2005:104 CIV MASTER’S THESIS How Improve a CAD/CAM/CNC-process A study of organization and technology at Electrolux AE&T EMMA BODEMYR DANIEL VALLIN MASTER OF SCIENCE PROGRAMME Luleå University of Technology Department of Human Work Sciences Division of Industrial Work Environment 2005:104 CIV • ISSN: 1402 - 1617 • ISRN: LTU - EX - - 05/104 - - SE Abstract This thesis is the final project within the education for Master of Science with the concentration on Industrial manufacturing at Luleå University of technology. The work was performed during September 2004 – January 2005 at Electrolux Automated Equipment and Tooling, AE&T, in Adelaide, Australia, where the Centre for Advanced Manufacturing Research at University of South Australia was one of the supervisors. The goal with the project was to improve the technology and organization with the interaction between CAD, CAM and CNC-machines in a manufacturing process. I Summary This Master thesis was mainly performed at Electrolux Automated Equipment and Tooling (AE&T) in Adelaide, Australia between September 2004 and January 2005. The aim with this project was to investigate the process and co-operation of the areas CAD, CAM and CNC-machines at the plant and come up with more efficient solutions. The outcome of the project is an investment recommendation and organizational change. The project has been performed at AE&T and finished in Sweden. The current situation has been documented and analysed, literature has been reviewed, benchmarking visits have been made, a questionnaire has been sent out and the future situation and requirements have been analysed. AE&T is a toolmaking company within the Electrolux organisation. Though, its future has been discussed a lot during this last year. The plant was up for sale during fall 2004 as it was not a part of the core business, according to Electrolux. In December 2005, Electrolux decided to keep the business in the organisation anyway. It is a tough situation for tooling companies at the moment and to be competitive on the world market one has to have an optimal and efficient organization, have skills and new technology, be suitable and helpful to meet customer requests, be time saving and have a helpful system to support the business. AE&T have the skills, but need to use them in the right place of organization and update its technology. Our recommendation is in two steps. The first is to train the CNC operators to do the CAM at the shop floor instead of having a designated CAM programmer. They also need to replace the old CNC-machines and increase the total quantity to get higher capacity and more effective production hours. The designers should become project leaders and together with a new information- and planning-system make the manufacturing go smoother with shorter lead times. The organization change will improve the motivation and quality in work as well as in products. Another change is to employ missing skills, like salesmen. Salesmen are needed to get more work to the shop and fill up all the three coming shifts as planned in this solution. The recommendation concerning the software is to keep the current solution, but be prepared to change software to attract more customers and come by file translation and rework and thereby also save time. The second step is to buy a new set of three CNC-machines and a new information- and planning- system that is self-learning and decision-making. The economical appraisal shows that the changes and investments for both steps are profitable and payback time is two years, which is a demand from Electrolux. II Preface This Master thesis was mainly performed in Adelaide, Australia, at Electrolux Automated Equipment and Tooling (AE&T) between September 2004 and January 2005. It was completed and presented at Luleå University of Technology (Ltu) in February 2005. This thesis is the final project in the Master Program for Engineering within Industrial manufacturing at Ltu. The result of this project is recommendations for investments and organizational changes to be implemented at AE&T to become more efficient and be a competitive actor on the tooling market. There are some people we would like to thank for helping us making this thesis possible: Mr. Evangelos Lambrinos for giving us the opportunity to come to Australia, Mr. Bob Speedie for time, help and support, Mr. Juergen Bracht for giving us the opportunity to perform the thesis at AE&T and at last our mentor and supervisor Mr. Magnus Stenberg at Ltu whose feedback and help has been highly appreciated. Adelaide, Australia 21/01/05 Luleå, Sweden 25/02/05 Miss Emma Bodemyr Mr. Daniel Vallin III TABLE OF CONTENTS_________________________________________________________________________ Table of contents 1 INTRODUCTION................................................................................................1 1.1 COMPANY HISTORY.........................................................................................1 1.2 BACKGROUND.................................................................................................2 1.3 PROJECT DEFINITION .......................................................................................2 1.4 LIMITATIONS...................................................................................................3 1.5 PROJECT ORGANIZATION.................................................................................3 2 METHODOLOGY AND TOOLS......................................................................4 2.1 METHODOLOGY ..............................................................................................4 2.2 METHODS........................................................................................................5 2.2.1 Interviews...............................................................................................5 2.2.2 Brainstorming ........................................................................................5 2.2.3 Feedback and supervision......................................................................5 2.2.4 Benchmarking visits...............................................................................5 2.2.5 Market research.....................................................................................5 2.2.6 Questionnaire.........................................................................................5 2.2.7 Literature studies ...................................................................................6 2.2.8 The usage of the CNC-machines............................................................6 2.2.9 Choosing CAD/CAM software for a business........................................6 3 THE CURRENT SITUATION...........................................................................8 3.1 AE&T.............................................................................................................8 3.1.1 The economical situation .......................................................................9 3.1.2 Job process...........................................................................................10 3.1.3 The flow of communication..................................................................12 3.1.4 Machinery ............................................................................................13 3.1.5 Software ...............................................................................................16 3.2 ANALYSIS .....................................................................................................17 3.2.1 The economical situation .....................................................................20 3.2.2 Job process...........................................................................................20 3.2.3 The flow of communication..................................................................21 3.2.4 Machinery ............................................................................................21 3.2.5 Software ...............................................................................................22 4 LITERATURE REVIEW .................................................................................24 4.1 HISTORY AND THEORY ..................................................................................24 4.1.1 CAD......................................................................................................25 4.1.2 CAM .....................................................................................................26 4.2 INTEGRATION OF CAD, CAM AND CNC ......................................................26 4.3 CAPP, A WAY TO FURTHER INTEGRATION AND AUTOMATION.......................30 4.4 HIGH PERFORMANCE CUTTING (HPC) AND HIGH SPEED CUTTING (HSC)....30 5 MARKETING RESEARCH.............................................................................32 5.1 SOFTWARE ....................................................................................................32 5.2 HARDWARE...................................................................................................32 6 BENCHMARKING ...........................................................................................34 6.1 COMPANY VISITS...........................................................................................34 6.2 QUESTIONNAIRE ...........................................................................................35 IV TABLE OF CONTENTS_________________________________________________________________________ 7 THE FUTURE SITUATION ............................................................................36