100384-1-a CIM1_AC(OpenCIM) 05-03

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tek

LINK

CIM Technology 1

OpenCIM

Student Activities Book

Catalog No. 100384 Rev. A

May 2003

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CIM Technology 1 – OpenCIM Student Activities Book

Every effort has been made to make this book as complete and accurate as possible. However, no warranty of suitability, purpose, or fitness is made or implied. Intelitek is not liable or

responsible to any person or entity for loss or damage in connection with or stemming from the use of the software, equipment and/or the information contained in this publication.

Intelitek bears no responsibility for errors which may appear in this publication and retains the right to change specifications without prior notice.

Intelitek Inc.

444 East Industrial Park Drive Manchester, NH 03109-5317 USA Tel: (603) 625-8600 Fax: (603) 625-2137 website: http://www.intelitek.com email: [email protected]

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Objectives ...2-1 Skills ...2-1 Materials ...2-1 Overview ...2-2 Procedures ...2-7 Task 2-1: Accessing Working Cells from the Project Manager ...2-7 Task 2-2: Identifying Components of OpenCIM Software. ...2-9 Task 2-3: Rotating and Zooming in the Graphic Display Window...2-10 Task 2-4: Redirecting the Camera...2-11 Task 2-5: Observing a CIM Production Cycle ...2-13 Task 2-6: Team Discussion and Review ...2-16

Activity 3 Parts and Production Flow ...3-1

Objectives ...3-1 Skills ...3-1 Materials ...3-1 Overview ...3-2 Procedures ...3-7 Task 3-1: Identifying Parts of a Template ...3-7 Task 3-2: Review of Production Components...3-8 Task 3-3: Running a Basic CIM Production ...3-9 Task 3-4: Team Discussion and Review ...3-10

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Activity 4 Storage Setup ...4-1 Objectives ...4-1 Skills ...4-1 Materials ...4-1 Overview ...4-2 Procedures ...4-6 Task 4-1: Identifying the Location of a Part in Storage ...4-6 Task 4-2: Setting the Storage Stock ...4-8 Task 4-3: Setting the Storage Stock and Part Location ...4-10 Task 4-4: Observing the ASRS Contents after Production ...4-13 Task 4-5: Setting Default Storage ...4-15 Task 4-6: Team Discussion and Review ...4-16

Activity 5 Production Planning ...5-1

Objectives ...5-1 Skills ...5-1 Materials ...5-1 Overview ...5-2 Procedures ...5-7 Task 5-1: Editing a Customer Order ...5-7 Task 5-2: Updating a Manufacturing Order ...5-11 Task 5-3: Tracking Production Following MRP Modification ...5-13 Task 5-4: Editing the Customers List...5-14 Task 5-5: Ordering Parts for the New Customer...5-15 Task 5-6: Team Discussion and Review ...5-17

Activity 6 Processes and Machine Definition ...6-1

Objectives ...6-1 Skills ...6-1 Materials ...6-1 Overview ...6-2 Procedures ...6-8 Task 6-1: Process Types in OpenCIM...6-8 Task 6-2: Adding a New Process to an Existing Machine ...6-8 Task 6-3: Team Discussion and Review ...6-11

Activity 7 Part Definition...7-1

Objectives ...7-1 Skills ...7-1 Materials ...7-1 Overview ...7-2 Procedures ...7-7 Task 7-1: Viewing Supplied Part Information ...7-7 Task 7-2: Viewing Product Part Information ...7-8

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Activity 8 Defining a Product Part...8-1 Objectives ...8-1 Skills ...8-1 Materials ...8-1 Overview ...8-2 Procedures ...8-5 Task 8-1: Adding a New Supplied Part to the Basic CIM Cell...8-5 Task 8-2: Adding and Defining a Product Part ...8-9 Task 8-3: Team Discussion and Review ...8-17

Activity 9 Producing a New Part ...9-1

Objectives ...9-1 Skills ...9-1 Materials ...9-1 Overview ...9-2 Procedures ...9-3 Task 9-1: Updating Storage...9-3 Task 9-2: Placing an Order for the New Product Part...9-6 Task 9-3: Tracking Production of WOOD PROD in the CIM cell ...9-10 Task 9-4: Team Discussion and Review ...9-11

Activity 10 Timing and Optimization...10-1

Objectives ...10-1 Skills ...10-1 Materials ...10-1 Overview ...10-2 Procedures ...10-7 Task 10-1: Preparing to Observe Production Timing...10-7 Task 10-2: Observing Production Timing with the Scheduler Gantt ...10-11 Task 10-3: Team Discussion and Review ...10-15

Activity 11 Viewing Production Details in the Device View...11-1

Objectives ...11-1 Skills ...11-1 Materials ...11-1 Overview ...11-2 Procedures ...11-4 Task 11-1: Viewing Device Activity at Station 1...11-4 Task 11-2: Viewing Device Activity at the CNC Station ...11-10 Task 11-3: Team Discussion and Review ...11-15

Activity 12 Viewing Production Details in the Storage View ...12-1

Objectives ...12-1 Skills ...12-1 Materials ...12-1 Overview ...12-2 Procedures ...12-3 Task 12-1: Viewing Production Details in the Storage View...12-3 Task 12-2: Team Discussion and Review ...12-13

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Activity 13 Adding a CNC Machine ...13-1 Objectives ...13-1 Skills ...13-1 Materials ...13-1 Overview ...13-2 Procedures ...13-4 Task 13-1: Inserting a New Object into the Basic CIM Cell...13-4 Task 13-2: Configuring the Connectivity Settings ...13-15 Task 13-3: Team Discussion and Review ...13-17

Activity 14 Defining Part Production in the Lathe ...14-1

Objectives ...14-1 Skills ...14-1 Materials ...14-1 Overview ...14-2 Procedures ...14-2 Task 14-1: Defining a New Process for the Lathe...14-2 Task 14-2: Adding a New Part ...14-7 Task 14-3: Team Discussion and Review ...14-17

Activity 15 Integrated Production ...15-1

Objectives ...15-1 Skills ...15-1 Materials ...15-1 Overview ...15-2 Procedures ...15-2 Task 15-1: Setting the MRP Manufacturing Order ...15-2 Task 15-2: Updating Storage...15-8 Task 15-3: Team Discussion and Review ...15-10

Activity 16 Tracking Integrated Production ...16-1

Objectives ...16-1 Skills ...16-1 Materials ...16-1 Overview ...16-2 Procedures ...16-3 Task 16-1: Tracking the Sequence of Production ...16-3 Task 16-2: Tracking the Sequence of Production with

Updated Process Durations...16-8 Task16-3: Team Discussion and Review ...16-11

Activity 17 Improving System Performance ...17-1

Objectives ...17-1 Skills ...17-1 Materials ...17-1

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Introduction

About This Activities Book

This manual contains 17 activities, each of which can be completed in one 45-minute lab session. For each of the activities you will require a PC with OpenCIM Version 3.0 software installed. At the beginning of each activity you will encounter several lists:

♦ Objectives are the goals you will achieve.

♦ Skills are the competencies you will develop.

♦ Materials are the specific items you will need for each activity.

The Overview introduces you to the subjects you will explore in each activity.

The Procedures contain a series of Tasks, or operations. The first time an operation is to be performed, instructions are given in a tutorial manner. In subsequent tasks you should be able to perform these operations without guidance.

Many tasks are best performed when each team member takes on a different role. One student may, for example, handle the hardware while another student manages the software. The

activities are designed so that team members can switch roles and repeat tasks, thereby allowing everyone more hands-on time.

Questions and tables for entering results and observations appear throughout the tasks. Questions for discussion and review conclude each activity. All questions and tables are printed on a set of Worksheets supplied with this book. Record your answers in the worksheets, or as directed by your instructor. Do not write in this book.

You will be directed to perform inventory and safety checks at the beginning of every working session, and to shut down the system properly at the end of each activity.

It is assumed you are familiar with the PC and are comfortable working in the Windows/DOS operating environment. However, instructions are explicit enough to allow novices to use the tekLINK's specific software.

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Safety

Safety precautions in the workplace serve to protect both the human operators and the

equipment. You will be working offline in the CIM Technology 1 tekLINK so safety should not be an issue. However, it is important to remember these safety issues.

♦ Make sure that the CIM system is offline before beginning the tekLINK. Previous users may have left the system online which could cause a potentially dangerous environment for both the human operators and CIM equipment.

♦ Read the instructions and ensure you understand them clearly.

♦ Ensure that the computer is turned on and shut down properly when working on the activities.

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Activity 1

Getting Started

Before you begin this activity, take the pre-test according to your teacher’s instructions. The purpose of the pretest is to measure your knowledge and skills in the field of Computer Integrated Manufacturing (CIM). This test

will not affect your tekLINK grade. When you finish the pre-test, please

hand it in to your teacher.

OBJECTIVES

In this activity you will accomplish the following:

♦ Understand the concept of Computer Integrated Manufacturing (CIM)

♦ Identify the main components and devices in a basic CIM cell

♦ Identify the various phases of CIM production

SKILLS

In this activity you will develop the following skills:

♦ Academic and Employability:

Understand how CIM cells are used to simulate the production

cycle from planning through the production stages.

Determine the advantages of CIM manufacturing. Describe the role of robotics in CIM.

♦ Occupational and Technical:

Describe the main CIM components of the CIM cell. Operate the OpenCIM software.

MATERIALS

In this activity you will need the following materials:

♦ Pre-test and Pre-test Answer Sheet

♦ A PC with the OpenCIM software installed

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OVERVIEW

What is Automation?

Automation is a system of manufacture designed to enable machines to perform specific tasks formerly done by humans, and to control sequences of operations without human intervention.

The term automation has also been used to describe non-manufacturing systems in which programmed or automatic devices can operate

independently or nearly independently of human control.

In the fields of communications, aviation, and astronautics, for example, automated devices are used to perform various operations much faster or better than could be accomplished by humans. These include automatic telephone switching equipment, automatic pilots, and automated guidance and control systems.

What is Computer Integrated Manufacturing (CIM)?

To stay competitive, factories are increasingly automating their production lines with Computer Integrated Manufacturing (CIM) systems. A CIM cell is an automated assembly line that uses a network of computers to control robots, production machines and quality control devices. The CIM cell can be easily programmed to produce custom parts and products.

Educational CIM cells are used to simulate the production cycle and enable control and analysis of various aspects of the cycle, from the planning through production.

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Advantages of CIM

CIM systems offer the following advantages:

♦ Computer integration of information provides all departments of a factory rapid access to the same production data.

♦ Accessibility of production data results in faster response to change. This in turn shortens lead times, increases the company's

responsiveness to customer demands and competition, and improves due-date reliability.

♦ Computer-aided scheduling optimizes use of the shop floor. This improves the utilization of machine tools, and reduces work-in-progress and lead times.

♦ Real-time production data can improve quality by using techniques such as statistical process control to optimize the production processes.

♦ Computer analysis and prediction of material requirements for

production can reduce inventory levels and lead times. The integration between suppliers and customers are also benefits.

♦ Downloading machining instructions, including tool changes, from CAM (Computer Aided Manufacturing) systems to CNC (Computer Numerically Controlled) machines reduces machine setup time and increases machine utilization.

The trend among manufacturers today is to produce smaller batches of more varied products. Without CIM automation, this trend would result in higher costs because of increased setup time and additional labor.

CIM Training

Industry today is experiencing a shortage of qualified CIM technicians and engineers. Manufacturers demand graduates whom understand the

integration between all elements of a CIM. This CIM training module aims to address this need by providing an industrial-level training system for the educational environment.

This CIM training module is the first in a series of three modules that will introduce you to the principles and practice of CIM production. In this module, you will work entirely in an “off-line” mode, meaning that you will use solely OpenCIM simulation software to simulate a working CIM environment. In future modules, you will also practice your CIM skills in an “online” environment, using actual CIM hardware.

In the following activities, you will simulate the manufacture of several unique parts using CIM simulation software (OpenCIM). In doing so, you will gain a more complete understanding of the overall operation of a CIM system.

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Main Components of CIM

All CIM systems generally share the following components, which are necessary for most production processes:

♦ Robotic Arms: CIM systems are fully automated, and robotic arms

are critical components in these automated systems. In CIM, robotic arms perform tasks that would otherwise require human intervention, thus enabling the system to be fully automated. Examples of tasks performed by robotic arms include the picking and placing of parts in/from machines, removing of parts from storage, assembling of parts and handling of parts for quality control. In later activities, you will be introduced to some of the robot types and robot tasks used in CIM.

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♦ Storage: A storage station is used to store raw materials prior to

production, as well as finished products following the production process. Such stations are fully automatic and controlled by robotic arms.

A typical CIM storage station includes a machine known as an ASRS or Automated Storage and Retrieval System. The ASRS is a robotic storage device used to store and retrieve parts in a CIM cell. The ASRS is used as the main source of raw material for the cell, and can also serve as a warehouse for parts in various stages of production. Storage cells in the ASRS contain templates, either empty or containing parts. A CIM cell may contain any number of ASRS stations.

Figure 1-3: ASRS Photos

♦ Machines: “Machine” is a

generic term used to describe a wide variety of production devices, such as CNC machines and laser engravers. Such machines require that parts be inserted or placed into them, usually by a robotic arm. The inserted parts are predefined in size and nature. The machine is programmed in advance to process a particular part, ensuring precise and exact part production.

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♦ Quality Control (QC): This group of equipment includes measuring

devices, such as optical systems, laser scan meters and CMMs

(Coordinate Measuring Machines). The purpose of these devices is to determine whether a product meets the quality control specifications defined prior to the production process.

QC components include high precision measuring tools that the system uses to determine whether the product should advance to shipment or be rejected. Following the rejection of a product, the system must be capable of adjusting itself so that it does not automatically reject subsequent parts.

Figure 1-5: QC using Laser Scan Meter

♦ Closed Loop Conveyor: By

nature, CIM components tend to be located in multiple production stations that are physically distant from one another. This requires a system that moves parts from one robotic station to another (for

example from an ASRS to a CNC Figure 1-6: Conveyor Photo

machine). A closed loop conveyer with stop stations controlled by PLC is typically used for this purpose. Stop and release units (i.e. stop stations) are located on the conveyor in front of each production station. The stop stations are controlled by the PLC and enable the robot to pick a part from the conveyor and place the part on it.

CIM systems can also include a wide variety of components in addition to the equipment previously mentioned. Many of the equipment types will be

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A Basic CIM System

This module focuses on a basic CIM cell with the following components:

♦ ASRS (with 36 storage cells)

♦ Machine (mill) tended by a robot

♦ Conveyor (with 2 stop stations)

This basic simulated CIM cell will be used for all of the activities in this module. As your knowledge of CIM increases, you will be introduced to increasingly complex CIM configurations.

Figure 1-7: Example of a basic CIM system

Storage

In this module, you will work with an automatic storage device known as an ASRS (Automatic Storage and Retrieval System). The

ASRS (36) is used to store either empty templates or templates that contain parts. The parts can be supplied parts or finished products. The ASRS you will use is built like a bookcase with special compartments designed for the templates.

This “bookcase” is tended by a robot that removes parts from the device and places finished products into the device for storage.

ASRS (36 cells) Conveyor (2 stop stations) Machine (CNC mill)

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This “bookcase” type ASRS represents only one configuration and type of ASRS (Automatic Storage and Retrieval Systems). These ASRS storage devices can be found in many types of configurations (i.e., varying number of cells, varying sizes, varying cell dimensions) and types (i.e., round, rectangular).

Figure 1-8: Graphic representation of ASRS

CNC Machine

The machine used in this cell is a CNC mill, which is frequently used for the processing of many types of materials. CNC mills are used to shape raw materials, such as wood, plastic, or metal, into parts of predefined dimensions.

Generally, the CNC machine needs to be fed a part, either manually or by a robotic arm. To achieve fully automated functionality in the CIM system, the parts are fed to the CNC machine by a robotic arm.

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Conveyor

The basic CIM cell described in this module includes two separate robotic stations, an ASRS and a machine. The conveyor is the mechanism responsible for

transferring parts from one station to another. The conveyor has predefined stop locations, where the part is loaded on the conveyor and unloaded from it.

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PROCEDURES

Task 1-1: Determining the Advantages of CIM

Answer the following true or false questions.

Q Do CIM systems use computer-aided scheduling and CAM systems to

increase machine utilization?

Q Does computer analysis and planning increase lead-time and

inventory levels?

Task 1-2: Review Main Components of CIM

Q CIM uses computers to do which of the following three tasks?

Provide access to production data. Produce raw materials.

Control robots and quality control devices. Produce parts.

Q Determine which of the following three items can be stored using an

ASRS:

Raw materials. Finished products. Templates.

Partially processed parts.

Q Does the PLC control the stop stations of the conveyor?

Q Is the conveyor used to move the robot from one place to another?

Q Determine which of the following devices may be integrated into a

CIM cell:

Storage Machine

Quality control devices

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Task 1-3: Review of Basic CIM System Components

Q Are robotic arms used in the ASRS?

Q Is a conveyor used to move parts between predefined stations in the

CIM cell?

Task 1-4: Team Discussion and Review

Q Discuss whether or not automation increases or reduces human

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Activity 2

Introducing OpenCIM Software

OBJECTIVES

♦ Learn basic operation of CIM simulation software

♦ Use CIM simulation software to run a simulated production cell

♦ Identify the main components of the OpenCIM software

SKILLS

Observe a CIM production cycle using the CNC milling machine. Learn how the OpenCIM software can be used to represent an

actual virtual production cycle.

Select your working cell from the CIM Project Manager and then

access the CIM Manager and Virtual CIM applications for the selected cell.

Identify the OpenCIM Manager components.

Define the viewing options of the Graphics Display window. Initiate and then observe production cycle, by following the route

of one part.

MATERIALS

♦ A PC with OpenCIM software installed

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OVERVIEW

OpenCIM© Software

In this activity you will use CIM simulation software, known as OpenCIM, to learn the basics of CIM operation and management. OpenCIM is designed to teach students the principles of automated production using integrated robotics, computers and CNC machines. It also allows advanced users to search for optimal production techniques through off-line and on-line experimentation.

The following features characterize the software:

♦ OpenCIM software enables users to create and modify CIM cells and components. The CIM cell setup may represent an actual installation or it may be a virtual cell.

♦ OpenCIM allows for targeted training at a given station or device.

♦ OpenCIM includes a 3D solid model graphic display that dynamically and accurately simulates the CIM components and features. It provides both online tracking of the production process and off-line simulation.

♦ OpenCIM provides the opportunity to observe how a set of diverse hardware components works together in a real-world environment. Its ability to use equipment found in actual industrial CIMs enables realistic simulation

♦ OpenCIM resembles industrial CIMs in its ability to expand by using distributed processing at each production station. Distributed

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OpenCIM Project Manager

The CIM Project Manager window provides access to the functionality of different cells in the OpenCIM software. After selecting the required project in the CIM Project Manager window, you can then activate the following OpenCIM applications, as required:

♦ CIM Manager : Enables the user to centrally control all the activities of the selected CIM Cell.

♦ CIM Setup : Enables the user to create and modify the Virtual CIM setup of the selected CIM Cell.

Figure 2-1: CIM Project Manager Window

The CIM Project manager includes the following components:

♦ Menu Bar: Consists of four menus that enable the functionality of the

project manager described briefly below.

♦ Toolbar: Provides shortcuts to frequently used options of the project

manager.

♦ User Projects Tab: Contains the list of projects that were added to the

list by the logged in user.

♦ Archive Tab: Contains the list of predefined projects that were

automatically installed with the software.

♦ Status Bar: Contains information regarding the functionality of the

selected toolbar option.

The CIM project manager enables the user to:

♦ Select different CIM cells and then activate the CIM Manager or CIM Setup applications, for the selected cell.

♦ Copy cells from the project manager archive and save them in the user projects list.

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♦ Import existing CIM cells from a specified directory.

♦ Export CIM cells from the user projects list to a specified directory for backup purposes.

♦ Remove CIM cells from the user projects list. OpenCIM Manager Components

The OpenCIM Manager window provides access to the functionality of the OpenCIM software of the selected cell.

Figure 2-2: OpenCIM Manager window

The OpenCIM Manager window includes the following components:

♦ Menu bar: The menu bar, located at the top of the OpenCIM Manager

window, consists of five menus, each of which enables access to OpenCIM functionality. The menu options will be introduced in the activities you will perform in this module.

♦ Toolbar: The toolbar, located directly below the menu bar, consists of

buttons that provide shortcuts to frequently used commands. The specific toolbar buttons will be introduced in the activities you will perform in this module.

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♦ DeviceView: The Device View, located below the toolbar in the right

portion of the window, displays data regarding the activity taking place in the devices during the production process. This area will be introduced in the activities you will perform in this module.

♦ Viewing Area: The Viewing area enables you to monitor various

aspects of the production cycle on a real-time basis by selecting one of seven tab views. By default, the Graphic Display tab is selected and the viewing area displays 3D graphic simulation of the CIM

production cycle. The specific tab views will be introduced in the activities you will perform in this module.

♦ Graphic Display Toolbar: The Graphic Display toolbar, located in

the left of the Viewing area when the Graphic Display tab is selected, consists of buttons that enable you to alter the graphic display. The specific toolbar buttons will be introduced in the activities you will perform in this module.

♦ PLC Status Bar: The PLC Status Bar, informs us whether or not the

connection is active.

♦ Information Bar: The Information Bar displays general messages that

occur during production.

♦ Status Bar: The application’s status bar, located at the bottom of the

window, displays the status and location of the application. Such as, the current operation mode and the location of the WSO.ini file used by the manager.

OpenCIM Software Viewing Features

The OpenCIM 3D Image window simulates a video camera output screen. You can control the camera to focus in on the CIM cell actions, and rotate, angle, zoom or adjust the view by redirecting the camera.

The following options enable you to change the view of the CIM cell:

♦ Top View: Places the camera on top of the cell at the center of the image.

♦ Redirect Camera: Defines the position that will be in the center of the

image.

♦ Zoom In/Zoom Out: Zooms in and out of the image by pressing the

right mouse button and moving it forward or backward.

♦ Rotate the Image: Rotates the view of the image by pressing the right

mouse button and moving it to the right/left.

♦ Moving the Camera Up/Down: Use the window’s scroll bar to adjust

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CIM Production

How is production executed in a fully automated system? Naturally, it should be executed using the shortest route available with the most

efficient timing of duty cycles. In order to determine the shortest route and most efficient timing, you must first outline the production route by planning the steps that the system should execute.

As you already know, the goal of CIM production is to manufacture a product. For this basic CIM system, the product is to be produced by a milling machine (the only manufacturing device available).

The CIM cell produces this product by performing the following steps:

1 A part (raw material) is taken from the storage station and conveyed to the CNC station.

2 The CNC machine mills the part.

3 The part (product) is returned to the storage station.

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PROCEDURES

Task 2-1: Accessing Working Cells from the Project Manager

In this task you will copy the required cell from the project manager archives, save it in the user projects list and activate the CIM Manager application for the selected cell.

1 From your Windows Start menu, select OpenCIM | Project Manager . The CIM Project Manager window is displayed.

2 From the Archive tab select 102_ACT1-5, the project for this activity.

3 From the Project menu select Save As or select the button on the toolbar. The Save 102_ACT1-5 as window is displayed.

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4 In the Project name field, enter your user name followed by 2

(<USER>2), for example, JOHN2, and then click OK. This project is displayed in the User Projects tab.

5 From the User Projects tab select this <USER>2 project and click the

CIM Manager button on the toolbar to activate the CIM Manager

application for this project. All the tasks described in this activity refer to this selected <USER>2 project.

Note: Alternatively, you can also activate the CIM Setup application by

selecting the <USER>2 project and then selecting the CIM Setup button on the toolbar.

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Task 2-2: Identifying Components of OpenCIM Software.

Q Circle the OpenCIM toolbar in the OpenCIM Manager window.

Q Circle the OpenCIM menu bar in the OpenCIM Manager window.

Q Circle the CIM TIME counter in the OpenCIM Manager window.

Q Circle the Part area in the OpenCIM Manager window.

Q Circle the Device area in the OpenCIM Manager window.

Q Circle the Simulation Viewing area in the OpenCIM Manager window.

Q Circle the 3D Image toolbar in the OpenCIM Manager window.

Q Circle the PLC Status Bar in the OpenCIM Manager window.

Q Circle the status bar in the OpenCIM Manager window.

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Task 2-3: Rotating and Zooming in the Graphic Display Window

1 From the OpenCIM Manager window, click the Top View button. This command places the camera in the center of the cell ceiling facing downwards.

Figure 2-4: The OpenCIM Manager Window

Imagine that the image shown in the Viewing Area is the output of a video camera installed in the CIM cell.

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2 Place the cursor on the vertical scroll bar and drag it downward. This moves the camera up and down, changing the viewing angle.

3 Hold down the right mouse button (anywhere inside the Graphic Display window) and drag the mouse upward. The cursor turns into a magnifying glass.

Your action is similar to a video camera zoom in feature. The zooming in is performed so that the center of the cell stays in the center of the camera output image.

4 Hold down the right mouse button and drag the mouse downward. This action is similar to the zoom-out feature.

5 Hold down the right mouse button and drag the mouse to the right. The display is rotated counterclockwise.

6 Hold down the right mouse button and drag the mouse to the left. The display is rotated clockwise.

Task 2-4: Redirecting the Camera

In this task you will define a position that will be in the center of the image.

1 Click the Redirect Camera button .

The cursor turns into a magnifying glass with an arrow.

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2 Click the ASRS.

The ASRS now appears in the center of the window. This feature enables you to determine the object (or position) that will be in the center of the image.

Figure 2-7: OpenCIM Manager Window – Determining the Image Center

3 Deactivate the Redirect Camera feature by re-clicking the depressed button.

4 Place the cursor anywhere inside the Graphic Display window.

5 Hold down the right mouse button and drag the mouse upward and downward.

Now the zoom in feature is performed so that the ASRS stays in the center of the camera output image.

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6 Hold down the right mouse button and move to the right and left. This rotates the displayed image. The center of rotation is the position selected when you executed the Redirect Camera command.

Figure 2-9: OpenCIM Manager Window – Center of Rotation

Throughout this module you will learn to adjust the viewing tools in order to find the most comfortable viewing angle and position for you.

Task 2-5: Observing a CIM Production Cycle

You will now initiate a CIM production cycle and follow the route of one part. OpenCIM software features an excellent tool for observing the actions of a particular object throughout program execution – the Follow Me Camera tool. By selecting this tool and clicking a part, the “camera” will automatically follow this part through its production cycle.

1 To initiate the cycle, click the Start button from the OpenCIM toolbar.

The following message is displayed:

Figure 2-10: CIM Manager - Refresh Storage Confirmation Message

2 Click OK.

3 To start the simulation of the production cycle, click the Run button from the OpenCIM toolbar.

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4 Click the Follow Me Camera button from the Graphic Display toolbar.

The cursor turns into an arrow.

Figure 2-11: OpenCIM Manager Window – Follow Me Camera Option

5 Zoom in on the ASRS to locate the part.

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6 Click the part in the ASRS (the red square on a gray template) to define the object that is to be followed by the camera.

Figure 2-13: OpenCIM Manager Window – Defining the Follow Me Object

The camera will now automatically follow the selected part’s route throughout the production process.

7 You may pause the cycle at any time by clicking the Pause button from the OpenCIM toolbar.

After pausing a cycle, you can restart it by clicking the Continue button from the OpenCIM toolbar.

8 Observe the whereabouts of the part at each point in time. To re-run the production cycle, repeat steps 5 to 7.

9 Complete the following sentences based up on the exact sequence that took place in the simulated production cycle. Re-run the production cycle if you need assistance. Use the Pause and Continue options as required.

Q Phase 1: Is the raw material/product retrieved, transferred, or

processed from the ASRS?

processed to the machine?

processed in the machine?

processed to the ASRS?

Q Does the ASRS retrieve parts and put them in the milling machine?

Q Does the ASRS take parts from the conveyor and place them in

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Q Does the CNC machine receive parts from the conveyor that are picked by a robotic arm?

Q Does the CNC machine process the part after it has been stored in the

ASRS?

Q Does the CNC machine wait for the robotic arm to insert the part in it

before commencing operation?

Q Does the conveyor move parts from one stop station to another?

Q As a part arrives at the stop station, does the conveyor change the

direction of its movement? Task 2-6: Team Discussion and Review

Q Can OpenCIM be used to represent an actual installation or a virtual

cell?

Q Can OpenCIM perform online tracking of the production process?

Q Once simulation of the production cycle has begun, can it be paused

and restarted only once?

Q Which one viewing option redefines the center of graphic viewing

image?

Top view

Redirect Camera Follow Me Camera

Q Which one viewing option enables you to focus on the location of

specific part during a production cycle?

Top view

Q Which one viewing option places the camera in the center of the cell

ceiling facing downwards?

Top view

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Activity 3

Parts and Production Flow

OBJECTIVES

♦ Define the term production

♦ Distinguish between a raw material and product

♦ Identify the following CIM components: part, template, stop station, and buffer

♦ Differentiate between temporary and long-term storage devices

♦ Observe part flow in CIM and analyze the interaction of the various components involved

SKILLS

Describe the role of industrial safety Describe the CIM production workflow

Identify template parts

Review the production components

Run a basic CIM Production and observe and track part flow Identify the location of a part at a given time

MATERIALS

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OVERVIEW

Parts and Production

In the previous activity you tracked the production of a part by a machine. The term part was often used but was not clearly defined. In this activity you will learn to define the word part in terms of CIM, as well as define the relationship between a part and its production.

In CIM, parts are divided into two categories that refer to the nature of the part in its pre and post-production phase:

♦ Supplied Part: A part in its pre-production phase. It is also referred to as a raw part.

♦ Product: The finished part produced from the raw material in the production process. Production can consist of several processes or actions on the raw material, which together produce a final product. The production process creates the product. Production is designed

according to various production parameters, such as, cost, time, number of parts to be produced, available resources and more.

In the previous activity you observed that part flow was related to the production process and occurred in the following sequence:

♦ A unit of raw material (or supplied part) was retrieved by the ASRS.

♦ The ASRS robotic arm placed the part on the conveyor.

♦ The part was conveyed to the station that contains the milling machine.

♦ The robot that tends the milling machine retrieved the part from the conveyor and placed it into the mill.

♦ The part was machined according to the activated G-Code.

♦ The product was conveyed to the ASRS station for storage. As you tracked part flow, you probably noticed that additional

components in the CIM cell enabled easier and more efficient part flow. Important Production Components

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The template shown holds a rod-shaped part kept in place by six fixturing pins.

Figure 3-1: Template with a fixture for the part

♦ Metal (or plastic) pins determine the part location and keep it in place. To hold the part firmly in place an additional fixture is required. These pins can be placed in any number of configurations, enabling the storage of many different parts of varying shapes and dimensions.

♦ The template contains a handle that is designed according to the gripper of the robot. This handle enables the robot to easily pick and place the template.

Pallets

In order to convey the template along the conveyor, a carrier device is required. This device, known as a pallet (shown in figure 3-2, below), is designed to carry a template. The robot places the template carrying the part onto a pallet on the conveyor. The conveyor then transports this pallet in a continuous cycle from station to station. A PLC (Programmable Logic Controller) controls the movement of the pallets on the conveyor.

Figure 3-2: Pallet on Conveyer Figure 3-3: Virtual Pallet

The pallets always remain on the conveyor. When a part is needed, the template holding that part is unloaded from the pallet by a robotic arm; the pallet continues to travel on the conveyor. However, a robot cannot unload a template, if the pallet is in motion. The pallet must be immobilized to allow a template to be unloaded.

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Stop Station

In OpenCIM, stop stations contain magnetic sensors that are connected to the PLC controller to enable pallet identification and control of the stop pistons.

Pallets are immobilized at stop stations, as discussed briefly in the first activity. A stop station employs a stop

mechanism that halts a pallet at a pre-defined location, where the robotic arm can unload the template from the pallet.

Using templates placed on pallets that stop at stop stations along the conveyor, you now have a practical way to

transport the parts from one station to

another. Figure 3-4: Stop Station

Buffer

In a typical CIM cell, a part is stored on a template in the ASRS. When the CIM Manager orders the part, the template with the part on it is retrieved by the ASRS robotic arm and is placed on the pallet. The pallet is

transferred to the target station designated by the production order. At that station, the template is unloaded from the pallet by a robotic arm. The pallet continues to travel along the conveyor.

Templates are stored at a temporary storage device at each robotic station, known as a buffer in OpenCIM.

Some stations (such as, the ASRS, Pneumatic Feeders, Welding stations) do not contain buffers. A buffer is a tray designed to hold a template when it is removed from the conveyor, for as long as it is needed at the station. Buffers are used to optimize the production flow in a production system.

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CIM Production Workflow

In the previous activity, we observed the production cycle using the basic CIM cell and noted the overall route traveled by a part. Closer

examination of the route of the part in terms of the CIM components described previously shows that the basic CIM cell carries out the following sequence of actions:

1 A pallet (empty) is stopped at the ASRS stop station (station 1).

2 The ASRS retrieves a template (with the raw part on it).

3 The ASRS puts the template on the pallet at station 1.

4 The pallet (with the raw part) is released from station 1.

5 The pallet (with the raw part) is stopped at the stop station of the CNC machine (station 2).

6 The robot at station 2 lifts the template with the supplied part off the pallet.

7 The empty pallet is released from station 2.

8 The robot at station 2 puts the template (with the raw part) on the buffer.

9 The robot takes raw part from the template in the buffer.

10 The robot inserts the raw part into the CNC machine.

11 The machine mills the part.

12 The robot takes the finished part (product) from the machine.

13 The robot puts the product onto the template in the buffer.

14 An empty pallet is stopped at station 2.

15 The robot takes the template with the product from the buffer and puts it on the pallet.

16 The pallet (with the product) is released from station 2.

17 The pallet with the product is stopped at station 1.

18 The ASRS takes the template with the product from the pallet.

19 The empty pallet is released from station 1.

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Industrial Safety

Industrial Safety is an area of safety engineering and public health that

deals with the protection of workers' health, through control of the work environment to reduce or eliminate hazards. Industrial accidents and unsafe working conditions can result in temporary or permanent injury, illness or even death. They also take a toll in reduced efficiency and loss of productivity.

Annually in the United States, 1 of every 11 workers in private industry experiences a work-related injury or illness. Although most of these incidents are minor, approximately two million cases each year involve lost work time, and about 14,000 American workers die each year because of work-related injuries or accidents.

In recent years, engineers have attempted to develop a systems approach (termed safety engineering) to industrial accident prevention. Because accidents arise from the interaction of workers and their work environments, both must be carefully examined to reduce the risk of injury.

Injury can result from poor working conditions, the use of improperly designed equipment and tools, fatigue, distraction, lack of skill, and risk taking. The systems approach examines the following areas: all work locations to eliminate or control hazards, operating methods and practices, and the training of employees and supervisors. The systems approach, moreover, demands a thorough examination of all accidents and “near misses.” Key facts about accidents and injuries are recorded, along with the history of the worker involved, to check for and eliminate any patterns that might lead to hazards.

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PROCEDURES

Task 3-1: Identifying Parts of a Template

Q In the template shown, circle the gripping location.

Q In the template shown, circle the fixturing pins.

Q In the template shown, circle the raw part.

Figure 3-6: Template for Hotspot

Q Are parts on a template always raw materials?

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Task 3-2: Review of Production Components

Q Match the following terms to their definitions:

Q A buffer is used to temporarily store which one of the following:

Parts Templates Pallets Products

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Task 3-3: Running a Basic CIM Production

In this activity, you will again run a production cycle using the basic CIM cell from the previous activity. You will now analyze that production cell in terms of the CIM components described above. While observing the production cycle, you will monitor the exact location of a part at all times.

1 From your Windows Start menu, select OpenCIM | Project

Manager . The CIM Project Manager window is displayed.

2 From the Archive tab, select 102_ACT1-5, and then click Save as to save the project as <USER>3 (for example, JOHN3) in the User

Projects tab, as described in Activity 2, Task 2-1: Accessing Working

Cells from the Project Manager.

3 From the User Projects tab, select this <USER>3 project and then click CIM Manager to activate the CIM Manager application for this project. All the tasks described in this activity refer to this selected

<USER>3 project.

4 From the OpenCIM Manager main window click Start on the toolbar to initiate a production cycle.

5 When the “Do you want to refresh storage” message appears, click

OK.

6 To start simulation of the production cycle, click the Run button from the OpenCIM toolbar. The production cycle starts.

7 Observe and track the part flow. Pay special attention to the actions the robotic arms are performing and make note of all of the actions that take place during the cycle. Make sure you identify the location of the part at each given time.

You may pause the cycle at any time by clicking the Pause button from the OpenCIM toolbar.

8 If you want to continue observing the current production cycle, click the Continue button from the OpenCIM toolbar.

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Q Place the following actions into the correct order based upon your observation of the CIM production cycle.

The ASRS puts the template on the pallet at station 1. The ASRS retrieves a template (with the raw part on it). The pallet (with the raw part) is released from station 1.

A pallet (empty) is stopped at the ASRS stop station (station 1). The pallet (empty) is released from station 2.

The robot at station 2 puts the template (with the raw part) on the

buffer.

The pallet (with the raw part) is stopped at the stop station of the

CNC machine (station 2).

The robot at station 2 picks the part from the pallet. The machine mills the part.

The robot inserts the raw part into the CNC machine. The robot puts the product onto the template in the buffer. The robot takes the finished part (product) from the machine. The robot takes the raw part from the template in the buffer. An empty pallet is stopped at station 2.

The pallet with the product is stopped at station 1.The robot takes

the template with the product from the buffer and puts it on the pallet.

The ASRS stores the template with the product in one of its cells. The pallet (with the product) is released from station 2.

The empty pallet is released from station 1.

The ASRS takes the template with the product from the pallet.

Q Is a part that is taken out of a machine known as a raw material?

Q Can a part be raw material, a partially processed part or a finished

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Q Are pallets placed on and removed from the conveyor by robotic arms?

Q Do buffers serve as temporary storage stations for pallets or for

templates?

Q Can industrial accidents and unsafe working conditions result in

temporary or permanent injury, illness or even death?

Q Which of the following three factors may contribute to industrial

accidents:

Improperly designed equipment and tools Fatigue

Low salaries Inadequate training

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Activity 4

Storage Setup

OBJECTIVES

♦ Prepare the ASRS station for operation

♦ Understand the purpose of storage in CIM

♦ Identify various types of templates

♦ Identify two new storage devices: feeder and palletizing rack

♦ Set up storage management

♦ Insert parts into storage according to a given production definition

♦ Use the Storage utility program to prepare the CIM for production

SKILLS

Define how the ASRS storage settings determine the quantity of

parts that are available for processing.

Understand how stock management of the ASRS works and the

advantages of ASRS as opposed to other storage options.

View the number of parts in storage

Identify the location of parts in storage according to part name,

Template ID and Cell number.

Set the storage stock by adding parts to the ASRS storage device

and observe the contents of the ASRS after production

Submit a subpart report MATERIALS

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OVERVIEW

Storage and Stock Management

As you may recall, a typical CIM cell includes an ASRS (Automated Storage and Retrieval System) that is used to store and retrieve parts. The ASRS is used as the main source of raw material for the cell, and can also serve as a warehouse for parts in various stages of production. A CIM cell may contain multiple ASRS stations.

Figure 4-1: ASRS Station

In this activity you will learn how to view storage information and define the stock and location of parts in storage.

When managing an automated factory, the management system must have the ability to track the contents of the storage devices (ASRS, racks, feeders and more) and temporary storage devices (robots, buffers and more) at all times. It is critical that the following information be collected and available to users:

♦ Number and type of parts in stock.

♦ Location of all parts (i.e., on which template, in which storage device, in which cell of the storage device).

OpenCIM software enables the user to determine the exact contents of the storage databases all times, keeping track of which parts are in storage and which templates are available to move the parts.

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Part Name, Template ID# and Cell Numbers

Certain storage devices (such as the ASRS, pallets, and buffers) store parts on templates in the storage device. In this activity you will identify the location of the parts (on the templates) in storage according to the following information:

♦ Part name

♦ Template ID (including template type)

♦ Cell number

This CIM Storage Definition window shows a part named BASE_PROD. BASE_PROD is stored on a template with template ID number 090002. The template type that is indicated by the first two digits of the template ID enables users to assign a specific part related to the pin layout. Finally, you can see that the part is stored in the ASRS in cell 1A.

Figure 4-2: Example of an OpenCIM storage management screen

Note: Most temporary storage devices (feeders, racks) do not contain

templates. Therefore, for these storage systems, you cannot identify the exact location of the parts.

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Feeders and Palletizing Racks

In addition to the ASRS, other types of storage devices are often used in CIM cells. In the OpenCIM system feeders and racks are used in addition to the ASRS, as described below:

♦ Feeder: The feeder is a device that dispenses parts at a station (typically

to a robot). Feeders are used to supply raw materials or parts at various stations around the cell. Each parts feeder supplies only one type of part. Feeders are typically located close to the station that is to process the part, for example, a milling machine or lathe.

The gravity feeder, in which parts move one after another to the feeder mouth (for retrieval) by means of gravity, is one of the more popular feeder types. Another popular feeder type is the pneumatic feeder.

Figure 4-3: Gravity feeder

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♦ Palletizing rack: A palletizing rack is a type of storage compartment

used to store parts at a specific station either before or after they are processed at that station. Each storage location in a rack is identified by an index number. The palletizing rack is built in a grid structure,

divided by fixed limits.

Figure 4-5: Palletizing rack

Feeders and palletizing racks offer the following advantages:

♦ Retrieving and storing materials or parts at (or adjacent to) a station shortens the part flow and reduces production time.

♦ When feeders and racks are used properly they can increase the product output of the system.

Feeders and palletizing racks will be discussed more thoroughly later in this module.

Storage Definition

Storage settings determine the quantity of parts available for processing. It is important that storage settings be defined to include the number of parts required for a production batch. A shortage of parts will disrupt the part flow in the middle of production.

Storage settings can be defined before the start of each production cycle, or you can define default storage settings that are stored in the system and reloaded for future production cycles. Default storage settings eliminate the need to edit the storage settings before each cycle.

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PROCEDURES

Task 4-1: Identifying the Location of a Part in Storage

In this task, you will use the OpenCIM Storage Definition utility to view the number of parts located in storage and identify the location of a specific part.

1 From your Windows Start menu, select OpenCIM | Project

Manager . The CIM Project Manager window is displayed.

2 From the Archive tab, select 102_ACT1-5, and then click Save as to save the project as <USER>4 (for example, JOHN4) in the

User Projects tab, as described in Activity 2, Task 2-1: Accessing

Working Cells from the Project Manager.

3 From the User Projects tab, select this <USER>4 project and then click

CIM Manager to activate the CIM Manager application for this project. All the tasks described in this activity refer to this selected

<USER>4 project.

4 From the OpenCIM Manager main window, select File | Default

Storage to define the default storage settings.

5 Select Utility Programs | Storage Manager. The CIM Storage Manager window is displayed.

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The window shows data for one storage device, ASRS1, including the following parameters:

Storage Type: The type and name of the storage device (ASRS1). ID: The ID number of the storage device (206).

Part Name: The name of the part(s) contained in this device. Quantity: The quantity of the part(s) in the storage device or the

number of empty cells in the storage device, as applicable. In this instance, the 36-cell ASRS1 currently holds one part named BASE_SUP, whereas its other 35 cells are empty.

The window does not show the location of the part (the cell number). In some instances, the number of parts located in storage may be sufficient information; however, in other cases it may be important to know the exact location of the part in storage.

6 To determine the exact location of the part, click the EDIT button in the CIM Storage Manager window. The CIM Storage Definition window is displayed:

Figure 4-7: Storage definition editing screen

The CIM Storage Definition window now shows the exact location of the part.

Q Identify whether or not the following statements are correct:

The only part in storage is known as BASE_SUP. There is only one cell in the storage device. BASE_SUP is located in cell 1A.

Cell 3C is empty.

Q #090002 is the ID number for:

The part. The template. The cell.

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Task 4-2: Setting the Storage Stock

In this task you will add parts to the storage device. Subsequently you will be able to view the number of parts located in the device throughout the production process.

1 Click the Initialize Storage button in the CIM Storage Manager window.

Figure 4-8: Initializing Storage – Confirmation Message

2 Click Yes.

Note that the content of the storage location is cleared (as a result of its initialization).

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3 Click the Add New Row to ASRS Block button . A new row is created, as shown in the figure.

Figure 4-10: CIM Storage Manager Window – Adding Rows

4 Place the cursor on the new row and click to open the dropdown list.

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5 Select BASE_SUP from the list.

BASE_SUP is inserted into storage; however, you do not know the

exact location of the part.

Figure 4-12: CIM Storage Manager Window –BASE_SUP Part Inserted

The next task describes the method for inserting parts when information regarding their exact location is required.

Task 4-3: Setting the Storage Stock and Part Location

In some instances, it may be important to know the exact location of parts in storage, for example when using the OpenCIM in conjunction with online production. In this task you will add a part named

BASE_SUP into cell 1F to the storage location and define its exact

location as cell 1F.

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2 Click Yes.

Note that the content of the storage location is cleared (as a result of its initialization).

Figure 4-14: CIM Storage Manager Window – Storage Location Cleared

3 Click the EDIT button . The following window is displayed:

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4 Double-click the cell 1F or click the cell once and select Edit | Insert

Part/Template.

The following window is displayed:

Figure 4-16: Cell Edit Window

5 Select BASE_SUP from the PART dropdown list. Note that the template is chosen automatically to match the part

(TEMPLATE#090001).

6 Click the Save button .

Note that cell 1F now contains the part BASE_SUP on TEMPLATE#090001.

7 Close the CIM Storage Definition window and return to the CIM Storage Manager window.

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Task 4-4: Observing the ASRS Contents after Production

You will now run the basic CIM cell with the storage updated to include the part BASE_SUP, which you just added. For the purpose of this simulation, BASE_SUP has been defined as the raw material used to produce the final product, BASE_PROD. Note you must ensure that the production cycle is stopped, before you access the MODES dialog box.

1 The goal of this task is to see the result of production, rather than to track production itself. Therefore, you will increase the speed of the simulation by doing the following:

Click the CIM Modes button or select File | Modes.

The MODES dialog box is displayed:

Figure 4-17: MODES Dialog Box

Set the simulation speed to a faster speed by dragging the slider to

the right.

Then click SAVE.

2 Click the Start button to initiate a production cycle.

3 When the “Do you want to refresh storage” message appears, click

Cancel.

4 Click the Run button to start the simulation of the production cycle

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5 Observe and track the part flow.

Note that the simulation speed is significantly faster now.

6 Wait for a message indicating that the order is complete. You can maximize the window to view the messages in their entirety.

Figure 4-18: Message indicating that the order is complete

7 Select Utility Programs | Storage Manager to recheck the contents of the storage device.

Observe the current storage contents.

Figure 4-19: CIM Storage Manager Window – Storage Contents

Q Which of the following statements is true?

BASE_SUP is back in the storage device. BASE_PROD is now in the storage device.

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Task 4-5: Setting Default Storage

Setting default storage will enable you to run a production cycle for this CIM with specific storage settings, without having to edit the storage settings before each cycle.

1 Select Utility Programs | Storage Manager.

.

Figure 4-20: Initializing Storage – Confirmation Message

3 Click Yes.

4 Insert BASE_SUP into the storage.

5 Click the Create Default Storage button . The following message is displayed:

Figure 4-21: Save Current Storage as Default – Confirmation Message

6 Click Yes.

7 Close the Storage Manager window.

You have set the storage default to contain one BASE_SUP part. In the future, each time that you restart production, you will prompt the system to reload this default storage.

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Q Can an ASRS store both raw materials and finished parts?

Q Can a CIM cell include more than one storage station?

Q In CIM, what does ASRS stands for?

Automatic Storage and Removal System. Automated Storage and Retrieval System. Automated Stock Retrieval System.

Q Are parts stored on templates or pallets in the storage device?

Q Can a feeder dispense a specific type of raw materials or parts to a

specific station?

Q Which of the following stations would be the appropriate location for a

feeder?

The ASRS station.

The milling machine station.

Q Can a palletizing rack be used to store parts before as well as after

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Q Which of the following are examples of storage devices:

Figure 4-22 Figure 4-23

Figure 4-24 Figure 4-25

Q Is a feeder typically used to dispense raw materials to a CNC station?

Q Which two of the following are advantages in using feeders and

palletizing racks:

The distance of the part flow is shortened, reducing production time. Raw materials are located adjacent to the processing station,

increasing production time.

Increased storage space is available on the main storage device for

raw materials.

Increased storage space is available on the main storage device for

products.

Q Does initializing storage clear the contents of the storage location?

Q The location of parts must be, can be, or cannot be defined when they

are added to storage?

Q Does defining default storage eliminate the need to edit the storage

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100384-1-a CIM1_AC(OpenCIM) 05-03

tek

LINK

CIM Technology 1

OpenCIM

Student Activities Book

Catalog No. 100384 Rev. A

May 2003

Table of Contents

Introduction

About This Activities Book

Safety

Activity 1

Getting Started

Activity 2

Introducing OpenCIM Software

Activity 3

Parts and Production Flow

Activity 4

Storage Setup