DD 203-1:1991

This standard DD 203-1:1991 Industrial automation: shop floor production. is classified in these ICS categories:

• 25.040.01 Industrial automation systems in general

1.1 Scope

This report presents and describes a means of identifying where new or revised manufacturing standards may be required. It establishes a Reference Model for Shop Floor Production, which is then used as the basis for developing a methodology for the identification and extraction of areas for standards. The assumptions used to develop the Reference Model are:

• the field of interest is the manufacture of discrete parts and in particular the production (physical realisation) of these parts,
• the Reference Model needs to be open-ended so that it can be revised to incorporate new technologies, and
• the Reference Model needs to be generic in nature so that it can be applied to a wide range of applications and is not directed to a particular organisational structure of manufacturing.

It is emphasised that the Reference Model:

• provides a conceptual framework for understanding manufacturing and
• can be used to identify areas of standards necessary to integrate manufacturing systems.

The Reference Model does not however provide a methodology for designing, implementing, operating and maintaining any existing or future manufacturing automation system. There may be a need to develop other Reference Models which can be used for those purposes, perhaps based on the work described in this report. The development of such models is beyond the scope of this technical report.

1.2 Field of Application

The Reference Model described in this report is intended for use in the identification of standards within the Shop Floor Production area of manufacturing.

Manufacturing is perceived to be all inclusive, from customer order through to delivery of the product. Twelve manufacturing functions have been identified as being a part of manufacturing. The following is a list of these twelve functions, together with illustrative, non-exhaustive activities typically related to these functions:

1. Corporate management, e.g.
   • Direction of enterprise
   • Strategic planning
   • Feasibility study for investment
   • Risk management
2. Finance, e.g.
   • Financial planning
   • Corporate budgeting
   • Financial accounting
3. Marketing and sales, e.g.
   • Marketing research
   • Advertising
   • Sales forecasting
   • Sales scheduling
   • Pricing
   • Sales (order, delivery, invoice)
   • Product service
4. Research and Development, e.g.
   • R & D planning
   • Basic research
   • Applied research
   • Product development
   • Manufacturing development
5. Product design and Production engineering, e.g.
   • Define product specifications
   • Preliminary design and testing
   • Detailed design
   • Design analysis, test, evaluation
   • Revise design
   • Release design for production planning
   • Project management
   • Process planning
   • Programming of numerical control and programmable control
   • Tooling
   • Plant engineering
   • Bill of material
   • Quality assurance planning of production
   • Production configuration
6. Production management, e.g.
   • Production scheduling
   • Product and Inventory control
   • Production monitoring
   • General maintenance request
   • Quality control
   • Cost control and cost management
7. Procurement, e.g.
   • Vendor performance
   • Purchasing
   • Receiving
   • General stores
8. Shipping, e.g.
   • Product storage
   • Distribution
9. Waste material treatment, e.g.
   • Waste material processing
   • Waste material storage
10. Resource management, e.g.
    • Facility management
    • Tool control
    • Energy management
    • Time and Attendance
    • Facility security
    • Health and Safety
    • Environment control
11. Maintenance management, e.g.
    • Preventive maintenance
    • Corrective maintenance
12. Shop Floor Production, e.g.
    • Material store
    • Transport material
    • Transform material
    • Incoming inspection
    • In-process gauging and testing
    • In-process audit
    • Product audit

As shown in Figure 1 and described in the definitions which follow in Section 2.2, these functions tend to be grouped under three main headings. Items 1) through to 4) are functions of the Enterprise concerned with strategic long term planning activities. Items 5) through to 11) are functions of the Facility, concerned with tactical planning of the production process, resource management and product modelling. The final item, 12) Shop Floor Production, is a function which involves the activities that actually create a physical product.

The twelve manufacturing functions are interrelated and a single Reference Model covering all twelve functions would be desirable. After careful study of existing work, it was decided that the development of a single Reference Model covering every function of manufacturing was not manageable at this time.

The area of Shop Floor Production on the other hand has shown an urgent need for and a willingness to adopt standards. The Reference Model described in this technical report is intended to guide the planning for and the development of standards to assist the integration of an automated Shop Floor Production system. It is recognised that the Shop Floor Production function will be required to interface with functions (and their activities) outside the scope of Shop Floor Production itself. Figure 2 is a clarification of how major functions of manufacturing might be interrelated.

In the future, Reference Models for manufacturing that include Enterprise and Facility functions may be developed. Any future modelling work in the area of manufacturing should take account of the Reference Model for Shop Floor Production presented here and every effort should be made to ensure compatibility between the Reference Model for Shop Floor Production and any Facility or Enterprise Reference Models that may be developed.

A means of identifying by a reference model where new or revised standards may be required. Restricted to discrete parts manufacturing but provides flexibility to incorporate new technologies and to apply to a wide range of applications.