Glossary

Adaptive control : A sytem that can modify its behaviour in response to changes in the dynamics of the process and the character of the disturbances.

Agile manufacturing : A means of thriving in an environment of continuous change, by managing complex inter and intra-firm relationships through innovations in technology, information, and communication, organizational redesign and new marketing strategies.

AGVS : Automated guided vehicle system, vehicles equipped with automatic guidance equipment which follow a prescribed path, stopping at each machining or assembly station for loading or unloading of parts.

Artificial intelligence : The concept that computers can be programmed to assume capabilities such as learning, reasoning, adaptation, and self-correction.

Automation : (1) The conversion to and implementation of procedures, processes, or equipment by automated means. (2) Industrial open- or closed-loop control systems in which the manual operation of controls is replaced by servo operation.

Autonomous system : A network that is administered by a single set of management rules that are controlled by one person, group or organization. Autonomous systems often use only one routing protocol, although multiple protocols can be used. The core of the Internet is made up many autonomous systems.

Available-to-promise : Automated available-to-promise is achieved by giving order takers access to inventory and capacity information, and in some cases even vendor information, so that they are able to commit to reliable delivery dates while the customer is still on the phone.

Benchmark : A fixed point of reference or a standard for comparison and used to achieve excellence within the manufacturing firm. An outstanding example, appropriate for use as a model.

Best practice : A process of benchmarking against competition to find out how the best is done.

Bill of material : A listing of all the subassemblies, parts, and raw materials that go into a parent assembly.

CAD : Computer-Aided Design is the use of high-resolution graphics in a wide range of design activities, allowing quick evaluation and modification of intent.

CAM : Computer-Aided Manufacturing is the use of computer technology to generate data to control part or all of a manufacturing process.

Capacity requirements planning : CRP, used in manufacturing (MRP), is a technique for projecting resource requirements for critical work stations, generated from scheduled receipts and planned order releases.

Cell control : A manufacturing unit consisting of two or more workstations or machines and the materials, transport mechanisms, and storage buffers that interconnect them.

Changeover time : The time required to modify a system or workstation, usually including both tear down time for the existing condition and set-up time for the new condition. Typically associated with a switch to new product.

CIM : Computer-Integrated Manufacturing is the increased integration of business and manufacturing functions through application of information technology; the use of computers in all aspects of manufacturing, with integration of functions and control in a hierarchy of computer systems.

CNC : Computer Numerical Control allows the control of motion in an accurate and programmable manner through the use of a dedicated computer within a numerical control unit, with a capability of local data input such that machine tools are freed from the need for hard-wired controllers.

Concurrent engineering : The restructuring of the engineering process so that the input of all concerned parties-including manufacturing, sales, and even customers-are heard from during a project's conception.

Continuous-flow production : Lotless production where products flow continuously rather than being proportioned into lots.

Continuous improvement : A philosophy of frequent and small changes to production processes developed in Japan. The cumulative results lead to high levels of quality and efficiency.

Continuous process control : The use of transducers (sensors) to monitor a process and make automatic changes in operations through the design of appropriate feedback control loops. Such devices have been historically mechanical or electromechanical, there is now widespread utilization of computers and centralized control.

Control system : The deliberate guidance or manipulation of the elements in a system in order to achieve a prescribed value or performance of a system to complete a defined process.

Dark factory : A term to depict a completely automated factory with no labour.

Data acquisition system : Any instrument or computer that acquires data from sensors via amplifiers, multiplexers, and any necessary analog to digital converters. Typically associated with process industries.

Database : A collection of structured data, independent of any application.

DCS : Distributed Control Systems evolved from centralized process control computers common in the 1960s. The systems were developed for continuous-flow processes that required loop, analog, and limited discrete control. A DCS is a real-time, fault-tolerant system for continuous and complex batch-process applications.

Decision-support tools : PC, client or application server-based systems that use memory-based processing to perform rapid simulations using data drawn from business-transaction processing systems such as enterprise resources planning.

Demand management : see Forecasting.

Dependent demand : In manufacturing is demand for an item that results from the production decisions for its parent items. An order for a parent part can only be completed if all of its components are available.

Direct-to-plate thermal imaging : A technology in which plates are made directly from digital computer data and in which heat is used rather than light to image printing plates.

Discrete manufacturing : Production of distinct items such as automobiles and computers.

Discrete-event simulation : Material-flow or discrete-event simulators have most often been used by engineers in the design and modification of production systems. The models output statistical estimates of performance, using graphic animation to help create a greater understanding of system dynamics.

Distribution management : Determines optimal quantities of each product to be made at each plant and to be distributed to each warehouse, such that manufacturing and distribution costs are minimized and customer demand is met.

Document management system : Allows users to store, search and manipulate documents electronically, and to maintain a library of text and images in a compact space. Most systems also provide a means for passing documents across a network.

Dynamic scheduling : Software that allows refinement of production schedules as conditions change.

EDI : Electronic Data Interchange is a standard for automated exchange of business documents. Using EDI, purchasers and suppliers can exchange digital paperwork including purchase orders, invoices, and other business documents, and perform electronic funds transfers.

Enterprise management : Enterprise Management is the planned, coordinated automation of IT functions across all the computing resources within an enterprise.

ERP : Enterprise Resources Planning is an extension of the manufacturing resources planning concept standardized by APICS (American Production and Inventory Control Society).

Expert system : A computer program that uses knowledge and reasoning techniques to solve problems normally requiring the abilities of human experts.

Fault tolerance : The ability of a system to execute tasks regardless of strategic components failure.

Finite element analysis : A CAD method that determines the structural integrity of a mechanical part or physical construction under design by mathematical simulation of the part and its loading condition.

Flexible automation : Short set-up times and the ability to switch quickly from one product to another.

Flexible machine centre : (FMC) Usually an automated system, comprised of CNC machines with robots loading and unloading parts conveyed into and through the system.

Flexible manufacturing system : (FMS) A manufacturing process designed so that the production line may be rebalanced often, rapidly matching output to changes in demand.

Forecasting : Seeks to predict levels of weekly or monthly product activity over a time horizon, typically two years. The statistical methods proven to make such predictions have been used by manufacturers and distributors since the advent of MRP II systems. More complex forms of forecasting also have become available to manufacturers and distributors of products. These systems use neural processing to determine and predict the effect cause, or event-driven; factors have on demand. Factors may include consumer-goods related data such as pricing policies, promotions, and competitor's pricing, as well as macroeconomic indicators such as gross domestic product or new housing starts within a given time period.

Fuzzy logic : A method used to model linguistic expressions that have nonbinary truth values. It has been used with PID algorithms in process control, especially where process relationships are nonlinear.

Globalization : The process whereby competition has expanded geographically through the expansion in freer trade arrangements and improvements in transportation and communications.

Group technology : An engineering and manufacturing philosophy which identifies "sameness" of parts, equipment, or processes. it provides for the rapid retrieval of existing designs and anticipates a cellular type production equipment layout.

Hardware : The physical, manufactured components of a computer system, such as the circuit boards, CRT, keyboard, and chassis.

Holonic maufacturing systems : An HMS is a way of organizing a manufacturing system. The entire range of manufacturing activities from order booking through design, production, and marketing are integrated to realise the agile manufacturing enterprise. In an HMS, key elements such as machines, work centers, plants, parts, products, persons, departments, or divisions have autonomous and cooperative properties. These elements are called "holons". In the system, each holon's activities are determined through the cooperation with other holons, as opposed to being determined by a centralized mechanism.

Hydroforming : Hydroforming is a metal forming process in which the metal tube blank is formed into a desired shape with the use of internal water hydraulic pressure. Hydroforming is applicable in any industry where complex shapes must be formed with a high degree of precision.

Industrial-hardened : Computer equipment installed to withstand the effects of the manufacturing environment, including dirt, heat, shock, and vibration, as well as insulating the equipment from poor-quality electrical power.

Instrument : (1) The term for any item of electrical or electronic equipment designed to carry out a specific function or set of functions. (2) A device for measuring the value of an observable attribute. The instrument also may control the value.

Instrumentation systems : Systems of instruments used to observe and control a physical object or process.

Integrated manufacturing systems : Linking together a unique technology, such as laser, with machine controls, sensors and drive systems.

Interface : (1) A shared boundary between two pieces of equipment. (2) The hardware and software needed to enable one device to communicate with another.

Internet : The infobahn of tens of thousands of public and private networks throughout the world. The Internet's TCP/IP communications standards mean computers anywhere in the world-even though running different operating systems and applications-can communicate with one another. HyperText Markup Language (HTML) lets the computers display the accessed information in graphical pages.

Intranet : Networks within a business. It uses the same technology that is the foundation of the global Internet.

Island of automation : Stand alone pocket of automation (robots, CAD/CAM system, CNC machines) that are not connected into a cohesive system.

JIT : Just-in-Time is an approach to manufacturing that stresses the benefits inherent in a system, where material is brought to the work site only when it is needed. To achieve this goal, each operation must be synchronized with those subsequent to it.

Kanban : The Japanese methodology for achieving JIT, often involving the use of kanbans, or cards, to indicate parts status.

Knowledge-based system : Software that uses artificial intelligence techniques and a base of information about a specialized activity to control systems or operations.

LAN : Local Area Networks span a limited geographical area to connect computers and terminals, usually at moderate-to-high data rates.

Lean Production : The system of organization production developed in japan that stresses quick tool changeover times, minimum parts and work-in-progress inventories, high levels of quality and continuous improvement.

Load cell : A transducer for the measurement of force or weight. Action is based on strain gages mounted within the cell on a force beam.

Machine vision : (1) A computer perception of a visually-based sensory output used to produce a concise description of an image. (2) Devices used for optical non-contact sensing to automatically receive and interpret an image of a real scene in order to obtain information or to control a process.

Maintenance management systems : Automated software systems for handling maintenance work orders, as well as associated inventory, purchasing, accounting, and human-resources functions.

Manufacturing automation protocol : MAP is a specification for a suite of communication standards for use in manufacturing automation developed under the auspices of General Motors corporation.

Mass customization : A system of production stressing the production of small lots of customized goods as opposed to large volumes of standardized products.

Master production schedule : An expression of the operational plan of production by period, indicating the timing and size of end item quantities (used in MRP).

MEMS : Micro-electrical-mechanical systems allow sensors, electronics, and actuators to be batch fabricated on a single chip. MEMS can perform extremely delicate operations such as drilling holes with bits finer than the human eye can see unaided.

MES : Manufacturing Execution Systems use network computing to automate production control and process automation. They do so by downloading recipes and work schedules, and uploading production results, thereby bridging the gap between business and plant-floor or process control systems.

MRP : Materials Requirements Planning was the first phase in the development of MRP II. An MRP software module uses the bill of material, inventory data, and the master production schedule (MPS) to calculate requirements for materials. It makes recommendations to release replenishment orders (POs) for materials. Further, since it is time phased, it makes recommendations to reschedule open orders when due dates and need dates are not in phase. Time-phased MRP begins with the items listed on the MPS and determines : 1) the quantity of all components and materials required to fabricate those items, and 2) the date that the components and materials are required. Time-phased MRP is accomplished by exploding the bill of material, adjusting for inventory quantities on hand or on order, and offsetting the net requirements by the appropriate lead times.

MRP II : Manufacturing Resources Planning is a computerized method for planning the use of a company's resources, including scheduling raw materials, vendors, production equipment, and processes. System includes financials, manufacturing, and distribution management.

Nanotechnology : Nanotechnology is molecular manufacturing or, building things one atom at a time. A nanometer is one billionth of a meter and approximately ten atoms fit inside one nanometer. Utilizing the physical properties of atoms and molecules, nanotechnology proposes the construction of nanosize devices possessing extraordinary properties.

NC : Numerical Control is a technique of operating machine tools or similar equipment in which motion is generated in response to numerically-ordered commands generated by CAD systems, punched tapes, or other communication media.

Net shape processing : Any manufacturing process which creates an object in its finished form without the need for finish machining or other actions.

Network : (1) Any system of computers and peripherals. (2) In an electrical or hydraulic circuit, any combination of circuit elements.

Networked organization : An company organized in the form of a group of peers rather than a hierarchy or a system of departments.

Neural network : A processing architecture derived from models of neuron interconnections of the brain. Unlike typical computers, neural networks are supposed to incorporate learning, rather than programming, and parallel, rather than sequential, processing.

Next Generation Manufacturing Systems : Systems used to link customers, suppliers, and the many functions within a company with other companies in the enterprise. Next Generation Manufacturing Systems assume that next generation manufacturing enterprises are organized into distributed work units, that the work units have a high degree of autonomy, and that they behave intelligently.

Object-oriented database : A database used to store objects that form the bases of object-oriented computing, in which data as well as references to the procedures used to perform operations on that data are combined.

Object-oriented software : Results from a kind of modular programming. Each object is a software package containing a collection of related procedures and data that can be reused, shortening application development time. Objects also make it easier to customize software systems to mirror actual business processes, and to do so without negatively impacting the ability to migrate to later software releases.

Optimised production technology : OPT is a technique for production scheduling and inventory control that recognises capacity constraints (which MRP does not). The goal of OPT is to simultaneously increase throughput and decrease inventory and operating expenses.

Output : (1) The end result of a process or system. (2) Information leaving a device; data resulting from processing. (3) An audio, electric, or mechanical signal delivered by an instrument to a load.

Parallel development : Design and production engineers at a company and at its suppliers work jointly from beginning to end, not in a sequential manner.

Parent : In manufacturing, an item that has one or more components.

PID control : Proportional plus Integral plus Derivative control is used in processes where the controlled variable is affected by long downtimes.

Planning and scheduling systems : A new generation of planning and scheduling tools, which unlike MRP II, includes constraint models that deal with both materials and capacity. These technologies can be applied along a continuum extending from short-term plant-floor scheduling to strategic planning of supply chains.

PLC : A Programmable Logic Controller controls large numbers of discrete elements using very fast I/O (Input/Output) scan times. Today, even the smallest PLCs may be equipped with serial communication and analog control capabilities, and perform arithmetic functions.

Precision engineering : Sensing, control, and fabrication at scales comparable to or smaller than optical wavelengths.

Predictive control : A type of automatic control in which the current state of a process is evaluated in terms of a model of the process and controller actions are modified to anticipate and avoid undesired excursions.

Process : A natural phenomenon marked by gradual changes that lead toward a particular result. A series of actions or operations leading to an end. A continuous operation or treatment in manufacturing. Continuous and regular production executed in a definite, uninterrupted manner.

Process automation : Includes objectives of control and also those of enterprise management. This requires an integrated approach to plant operations and enables a variety of applications such as production scheduling, inventory control, performance monitoring, statistical process control, maintenance management and environmental audit.

Process control : Automatic monitoring and control of a process by an instrument or computer programmed to respond appropriately to feedback from the process.

Process simulation : Use of a mathematical model by a computer program to envision process design scenarios with real-time visual and numerical feedback. Process optimization and the ability to forecast potential problems are the results.

Productivity : A measurement of output for a given amount of input(s). In this document, labour productivity (value added per employee) is used as the measure of productivity. Increases in productivity are considered critical to raising living standards.

Program : (1) A complete structured sequence of program statements directing a computer to implement an algorithm. (2) All software programming necessary to solve a problem.

Protocol : A standard set of procedures to allow data to be transferred among systems.

Quality circle : A small group of people who normally work as a unit and meet frequently for the purpose of uncovering and solving problems with the quality of the items produced, process capability, or process control.

Rapid prototyping : A series of approaches to obtaining an initial or prototype of a part or assembly quickly. See, for example, stereolithograpy

Real time : Refers to tasks or functions executed so rapidly that the feedback is used to guide task completion. The performance of computations concerning a physical process such that their results are used in controlling the process.

Re-engineering : The redefinition of a company's internal processes.

Robotics : The study of the design and use of robots, particularly for their use in manufacturing and related processes.

Roll-forming : The process of bending a continuous strip of metal through a series of shaped rolls. The process gradually forms metal into a pre-determined shape. The nature of forming metal by this process allows for very tight tolerances to be met and maintained.

Rule-based system : A functional system in which knowledge is stored in the form of simple if-then or condition-action rules.

SCADA : Supervisory Control and Data Acquisition is typically accomplished in industrial settings by means of microcomputers.

Sensor : A transducer whose input is a physical phenomenon and whose output is a quantitative measure of the phenomenon.

Sequence control : The control of a series of machine movements, with the completion of one movement initiating the next. The extent of movements is typically not specified by numerical input data.

Servomechanism : An automatic device for controlling large amounts of power by means of small amounts of power.

Servomotor : A power-driven mechanism that supplements a primary control operated by a comparatively feeble force (as in a servomechanism).

Simulation : (1) A device, system, or computer program that represents certain features of the behaviour of a physical or abstract system. Vendors of planning and scheduling, forecasting and demand management, and other types of decision-support systems make growing use of simulation to compare the consequences of alternative courses of action. See Discrete-event simulation. (2) A CAD/CAM program that simulates the effect of structural, thermal, or kinematic conditions on a part under design. (3) Within MRP II, utilizing a mathematical model to test various design configurations.

SMART : Self Monitoring Analysis and Reporting Technology is a drive technology that reports its own degradation enabling the operating system to warn the user of potential failure.

Software : The entire set of programs, procedures, and related documentation associated with a computer.

Solid modelling : Three-dimensional modelling in which solid characteristics of an object are built into the database so that complex internal structures can be realistically represented.

SPC : Statistical Process Control is a quality-control method focusing on continuous monitoring of the process rather than the inspection of finished products, with the intent to achieve control of the process and eliminate defective product.

SQC : Statistical Quality Control applies the laws of probability and statistical techniques to the observed characteristics of a product or process.

Standardization : To promote conformity by means of a standard. Establishing criteria for uniform practices.

Stereolithography : A form of rapid prototyping involving the building of solid plastic objects from a CAD file by projecting a laser-generated beam of ultraviolet radiation onto the surface of a vat of photosensitive resin.

Supervisory control : The use of microcomputers and workstations to accomplish operator interface, data acquisition, process monitoring, and some degree of production control.

Supply-chain management : The use of information technology to endow automated intelligence to an ever-growing network of cash registers, delivery vehicles, distribution centres, factories, and raw material suppliers.

Supply-chain optimization : Software that allows management to look at the relationships among the various elements of the supply-chain (manufacturing plants, distribution centres, points of sale, as well as raw materials, relationships among product families, and other factors) to synchronize supply chains at a strategic level.

Systems integration : The ability of computers, instrumentation, and equipment to share data or applications with other components in the same or other functional areas.

Throughput : (1) The rate at which work proceeds through a manufacturing process. (2) The rate at which information is processed through a computer.

Time-based competition : There is a belief that the first producer and vendor of a product has a significant market advantage. Thus companies may be organized to minimize the time it takes to develop a product to exploit this advantage.

Total quality management : A holistic approach to quality control that stresses the building of manufacturing processes that force their users to confront quality problems, rather than passing them on.

Transducer : A device that converts signals from one physical form to another.

Transportation planning : Optimizes assignments from plants to distribution centres, and from distribution centres to stores. The systems combine moves to ensure the most economical means are employed on a scale that no human planner could match.

Vision systems : See machine vision

Warehouse management systems : Software that integrates mechanical and human performed activities with an information system to effectively manage warehouse business processes and direct warehouse activities.