UNIVERSITY

ASTON

Doug Love/Aston University

http://idmru.aston.ac.uk/camac

Coding & Classification Systems Controlling Variety

Coding & Classification Systems in Design & Manufacture

Controlling the Cost of Variety

Doug Love
Aston University

ID MRU

UNIVERSITY

ASTON

Doug Love/Aston University

http://idmru.aston.ac.uk/camac

Introduction

This presentation will cover

Coding & Classification Systems Introduction

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The cost of part variety finding by shape using coding & classification systems

alpha-numeric & binary systems functionality, costs and viability manufacturing v design applications

Development of an automatic part coding system

problems of coding of real 2D drawings a demonstration of Camac v6

Two hands-on exercises

Opitz coding Camac v6 coding & sketch-based retrieval

ID MRU 2

UNIVERSITY

ASTON

Doug Love/Aston University

http://idmru.aston.ac.uk/camac

Why bother to find existing parts?

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Engineering change control

Designing new parts generate costs

Coding & Classification Systems Cost of Variety

Engineering documentation

$1300-$12000/part

1
Service documentation

20%2-80%3 new parts unnecessary many companies create 000s parts/yr

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Release new part Process Planning NC Programming

a US company had 280,000 parts & created 1500 new parts/month2

A study at Scania4 in the late 1980s showed:

Costing ERP Entry Production Planning Raw Material Stocks Small Batch Set-ups Small Batch Handling Small Batch - WIP

manufacturing costs down 10% with 2x volume distribution costs down 30% with 0.5x part numbers design & development costs were proportional to the number of part numbers Scania spent 0.7 billion SEK/yr on development
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a competitor spent 1.3 bn SEK/yr & had 2x the number of part numbers.

Profit in this period varied 1.3-3.8 bn SEK/yr

Part Stocks

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Various estimates Hyer & Wemmerlov (1989) found that 20% of parts could be reused unmodified & that another 18% needed modification Gunn, T (1982) - seems optimistic! 4 Reported in: Johnson & Broms, Profit Beyond Measure, Nicholas Brealey (2000)
2 3

UNIVERSITY

ASTON

Doug Love/Aston University

http://idmru.aston.ac.uk/camac

Conventional Coding & Classification Systems

Coding & Classification Systems OPITZ

This is the Opitz Code for Rotational Parts

Engineer interprets drawing by selecting geometric properties Code number = geometric properties e.g. 05352 + 0021 Parts are retrieved via code number

ID MRU 4

UNIVERSITY

ASTON

Doug Love/Aston University

http://idmru.aston.ac.uk/camac

Conventional Coding & Classification Systems

Coding & Classification Systems OPITZ

The Opitz coding system

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Manual, inexpensive system

Popular in Europe

Originally developed for

Workpiece statistics & Group Technology

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form families of parts design a machining cell to make the family Machining Line

But also had applications in design retrieval

used to find existing parts by matching code number of desired & actual parts early example of a universal code that works for both production & design applications
HEAT-TREATMENT. MODULE. 8HR TURN-AROUND.

ID MRU

UNIVERSITY

ASTON

Doug Love/Aston University

http://idmru.aston.ac.uk/camac

Conventional Coding & Classification Systems

Opitz coding:

Coding & Classification Systems OPITZ

3 = Smooth or stepped to one end with functional groove 1 = External plane surface 1 = Stepped to one end, no shape elements

2 = Axial holes related by a drilling pattern, no gear teeth

0 = Rotational part L/D < 0.5

ID MRU 6

01312

Now try for yourself .

UNIVERSITY

ASTON

Doug Love/Aston University

http://idmru.aston.ac.uk/camac

Conventional Coding & Classification Systems

Opitz Coding Exercise Coding & Classification Systems O P I T Z Exercise

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This exercise should be done in pairs (as is the next one) Code the drawings on the following pages Using the Opitz Codes (see below)

5 digit shape code for rotational parts, and 4 digit material & dimensions code

1. , + 1...
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Note any problems in interpreting the code compare your code(s) with your neighbours

ID MRU 7

note any differences