UNIT - IV - Computer Aided Manufacturing Resource Planning.pptx

MRP

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4. 4 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM COMPUTER AIDED MANUFACTURING RESOURCE PLANNING Definition Computer Aided Manufacturing Resource Planning (CAMRP) is an integrated information system that combines computer-aided design (CAD), computer-aided manufacturing (CAM), and manufacturing resource planning (MRP II) to optimize the entire manufacturing process. It uses computer technology to plan, schedule, control, and monitor manufacturing operations, from raw material procurement to finished product delivery, ensuring efficient resource utilization, cost reduction, and improved productivity. CAMRP integrates various manufacturing functions including production planning, inventory management, capacity planning, shop floor control, quality management, and financial management into a unified computerized system. History and Evolution Early Developments (1960s-1970s) 1960s : Material Requirements Planning (MRP) emerged as the first computerized inventory management system, developed by Joseph Orlicky at IBM. MRP focused primarily on material planning and inventory control. 1970s : Manufacturing companies began adopting mainframe computers for basic production scheduling and inventory tracking. MRP II Era (1980s) Early 1980s : Manufacturing Resource Planning (MRP II) was developed by Oliver Wight, extending MRP to include capacity planning, shop floor control, and financial integration. Mid-1980s : CAD and CAM systems began integration with planning systems, laying the groundwork for CAMRP. The term "Manufacturing Resource Planning" was coined to distinguish it from the earlier Material Requirements Planning.

5. 5 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM COMPUTER AIDED MANUFACTURING RESOURCE PLANNING CAMRP Development (1990s) 1990s : True integration of CAD/CAM with MRP II created CAMRP systems. Client-server architecture replaced mainframes, making systems more accessible. Graphical user interfaces improved usability. Real-time data processing became feasible. Modern Era (2000s-Present) 2000s : Integration with ERP (Enterprise Resource Planning) systems. 2010s : Cloud-based CAMRP solutions emerged, offering scalability and accessibility. 2020s : Integration with IoT, AI, machine learning, and Industry 4.0 concepts for smart manufacturing.

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10. 10 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM COMPUTER AIDED MANUFACTURING RESOURCE PLANNING Traditional Manufacturing Resource Planning (MRP II) Components of Traditional MRP II 1. Master Production Schedule (MPS) Defines what products to manufacture, in what quantities, and when Based on customer orders and demand forecasts Provides the foundation for all planning activities 2. Material Requirements Planning (MRP) Calculates material requirements based on MPS Determines when to order materials Manages bill of materials (BOM) 3. Capacity Requirements Planning (CRP) Ensures adequate production capacity Identifies bottlenecks Plans workforce and machine utilization 4. Shop Floor Control (SFC) Manages work orders Tracks production progress Controls work-in-process inventory 5. Purchase Management Manages supplier relationships Creates and tracks purchase orders Monitors vendor performance Limitations of Traditional MRP II Limited integration with design and engineering Slow response to changes Manual data entry prone to errors Lack of real-time visibility Difficulty in handling complex product configurations Limited connectivity between different departments

11. 11 COMPUTER AIDED MANUFACTURING RESOURCE PLANNING Computer Aided Manufacturing Resource Planning (CAMRP) - Classification and Types 1. By Integration Level Type A: Basic Integration CAMRP Description : Links CAD/CAM data with MRP systems through file transfers or batch processing Features : One-way data flow from design to manufacturing Periodic data synchronization Limited real-time updates Applications : Small to medium manufacturing facilities Job shops with standard product lines Companies with stable product designs Advantages : Lower implementation cost Easier to implement Minimal disruption to existing processes Reduced training requirements Limitations : Data latency issues, Risk of data inconsistency Manual intervention required, Limited flexibility No real-time decision making Type B: Fully Integrated CAMRP Description : Complete bidirectional integration between CAD/CAM and MRP systems with real-time data sharing Features : Real-time synchronization Automated data flow Integrated database architecture Concurrent engineering support Applications : Large-scale manufacturing enterprises Aerospace and automotive industries Complex product manufacturing Mass customization environments Advantages : Real-time visibility across operations Reduced lead times, Improved accuracy Better resource utilization, Enhanced collaboration Faster response to changes Limitations : High implementation cost Complex integration requirements Extensive training needed Longer implementation time Requires robust IT infrastructure NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM

12. 12 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM COMPUTER AIDED MANUFACTURING RESOURCE PLANNING 2. By Deployment Model Type C: On-Premise CAMRP Description : Software installed and operated on company's own servers and infrastructure Features : Local data storage, Complete control over system Customizable architecture Applications : Companies with strict data security requirements Defense and government contractors Organizations with existing IT infrastructure Advantages : Complete data control Customization flexibility No recurring subscription fees Better perceived security No internet dependency Limitations : High initial capital investment Maintenance responsibility Scalability challenges Requires dedicated IT staff Longer deployment time Type D: Cloud-Based CAMRP Description : Software hosted on cloud servers and accessed via internet Features : Subscription-based model, Automatic updates Remote accessibility, Scalable resources Applications : Small to medium enterprises, Multi-location manufacturing Companies seeking rapid deployment Collaborative manufacturing networks Advantages : Lower upfront costs Automatic updates and maintenance Scalability and flexibility Accessible from anywhere Faster implementation Reduced IT burden Limitations : Ongoing subscription costs Internet dependency Potential security concerns Less customization Data residency issues

13. 13 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM COMPUTER AIDED MANUFACTURING RESOURCE PLANNING 3. By Functional Scope Type E: Process-Oriented CAMRP Description : Focused on process industries (chemicals, pharmaceuticals, food & beverage) Features : Recipe management, Batch processing control Quality compliance tracking, Regulatory reporting Applications : Chemical manufacturing, Pharmaceutical production Food and beverage industry, Batch processing operations Advantages : Industry-specific functionality Regulatory compliance support Formula/recipe management Traceability features Quality control integration Limitations : Limited applicability outside process industries, Complex configuration Higher cost due to specialization Requires industry expertise Type F: Discrete Manufacturing CAMRP Description : Designed for discrete product manufacturing (automotive, electronics, machinery) Features : Assembly line control, Work order management BOM explosion, Routing management Applications : Automotive manufacturing Electronics assembly Machinery production Consumer goods manufacturing Advantages : Optimized for assembly operations Strong BOM management Detailed routing capabilities Shop floor integration Configuration management Limitations : Not suitable for process industries Complex for simple operations Requires detailed setup Higher training requirements

14. 14 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM COMPUTER AIDED MANUFACTURING RESOURCE PLANNING 4. By Technology Integration Type G: IoT-Enabled CAMRP Description : Integrates Internet of Things sensors and devices for real-time monitoring Features : Real-time machine monitoring, Predictive maintenance Automated data collection, Digital twin integration Applications : Smart manufacturing facilities, Industry 4.0 implementations High-value equipment operations Predictive maintenance programs Advantages : Real-time operational visibility Reduced downtime Predictive capabilities Automated data capture Enhanced decision making Reduced manual errors Limitations : High technology investment Complex integration Cybersecurity concerns Requires technical expertise Ongoing maintenance of sensors Type H: AI-Powered CAMRP Description : Incorporates artificial intelligence and machine learning for optimization Features : Demand forecasting, Intelligent scheduling Anomaly detection, Self-learning optimization Applications : High-volume manufacturing, Complex scheduling environments Demand-driven manufacturing Optimization-critical operations Advantages : Improved forecasting accuracy Optimized scheduling Adaptive learning Pattern recognition Reduced waste Better resource allocation Limitations : Very high implementation cost Requires substantial data Black box decision making Need for AI expertise Ethical and transparency concerns

15. 15 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM COMPUTER AIDED MANUFACTURING RESOURCE PLANNING Companies Providing CAMRP Solutions International Companies 1. Siemens (Germany) Products : Teamcenter (PLM), Opcenter (MES integrated with MRP) Strengths : Complete digital manufacturing suite, strong in automotive and aerospace Market : Global leader in integrated CAD/CAM/MRP solutions 2. Dassault Systèmes (France) Products : DELMIA, 3DEXPERIENCE Platform Strengths : 3D design integration, virtual manufacturing Market : Strong in aerospace, automotive, and industrial equipment 3. PTC (USA) Products : Windchill PLM, ThingWorx IIoT integrated with ERP Strengths : IoT integration, augmented reality capabilities Market : Manufacturing, aerospace, defense 4. SAP (Germany) Products : SAP S/4HANA Manufacturing, SAP Digital Manufacturing Cloud Strengths : Enterprise-wide integration, financial integration Market : Large enterprises across all industries 5. Oracle (USA) Products : Oracle Manufacturing Cloud, Oracle Fusion ERP Strengths : Cloud infrastructure, comprehensive ERP integration Market : Global enterprises, diverse industries 6. Autodesk (USA) Products : Fusion 360 with integrated CAM and PLM Strengths : Cloud-based design to manufacturing Market : SMEs, product development companies 7. IQMS (now Dassault Systèmes - USA) Products : DELMIAworks (formerly IQMS) Strengths : Real-time manufacturing ERP Market : Discrete and process manufacturing 8. Infor (USA) Products : Infor CloudSuite Industrial (SyteLine) Strengths : Industry-specific solutions Market : Manufacturing, distribution

16. 16 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM COMPUTER AIDED MANUFACTURING RESOURCE PLANNING Indian Companies 1. Tally Solutions (Bangalore) Products : TallyPrime with manufacturing modules Strengths : Cost-effective, India-focused Market : SMEs in India 2. Ramco Systems (Chennai) Products : Ramco ERP with Manufacturing Suite Strengths : Aviation MRO, multi-tenancy cloud Market : Mid-size to large enterprises 3. Saral Technologies Products : Manufacturing ERP solutions Strengths : Localized for Indian market Market : Indian SMEs 4. Focus Softnet (Dubai/India operations) Products : Focus 9 Manufacturing ERP Strengths : Middle East and Asia focus Market : Manufacturing SMEs

17. 17 COMPUTER AIDED MANUFACTURING RESOURCE PLANNING Companies That Have Implemented CAMRP International Implementations 1. Boeing (USA) - Aerospace Implemented Dassault Systèmes ' DELMIA and 3DEXPERIENCE Integrated design, manufacturing planning, and shop floor operations Results: Reduced design-to-manufacturing time by 40%, improved quality control 2. General Electric (USA) - Industrial Manufacturing Implemented Siemens Teamcenter and custom solutions Created digital factory concepts Results: 20% reduction in production costs, improved time-to-market 3. BMW (Germany) - Automotive Implemented Siemens Opcenter and Teamcenter Integrated virtual manufacturing with physical production Results: 30% reduction in planning time, improved production flexibility 4. Airbus (Europe) - Aerospace Implemented Dassault Systèmes ' 3DEXPERIENCE Platform Global collaboration across design and manufacturing Results: Enhanced collaboration across 16 sites, reduced development cycles 5. Caterpillar (USA) - Heavy Machinery Implemented SAP S/4HANA Manufacturing Integrated global supply chain with manufacturing Results: Improved inventory turns, reduced lead times by 25% 6. Volkswagen (Germany) - Automotive Implemented Siemens Digital Enterprise Suite Digital twin of entire production process Results: 30% faster production planning, reduced waste 7. Procter & Gamble (USA) - Consumer Goods Implemented SAP Manufacturing Execution Integrated 140+ plants globally Results: Real-time visibility, 15% productivity improvement NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM

18. 18 COMPUTER AIDED MANUFACTURING RESOURCE PLANNING Indian Implementations 1. Tata Motors (Automotive) Implemented Siemens Teamcenter PLM and manufacturing solutions Integrated design, engineering, and manufacturing across plants Results: Reduced product development time, improved coordination across facilities 2. Mahindra & Mahindra (Automotive/Farm Equipment) Implemented SAP S/4HANA with manufacturing modules Connected manufacturing across multiple business units Results: Improved production planning, better inventory management 3. Larsen & Toubro (Engineering & Construction) Implemented Oracle Manufacturing Cloud Integrated project management with manufacturing Results: Enhanced project execution, improved resource utilization 4. Bharat Forge (Automotive Components) Implemented Infor CloudSuite Industrial Global manufacturing network integration Results: Real-time production monitoring across 11 global facilities 5. Kirloskar Brothers (Pumps & Valves) Implemented QAD Manufacturing ERP Integrated engineering and manufacturing processes Results: Reduced lead times, improved on-time delivery 6. Bajaj Auto (Automotive) Implemented customized MRP II with CAD/CAM integration Connected design centers with manufacturing plants Results: Faster design changes implementation, reduced production errors 7. Hindustan Aeronautics Limited (HAL) - Aerospace Implemented Dassault Systèmes solutions Integrated design, manufacturing, and maintenance Results: Improved aircraft production efficiency, better documentation 8. Godrej & Boyce (Diversified Manufacturing) Implemented SAP Manufacturing modules Unified operations across diverse product lines Results: Better visibility, improved production planning 9. Thermax (Energy & Environment) Implemented Oracle ERP with manufacturing modules Integrated project-based manufacturing Results: Improved project execution, better cost control 10. TVS Motor Company (Automotive) Implemented IQMS (now DELMIAworks ) Real-time shop floor control and quality management Results: Reduced cycle times, improved quality metrics NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM

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20. 20 NALLA MALLA REDDY ENGINEERING COLLEGE CADCAM COMPUTER AIDED MANUFACTURING RESOURCE PLANNING Overall Benefits of CAMRP Implementation Reduced Time-to-Market : 30-50% reduction in product development cycles Cost Savings : 15-25% reduction in manufacturing costs Improved Quality : 40-60% reduction in defects Better Resource Utilization : 20-30% improvement in machine utilization Enhanced Collaboration : Seamless information flow across departments Real-time Visibility : Better decision-making with current data Regulatory Compliance : Automated documentation and traceability Scalability : Easier to expand operations and add new facilities Future Trends in CAMRP Digital Twin Integration : Complete virtual representation of manufacturing Blockchain : For supply chain transparency and traceability 5G Connectivity : Enhanced real-time data transmission Sustainable Manufacturing : Focus on energy efficiency and waste reduction Collaborative Robots : Integration with cobots and automated systems Edge Computing : Faster processing at the shop floor level Augmented Reality : For training, maintenance, and remote assistance