product and process design. These are far upstream from the FMS, but can
ive a big impact on FMS productivity due to the fundamental relationship
between product and process design
+ NC and robot program control operates in conjunction with offi
programming and scheduling. It ensures that software to drive NC machines and
robots is available and downloaded to the machines when required by the sched-
ule. Imay be coordinated with contingency management to assist equipment in
recovering from glitches such as dropped parts. This may also include a system
to make setup information readily accessible to plant personnel for machines
that require manual settings to switch between parts
* Decision support systems (DSSs) use data drawn from several database
suas to assist in running the FMS. This may be information supplied to sched-
Luling algorithms oF to humans who are optimizing FMS operation manually
Typical areas in which DSSs are used include parts selection, batching. and
balancing, managing of tools, dispatching of work orders, simulation, and queueing.
There may be several DSSs at different points in the hierarchy; for example, the
toprlevel mainframe would handle dividing orders into hatches (longer-term
decisions), whereas an FMS-level DSS would deal with reallocation of capacity
due to machine downtime
+ Ofrline programming allows development of NC programs (too! path
creation), robot programs, and often simulation to observe the actions of com-
pleted programs. Also included isa system to convert translate) programs into
the finished form required by the specifi brand(s) of robot or NC machine being
used. Software 10 perform these functions is among the most complex of the
FMS operation, and numerous databases are involved, including databases for
tools, materials, products, robots, NC machines, manufacturability, kinematics,
and others.
* Status monitoring is a real-time and/or a regularly scheduled function
which provides feedback on how well manufacturing is operating. This may be
used primarily for keeping watch on the automated systems or may also be used
for building up a historical database to analyze for downtime, mean-time-be-
{ween failures and productivity. Communications will be involved, interrogating
information stored in local programmable controllers and computers while gath-
ering data centrally. A complete status monitoring plan must also include a plan
for how these data will be used (do not collect them without a clear idea of how
to make use of them)
+ Inventory data are needed to allow planning of manufacturing based on
materials on hand. Finished goods inventory may or may not be closely linked
with the FMS. If automatic guided vehicles (AGVs) and automatic material
handling systems are used, inventory data management ic generally integrated
with FMS contro 134 Wiliam D. Engette
* Material handling. if handled by automated systems or AGVS, must be
linked in real time to the FMS operation. As with contingency management,
handling of exceptions will be a major part of the design. This application
involves primarily control software rather than database manipulation,
+ Ancillary process data refers to a collection of databases of highly spe-
cialized information (e.g., tool wear rates, machinability, material characteris-
tics, speeds, and feeds) which may be used by various applications such as
scheduling and optimization, CAD, and CAM. In more sophisticated systems,
this type of information may be captured as rules in a knowledge base and used
in conjunction with expert systems for optimization
* Order information provides input to scheduling, and also forms a basis
of information on which to base material requirements planning and just-in-time
production control systems.
+ CADICAMIFMS data preparation can be one of the most critical and
complex data flow/database applications in the business. As previously discussed,
initial CAD work must be done by a team which understands product produ
bility, the process, and data requirements for CAM/FMS. Engineering change
levels must be controlled so that only the appropriate data becomes available 10
downstream data users. At the CAD end, libraries of parts must be maintained,
‘The product and process will dictate requirements for CAM libraries: these may
include manufacturability databases, process information, machine/robot models,
and other information discussed in preceding sections. When required data prep-
aration has been completed, provision must be made to (a) test NC machine
and robot programs to ensure correctness before attempting to build product and
(6) inspect the finished product to ensure adherence to specifications. This i
volves procedure and management control which are ancillary to the database
system per se but are necessary for operation, and thus must be designed in
tandem with the database system.
B. SUPPORTING DATABASE SYSTEMS
Interconnection and timing of FMS database systems, subsystems, and
control require supporting activities and capabilities as follows:
+ Communications will be a mix of networking (numerous technical ap-
roaches are available; local area networks are often used in some form, with
specialized capabilites for the factory environment), direct computer-to-com-
Puter communication (e.g., RS-232 asynchronous or bisynchronous), and simple
‘on-off levels. Local area networks (LANs) must be planned to have sufficient
capability and speed, and can be a major factor in costperformance. Intercon-
nections between computer systems take on a major role if remote computer 5, Databases in Flexible Manufacuring Systems 13s
systems are doing part of the data preparation for the FMS, such as scheduling,
creating pick lists, or handling just-in-time production control. Avoid being at
the mercy of leased-line vendors to be able to run the Factory.
+ Contingency management and standby operation may form a significant
part of the software effort to avoid complete loss of manufacturing capability in
the event of failures. Some manual intervention will usually be required. Au-
tomated contingency management may be handled as part of a decision support
system, as previously discussed (changing order size, order deletion, modify
pallet contents, empty of load buffer store, etc.) or simply provide a means to
notify an operator of a problem and allow some manual operation.
+ Data backup allows the saving of database information to avoid loss of
work in case of lost computer files.
+ Remote diagnostics allow the user to test computer equipment at a dis-
tance. This is useful for tracking down the source of field failures from a central
location,
+ Data exchange with other manufacturing data systems to accept infor-
‘mation, make inquiries, and provide information on manufacturing performance.
This is a separate topic from communications in general, involving special areas
Of expertise. Transmittal of information between systems can take many forms,
from electronic mail to automatic updating of remote, distributed databases.
* Part programming and program verification provides a framework for
testing NC and robot programs. A large, active shop with many parts and frequent
new parts and changes will aso need a database system to track the development
and release of these programs.
Specifications for these auxiliary supporting functions should be developed in
tandem with overall general database system design, and examined for feasibility.
‘This ensures that impossible requirements and cost structures are not builtin.
C, SYSTEM DESIGN AND DATA FLOW PLANNING
1. System Engineering for a Flexible Manufacturing System
Database Layout
It is possible to buy flexible manufacturing systems and many of the
software packages needed to support them. Database structure, however, is best
designed in-house, to ensure a good fit with the business. At a minimum, even
if the FMS database system is designed by a consultant, the user should be
closely involved and take an active part in developing the functional specification,
‘The design of a database system and its associated software systems uses many
of the same well-defined design techniques that are used for designing systems
in general, and in particular, data processing systems, manufacturing/factory 136 William D. Engethe
systems, and communication systems. System engineering techniques and stan-
dardized data system design methodologies are applicable. To achieve computer-
integrated manufacturing (CIM), itis necessary to take a systems approach,
designing the entre system as an integrated unit, including the required specialty
areas, and considering the system's total life cycle. Otherwise there isa significant
risk that the CAD, CAM, MDS, and FMS areas will each end up as islands of
automation, Part of the systems approach also should include the development
of a data dictionary which defines all data fields (including length, format, and
content). This reduces duplicative effort in building systems, as the same data
format is adopted companywide for each fied
‘An idea familiar to the system engineer is the allocation of overall system
funetion from the uppermost levels of the hierarchy of subsystems down through
the lowest. Distributed database technology combined with networking allows
storage of pertinent data in the computer nearest to the application. This can
help reduce the amount of data traffic required to run the manufacturing operation.
‘Also, the increased reliability of eliminating single points of failure acts to prevent
4 shutdown of the entire factory in case of a computer malfunction
The fundamental concept here sto design an integrated computer, software.
‘and database system which meets the needs of the FMS and links tothe other parts
‘of the MDS. Usually the optimal overall system design will be somewhere be-
tween centralization and decentralization. The proper mix of processors and com
munication lines wil be determined by consiering the trade-offs between the needs
‘of integration (the overall system) and the needs of the individual processes. A
hierarchical approach has many advantages over total centralization or decentral-
ization. Hierarchy inherently preserves control and coremand over the process,
necessary 10 cary out the management plan. Distribution of intelligence, com
puter processing power, and data down tothe lowest possible level ofthe hierarchy
increase the throughput ofthe total system by ensuring that upper-level system
