Development of an automated process planning and production activity control system for the manufacturing of engineered work surfaces

This paper describes the design and implementation of an Automated Process Planning and Production Activity Control system for a make-to-order business and presents a formal methodology for the development of integrated manufacturing systems. The research is based on concepts developed in a project undertaken in a job shop Case Study facility, producing precision-engineered work surfaces. Industry today is facing numerous challenges on many fronts demanding improved availability and dissemination of processing information. On the demand side there is increased pressure on the manufacturer to meet deadlines and provide the customer with a prompt, efficient service, with accurate lead-time information, and a product of the utmost quality, on time. On the supply side there is increasing competition, variety in the market, a diverse product range, varying processing times and extremely short lead times. The nature of today's business world means that real-time information is a requirement and not an extra. This paper documents the design, structure and implementation of an Automated Process Planning system, which completely automates and integrates Order Entry stages from order receipt to order release. The developed system, namely the Manufacturing Optimization Information System, or MOIS, relays information to and from shop floor operators via a Production Activity Control system at each of the manufacturing stations. The MOIS is part of ongoing research endeavouring to integrate order processing, Process Planning and production control activities with a combined dynamic scheduling and material optimization module in a holistic manufacturing optimization system. The two specific aims of this paper are very clear; first, to bridge the theory-practice gap between theoretical concepts and real industrial issues surrounding Process Planning and Production Control. Secondly, to outline the design, structure and evolution of an integrated Automatic Process Planning and Production Activity Control system, installed in a make-to-order enterprise.