1. History of Manufacturing
Computer Integrated Manufacturing
© 2013 Project Lead The Way, Inc.

2. History of Manufacturing
CIM
Principles of Manufacturing
Overview
This presentation discusses
The need for manufacturing
A brief history of manufacturing
Key figures in manufacturing
An example of the manufacturing process

3. History of Manufacturing
CIM
Principles of Manufacturing
Why Manufacture?
Manufacturing accounts for 20% of the US gross domestic product
Manufacturing employs 17% of the U.S. workforce1
Domestic Product
Workforce
This illustrates the need for manufacturing. According to the statistics, 1/5 of the nation’s gross domestic product comes from the manufacturing industry, and nearly 1/5 of the United States workforce are employed within the manufacturing industry.
1according to the National Science and Technology Council

4. History of Manufacturing
CIM
Principles of Manufacturing
History of Manufacturing
Prior to 19th century
Artisans
Handmade products
Artisans are those skilled in a particular product. Each item is made one at a time. This makes production costly and untimely.
Some artisans are active today as hobbyists. There is still a demand for handmade, high quality merchandise.

5. History of Manufacturing
CIM
Principles of Manufacturing
History of Manufacturing
Prior to the 19th century
Eli Whitney invented the
cotton gin to process cotton
Eli Whitney is most famous for his invention of the cotton gin to process cotton. However, he went bankrupt due to poor business skills. He then left the South and traveled North to start over. He took on the job of mass-producing muskets, which led to the invention of a milling machine. He quickly realized that he needed to break the production process down into smaller parts that would not require a great deal of skill. He came up with the idea of interchangeable parts. In addition, he had the revolutionary idea that the workers of the factory should be treated with respect, an idea that did not catch on in American factories.
Photos courtesy of

6. History of Manufacturing
CIM
Principles of Manufacturing
History of Manufacturing
Early 1900s
Henry Ford introduced assembly line
Significant increase in production efficiency
Unskilled workers could be used
Henry Ford revolutionized manufacturing with the introduction of the assembly line. Ford’s idea was that manufacturing could be sped up if the assembling process was broken down into smaller parts so that unskilled laborers could be used. Ford had early problems with his labor force, however, because the repetitive nature of menial tasks lowered morale. The work was often dangerous, causing 200 severed fingers in 1911 alone. Ford stabilized his work force by more than doubling the pay from $2.25 a day to $5 a day. The happy work force soon began cranking out up to 8,000 “Tin Lizzies” in a single day, and the price dropped to $300 per car.
Ford Motor was responsible for the first human death by robot (1979) when a worker was hit in the head by a robotic arm.
Ford Model T Facts:
 October 1, 1908 marks the anniversary of the first Model T built for sale.
The Model T was the first low-priced, mass-produced automobile with standard, interchangeable parts.
The Model T was equipped with a 20-horsepower, four-cylinder engine with a top speed of about 45 miles per hour, weighed 1,200 pounds, and achieved miles per gallon.
The moving assembly line for the Model T revolutionized manufacturing in 1913.
More than 15 Million Model Ts had been sold by May 26, 1927, when a ceremony marked the formal end of Model T production.
Henry Ford called the Model T “the universal car,” a low-cost, reliable vehicle that could be maintained easily and could successfully travel the poor roads of the era.

7. History of Manufacturing
CIM
Principles of Manufacturing
History of Manufacturing
Early 1900s
Kiichiro Toyoda
Lean Manufacturing
Five areas drive lean manufacturing/production:
Cost
Quality
Delivery
Safety
Morale
Toyoda, the founder of what became Toyota Motor Company, developed JIT (Just In Time) manufacturing. In JIT, manufacturers buy the parts they need as the need arises, which saves money from handling parts in-house. Toyoda also introduced the idea of Kaizen – literally, good change – which allows for continuous improvement with employee input. The Japanese distinguish Kaizen from innovation, which they interpret as a radical change rather than a continuous change.
Lean Manufacturing, also referred to as the Toyota Production System, is the systematic elimination of waste. The phrase was coined in a 1990 book by James Womack called The Machine That Changed the World. The Lean Manufacturing Process is still in use today.

8. History of Manufacturing
CIM
Principles of Manufacturing
History of Manufacturing
Mid 1900s
Jervis B. Webb Co. creates the first electronically coordinated conveyor system
The Jervis B. Webb Co. was the one that introduced conveyor systems to Henry Ford. They have continued to work on their conveyor systems and offer a wide variety of conveyor systems.
Photo courtesy of Jervis B. Webb Col.

9. History of Manufacturing
CIM
Principles of Manufacturing
Manufacturing Today
Automatic Storage and Retrieval System (ASRS)
Moves material vertically or horizontally between storage compartment and transfer station or within a process
Automated Guided Vehicles (AGV)
Computer-controlled system using pallets to transport work pieces to NC machine tools and other equipment in a flexible manufacturing system
Artificial Intelligence (AI)
Machines learn from experience
Knowledge used to problem solve
Automatic Storage and Retrieval System is typically an arrangement of conveyors and vehicles to move and store materials for manufacturing or final products. The system requires minimal human input.
Automated Guided Vehicles have many methods of navigating within a static environment. Current research is providing significant advancements in vehicles that sense and react to their environment.
Beyond the manufacturing setting, AGVs are the focus of much research. The DARPA Grand Challenge and DARPA Urban Challenges are examples of contests to promote research in this area.
Artificial Intelligence allows machines to learn from experience and apply this knowledge to solve problems the same way that humans do.

10. History of Manufacturing
CIM
Principles of Manufacturing
Manufacturing Today
Computer Integrated Manufacturing
(CIM)
Company-wide management philosophy for planning, integration, and implementation of automation
Manufacturing Enterprise Wheel
Customer-centered
People and teamwork
Shared knowledge
Key processes
Resources and responsibilities
Infrastructure
CIM uses computers to coordinate all aspects of manufacturing, including engineering, planning, machine processes, financial issues, and marketing.
CIM was promoted by machine tool manufacturers in the 1980s and the Society for Manufacturing Engineers.
The Manufacturing Enterprise Wheel is detailed in the related curriculum PowerPoint.
Photo Courtesy of Kettering Communications

11. History of Manufacturing
CIM
Principles of Manufacturing
Manufacturing Today
Kaizen
Japanese word for “improvement”
Based on continuous improvement by everyone
Flexible Manufacturing Systems (FMS)
Adapts efficiently to changing need
Possibly increase productivity by 50%
Six Sigma is based on statistical analysis to maximize production and minimize defects.

12. History of Manufacturing
CIM
Principles of Manufacturing
Manufacturing Today
Just In Time Manufacturing (JIT)
Objective is to eliminate waste
Capable of producing mixed products
Utilizes cross-trained workers
Toyota Production System (TPS)
Applied to automotive manufacturing
Competes with mass production
Employs lean production strategy
Lean Manufacturing
Systematic elimination of waste
Entire system must participate to produce effectively
Sources will often vary on the origins of various manufacturing concepts depending on the perspective of the author.
TPS began in Japan in the 1980s to make manufacturing more efficient. All activities are highly coordinated to occur precisely when needed, minimizing storage, cost of goods not currently in use, and obsolescence. The processes of JIT, Lean Manufacturing, and Kaizen started in the mid 20th century but are still in use today.

13. Lean Manufacturing Video
History of Manufacturing
CIM
Principles of Manufacturing
Lean Manufacturing Video
Play video: Lean Manufacturing

14. History of Manufacturing
CIM
Principles of Manufacturing
Manufacturing Today
Six Sigma (6σ)
Indicates measure of quality for near perfection
Produces fewer than 3.4 defects per million opportunities
Identifies and corrects causes of defects
Utilizes the five “whys” to uncover root cause
Six Sigma is based on statistical analysis to maximize production and minimize defects. 6σ

15. History of Manufacturing
CIM
Principles of Manufacturing
Manufacturing Today
Rapid Prototyping
Prototype made directly from a computer model
Several technologies
Stereolithography
3D Printing
Selective Laser Sintering
Fused Deposition Modeling
Workcell
Manufacturing resources
arranged into a group
Work Envelope
Range of motion of a robot or machine
Degrees of freedom are individual movements
The work envelope is a volume which can be calculated based on all degrees of freedom.

16. References
Computer and Automated Systems Association of the Society of Manufacturing Engineers (3rd ed.). (1993). The new manufacturing enterprise wheel. Dearborn, Michigan: Author.
Elshennawy, A.K., & Schrader, G.F. (2000). Manufacturing processes and materials. Dearborn, MI: Society of Manufacturing Engineers.
Ford Motor Company. (n.d.) Ford Model T turns 100: Centennial celebrations underway for the historic icon. Retrieved from
Kettering University. (n.d.) Industrial engineering laboratories. Retrieved December 18, 2007, from
Kiichiro Toyoda. (2009). In Wikipedia, The Free Encyclopedia. Retrieved from
Microsoft Clip Art. (2009). Retrieved from

17. References
Rapid Prototyping. (2009). In Wikipedia, The Free Encyclopedia. Retrieved from
RobotWorx . (2009). Work envelope. Retrieved from
Rufe, P.D. (Ed.). (2002). Fundamentals of manufacturing. Dearborn, MI: Society of Manufacturing Engineers.
Six Sigma Dictionary (2009). In iSixSigma. Retrieved from
Toyoda, K. (2009). In Wikipedia, The Free Encyclopedia. Retrieved from