Information Technology (IT)

Especially in manufacturing today, Computer Numerical Control (CNC) machines, Computer Aided Design (CAD), Computer Aided Manufacturing (CAM) systems are among the most important applications of the information technology in manufacturing, which, in this research, will be called summarily as Computer Aided Technology or CAT for short.

Chapter 1 Introduction 1.1 Background

We are now in the information era Information Technology (IT) has been extensivelyused in almost all areas of the human life Especially in manufacturing today, ComputerNumerical Control (CNC) machines, Computer Aided Design (CAD), Computer AidedManufacturing (CAM) systems are among the most important applications of the informationtechnology in manufacturing, which, in this research, will be called summarily as ComputerAided Technology or CAT for short

CNC machines, CAD, CAM, have been applied widely not only in the developedcountries, such as the United States, Japan, Germany, but also in developing countries likeThailand, India, China, Taiwan and South Korea For example, in South Korea, from 1986 to

1990, the total value of CNC machines, CAD, CAM used in manufacturing increased from

289 to 420 US$ millions Such applications grow at the rate of 50% annually in South Korea(Jang Seung Hwan, 1988)

The US embargo, which did not allow the transfer of IT into Vietnam, was lifted in early

1994 Consequently, Vietnam is very out of date in terms of IT application Observation showsthat up to 1990, there were only 10,000 personal computers in Vietnam (Adam Schwarz,1995)

However, in recent years, with the "Open door" policy, IT has been graduallyintroduced in Vietnam At the beginning of 1995 the number of computers in Vietnam reachedabout 50,000, and is growing at the rate of about 40% annually (Adam Schwarz, 1995) Itsapplications, however, are restricted mostly to office management In enterprises, IT is used instoring data, accounting, and administrative work IT is rarely applied in manufacturing

Machine tool is one of the biggest industries in the manufacturing sector in Vietnam.However, the machines and equipment are old and obsolete, which have been in operationfor twenty or thirty years CNC machines, CAD, CAM are almost never used except someresearch centers such as the Research Institute of Machinery, the Design Institute ofChemical Industry, and the Hanoi University of Technology

Low technology used in the machine tool industry is seen as one of major reasons forlow quality of products Combined with low management skills, this leads to losing customers,and poor or even disastrous financial performance of many state-owned enterprises in recentyears In the emerging market economy of Vietnam, in order to compete effectively withforeign enterprises with high technology, and with the imported machine tools, theapplications of CNC machine, CAD, and CAM systems become an immediate survival needfor the domestic machine tool companies The increasingly critical demands of customers interms of designing, functioning, working life, productivity, ease in use and precision, alsorequire CNC machine, CAD, CAM systems to be introduced

1.2 Statement of Problem and Significance of the Study

As IT and CAT are very new for the country Managers of machine tool companies inVietnam do not know how CNC machines, CAD, and CAM can benefit them, what conditionsare required to introduce these technologies in their companies As a consequence, they donot know how to develop a plan to introduce CNC machine, CAD, CAM effectively, especiallywhen the production and market conditions are changing almost daily in the country

At the same time, many foreign investors are ready to transfer technological knowhow to the manufacturing sector in Vietnam, but they do not understand the major difficultiesVietnamese enterprises are facing

Introducing all these technologies at the same time would be extremly difficult, if not

at all impossible, for any Vietnamese machine tool firm Therefore, a major question is whatpriority order among CNC machine, CAD, CAM should is most appropriate to go ahead for aVietnam enterprise in machine tool firm, is still in question

1.3 Objectives

The study aims at helping managers in machine tool enterprises in Vietnam gaininsight into how these technologies can be introduced in their companies It may also providesuppliers of CNC machine, CAD, CAM some preliminary ideas about how a Vietnameseenterprise can apply them Furthermore, it is expected to provide some suggestions to assistthe formulation of appropriate policies to encourage the overall objective of the government

of Vietnam to "catch " in the more advanced technology

To achieve these goals, this research steps out the following specific objectives:

1 To develop a model for analyzing major factors in introducing of CAT inmanufacturing industry in Vietnam

2 To apply the model in one company in machine tool firm in Vietnam to analyzeconditions for introducing CAT

3 To suggest recommendations regarding CAT introduction to the company based onthe analysis

1.4 Scope and Limitations

CAT has many applications in manufacturing, the study focuses only on CNCmachines, CAD, CAM which means that issues like manufacturing resource planning (MRP II)system, or flexible manufacturing system (FMS) will not fall into the scope of the study, alsothe research is limited to the machine tool firms in Vietnam

The analysis is carried out based on qualitative information gathered throughsecondary information sources and direct interview of relevant managers in the company

under study There is not sufficient information about applications of CNC machine, CAD, andCAM of foreign companies to make comparison, so it lacks comparative analysis

1.5 Organization of the Report

The research is carried out in 5 steps

1 Literature Review

A review of the literature aims at an overall understanding of information technology,CAT and its applications in manufacturing The experiences in CAT applications of Asiancountries are useful for comparison with Vietnam

2 Developing a Model

In order to assess the conditions of company for introduction of CNC machine, CAD,and CAM, a conceptual framework is developed based on the review of literature andpersonal knowledge The framework is presented in the Figure 1.1

3 Data Collection

The data are collected through in-depth interviews with the managers and staff ofvarious functional departments of the firm under study, information technology development.Secondary data are the company's internal report articles in public media, and governmentdocuments on policy and regulations

4 Analyzing and Presenting

This step carries out the analysis of plant conditions in term of CNC machine, CAD,CAM applications based on the framework developed in step 3 The analysis is presented inthe form of comparison between actual conditions and related requirements to show the gaps

in introduction of CNC machine, CAD, and CAM

5 Making Recommendations

Recommendations for introduction of CNC machines, CAD, CAM to the managers ofthe plant under study are based on the analysis and conclusions presented in the previouschapters, opinions of manager of computer center of design institute of chemical industry,and manager of CAD department of research institute of machinery, regulations ofgovernment of information technology development to year 2000

COMPUTER AIDED TECHNOLOGY

APPLICATION

1-Knowledge Infrastructure 2- Internal Assets

3-Management 4-Target Products

ACTUAL REQUIRED

Constraints Advantages

Training Research

Framework for analyzing of factors for CAT application Figure 1-1

Chapter 2 Literature Review

2.1 Definition of Information Technology (IT)

There are now many definitions about information technology of authors in differentfields Each area of application has its own definition Here are some of them

-Mc Farlan (1984) stated that IT is "computer remote devices, telecommunications"-Bakkopoulus (1985): IT is a "set of non-human resources as dedicated to thestorage, processing and communication of information, and way in which these resources areorganized into the system capable of performing a set of tasks"

-Poster and Millar (1985): It must be conceived of broadly to encompass theinformation that business create and use as well as a wide spectrum of increasinglyconvergent and linked technologies that process the information"

-Gerstin (1987) referred IT to "the collective means to assemble and electronicallystores, transmit, process, and retrieve word, numbers, images and sound, as well as toelectronic means to control machines of all kinds, from every day applicant to vast automatedfactories"

The single definition of IT widely accepted and used is the "use of computers andcomputer related technology", (Guimaraes, et all, 1988) This definition is most suitable formanufacturing and will be adopted in this research

2.2 IT in manufacturing: Computer Aided Technology (CAT)

Computer aided technology (CAT) implies applications of information technology inmanufacturing At the CAT ' 91 conference in Bangkok, Pier Mercier, consultant of D.Appleton Company Europe, defined that CAT is a new set of technical tactic alternatives thatmay be used to achieve strategic objectives CAT is seen as tactics, not strategy CAT issingle tool that can improve productivity, product quality and reliability and cost reduction.Mikell Groover (1987) viewed CAT as directing the technology of manufacturing toward onegoal-the fully automated factory of the future

The major reasons for applying in CAT in engineering are product- related for discreteindustries, and process- related for process industries In the discrete industries the aim ofusing CAT is to reduce the time and cost of designing products and to increase productquality In the process industries the focus is the design of the process, and the integration ofthe production equipment The major areas in which technology can be applied in designingprocess are design synthesis, design analysis, documentation, simulation, preparation, and

planning of the manufacturing process The selection of the area in which technology will beapplied depends on the company and the industry sectors.( John Stark, 1992).

In engineering, after 30 years of applying computer It could be thought that greatproductivity gains would have been achieved in this area, and that there would not be muchmore progress to be made Yet the situation is completely the opposite Very few companieshave made significant productivity gains through the use of computers in productdevelopment, and there is still a lot more progress to be made Some companies havebenefited greatly from the use of computers in product development

In 1970s uses of computer in product development mainly were Computer AidedDesign, Numerical Control Programming, Finite Element Analysis, Computer Aided ProcessPlanning, Simulation, Computer Aided Technical Publications, Robot programming In 1990s,computers are mostly used in product development, engineering data management, productmodeling, engineering data exchange, information models, integration, engineering systemprocedures, training (John Stark, 1992)

Operations in the manufacturing are at the heart of any enterprise They are affectedstrongly by production management activities CAT applications in the production can makereal difference in the day to day operations and in the role of the people Finally the quality ofworking life can be significantly improved Jobs are enriched and no longer dominated by oldand inflexible technology Flexible automation can be introduced in production, particularly forreplacing manual labor in repetitive operations such as welding, assembly, and painting.Technological integrated factories can take advantages of flexible manufacturing systemsthat are able to handle a large variety of products economically

Advanced methods, supported by CAT, are becoming increasingly common in thefactories Its applications are all being used the fabrication of parts Mechanical assemblyequipment, usually reserved for very high-volume products with simple assembly process ismost frequently are now almost always present in large, modern factories Handingtechnology include robots, pick-and-place devices for assembly, machine loading, andpalletizing

The application of CAT can: 1.Create a streamlined process in engineering anddesign, fabrication, and assembly of products 2.Improve use of scare human resources, theproduct quality increase, and job's satisfaction employees are satisfied with the jobs.3.Improve cost structure (Pierr Merceir, 1991)

2.3 Components of CAT: CNC machine, CAD, CAM

According to Pierr Merceir (1991), the components of CAT include computer aideddesign (CAD), computer numerical control machine (CNC), flexible manufacturing system(FMS), robotics, and computer aided manufacturing (CAM) According to Mikell Groover(1987) CAM consist of Computer aided process planning (CAPP), Material RequirementsPlanning (MRP), Direct numerical control (DNC); Manufacturing Resource Planning (MRPII);Shop Floor Data Collection, Computer aided inspection (CAI), Computerized quality control(CAQ)

Given time limitation of this study, and the current manufacturing environment andpolicy in Vietnam, this research will concentrate only on 3 major components: CNC machine,CAD, and CAM which will be described in details below.

2.3.1 Computer Numerical Control Machine (CNC machine)

CNC was a significant achievement of development of numerical control (NC)technology in batch and job shop manufacturing It was introduced in the mid to late 1960sand was commercially offered during early 1970s

Computer numerical control machine is a numerical system using a dedicatedmicrocomputer as the machine control unit CNC systems utilize microcomputer to storemachining programs in read-only memories (ROM)

Microcomputer( software function )

hardwareInterfaceand servosystem

Computer-====>

<==== Machine tools

Figure 2.1 General configuration of a computer numerical control (CNC) system

(Source: Mikell Groover, 1987)

Figure 2.1 above shows the process of operating CNC machine the machiningprogrammed- which are in the form of tape- are transferred into "Tap-reader" In this stage allprogram are read Then they are stored in the " NC program storage" Microcomputer, which

is a functioning software, control the stored programs The relevant commands aretransferred to the "machine tools" to process, through the " inter face and servo system" Asconventional machines, CNC machine is mainly used to lathe, to bore, and grind, etc Theonly difference between CNC machine and conventional machine is that in CNC machineevery operation is controlled by computer, rather than worker in conventional machines

Their advantages include their adaptability to different types of machine tools, ease ofprogramming, and information retrieval, and the ability of one computer to simultaneouslycontrol one or more machine tools (UNIDO/ESCAP by technonet Asia Singapore, Nov 1986)

The advantages of computer numerical control over conventional NC are:

1.The part program tape and tape reader are used only once to enter the programinto memory The results in improved reliability, since the tape reader is commonlyconsidered the last reliable component of the conventional NC system; 2.Tape editing atmachine site The NC tape can be optimized during tape tryout at the site of the machinetool; 3 Greater flexibility The most significant advantage over conventional NC is CNC'sflexibility New options can be added to the system easily and at relatively low cost; 4 Metricconversion CNC can accommodate conversion of tapes prepared in units of inches into the

international system; 5 Total manufacturing system CNC is more compatible with the use of

a total manufacturing system ( Mikell Groover, 1987)

2.3.2 Computer Aided Design (CAD)

CAD was introduced in 1960s At the begin of 1970s it is applied strongly indeveloped countries Now it is used widely in different countries in the world, and becomes avery useful tool to gain competitive advantages

Mikell Groover (1987) defined CAD as any design activity that involves the effectiveuse of the computer to create, modifies, or document an engineering design CAD is mostcommonly associated with the use of an interactive computer graphics system

A computer aided design system can beneficially be used in four phases of the designprocess

1 Synthesis (geometric modeling).

The geometric modeling is concerned with the use of a CAD system to develop amathematical description of the geometry of an object The mathematical description permitsthe user of the CAD system to display an image of the model on a graphics terminal and toperform certain operations on the middle These operations include creating new geometricmodels from basic building blocks available in the system, moving the images around on thescreen, zooming in on certain features of the image These capabilities permit the designer toconstruct a model of a new product or to modify an existing model

There are various types of geometric models used in computer aided design Oneclassification distinguishes between two-dimensional models Two-dimensional models arebest utilized for design problems in two dimensions, such as flat objects and layout ofbuildings Three-dimensional CAD systems are capable of modeling an object in threedimensions The operation and transformations on the model are done by the systemaccording to the user instructions in three dimensions

Geometric models in CAD can also be classified as being either wire-frame models orsolid models A wire-frame model uses interconnecting lines to depict an object Wire-framemodel of complicated geometry can become somewhat confusing because all of the linesdipping the shape of the object are usually shown, even the lines representing the other side

of the object Solid models are a more resent development in geometric modeling Moreimportant for engineering purposes, the geometric model is stored in the CAD system as athree-dimensional solid model, thus providing a more accurate representation of the object

2 Analysis and Optimization (engineering analysis)

Some forms of engineering analysis must often be performed as part of the designprocess The analysis may take the form of stress-strain calculations, heat transfer analysis,

or dynamic simulation Two examples of the software typically offered on CAD system aremass properties and finite -element analysis Mass properties analysis involves thecomputation of such features of a solid object as volume, surface, area, weight, and center of

gravity The finite-element analysis is available on most CAD system to aid in heat transfer,stress-strain and other engineering computations.

3 Evaluation (design review and evaluation).

Some of the CAD features that are helpful in evaluating and reviewing a proposeddesign include

* Automatic dimensioning routines, which determine precise distance measuresbetween surfaces on the geometric model identified by the user

*Interference checking routines, which identify whether two objects occupy the sameplace

*Kinematics Routines, used to test the operation of mechanical linkages

4 Presentation (automated drafting)

CAD system can be used as automated drafting machines to prepare highly accurateengineering drawing quickly It is estimated that CAD system increases productivity in thedrafting function by about fivefold over manual preparation of the drawings (Mikell Groover,1987)

A Typical CAD System

A typical commercially available computer aided design system consists of components :

*One or more design workstations

*Processor

*Secondary storage

*Plotter and or other output devices

Figure 2.2 Configuration of a typical CAD system

Source: Emory, Zimmer, Mikell Groover, Englewood,NJ, 1984

The design workstation is the interface between CAD system and the user For theuser to accomplish the various phases of the design process, the workstation must be able toreceive input instructions from the user and to display output data and graphics to the user.Operator input devices are used for the input functions The input devices for a CAD systemtypically include an alphanumeric keyboard, electronic keypad or other device to input specialgraphic functions and a cursor control device ( e.g., a light pen, " mouse" ,joystick, or electrictablet and " puck") The graphical design out put is accomplished by means of a graphicsdisplay monitor The processor is the CAD system computer Connected to the processor is

a secondary storage for application program and design data Also connected to theprocessor are more or one output devises such as X-Y plotters, electrostatic plotters andsimilar equipment used for automated drafting function (Mikell Groover, 1987)

The important reasons for using a computer-aided design system to support theengineering design function:

1 To increase the productivity of the designer This is accomplished by helping thedesigner to conceptualize the product and its components In turn this helps to reduce thetime required by the designer to synthesize, analyze, and document the design

2 To improve the quality of the design The uses of a CAD system with appropriatehardware and software capabilities permit the designer to do a more complete engineeringanalysis and to consider a large number and variety of design alternatives The quality of theresulting design is thereby improved

3 To improve design documentation The graphical output of a CAD system result inbetter documentation of the design than what is practical with manual drafting Theengineering drawings are superior, and there is more standardization among the drawings,fewer drafting errors, and greater legibility.

4 To create manufacturing data base In the process of creating the documentation forthe product design (geometric specification of the product, dimensions of the components,material specification, bill of material, etc.), Much of the required data base to manufacturethe product is also created (Mikell Groover, 1987)

2.3.3 Computer Aided Manufacturing (CAM)

Mikell Groover (1987) defined CAM as the effective use of computer technology in theplanning management and control of the manufacturing function In his view the applications

of CAM consist of two broad

a-In Manufacturing Planning

CAM applications for manufacturing planning are those in which the computer is usedindirectly to support the production function, but there is no direct connection between thecomputer and the process The computer is used "off-line" to provide information for theeffective planning and management of production activities The important applications ofCAM are:

-Cost estimating

-Computer-aided process planning (CAPP)

-Computerized machine ability data systems

-Computer-assisted NC part programming

-Development of work standards

-Computer-aided line balancing

-Production and inventory planning

-Material requirements planning (MRP)

Material requirements planning (MRP) are a computational technique that convertsthe master schedule for end products into a detailed schedule for the raw materials andcomponents used in the end products Material requirement planning has two majorsobjectives: determine requirements and keep the priorities current The main object of anymanufacturing planning and control system is to have the right materials in the rightquantities available at the right time to meet the demand for the firm's products The MRP'sobjective is to determine what components are needed in order to meet the masterproduction schedule and, on the basis of lead time, to calculate the time periods when the

components must be available It must then determine what to order, how much to order,when to order, when to schedule delivery.(J.R.Tony Arhold, 1992)

The inputs to MRP system are master production schedule, Inventory records, bill ofmaterial The master production schedule is a statement of which end items are to beproduced, the quantity of each, and the dates they are to be completed Inventory is a majorinput to the MRP system When a calculation is made to find out how many are needed, thequantities on hand must be taken into account The bills of material are one of the mostimportant documents in a manufacturing company

Computer-aided process planning (CAPP) represents the link between design andmanufacturing in a CAD/CAM system It concerned with determining of processing andassembly steps that must be accomplished to make the product The processing sequence isdocumented on a form called a route sheet The route sheet typically list the productionoperations, machine cells, or workstations where each operation is performed, fixtures andtooling required, and the standard time for each task

There are two types of CAPP (1) Retrieval CAPP systems; (2) Generative CAPPsystems The Retrieval-type CAPP systems are based on the principles of group technologyand part classification and coding With these systems, a standard process plan (route sheet)

is stored in the computer files for each part code number The standard route sheets arebased on an ideal plan that is prepared for each family The generic CAPP systemsrepresent an alternative approach to automated process planning Instead of retrieving andediting an existing plan contained in a computer data base, a generic system creates theprocess plan based on logical procedures similar to the procedure a human planner woulduse In a full generative CAPP system, the process sequence would be planned without a set

of predefined standard plans.(Mikell Groover, 1987)

The benefits of CAPP are (1) Process rationalization and standardization, (2)increased productivity of process planners, (3)Reduced lead time for process planning, (4)Improved legibility, (5) Incorporation of other application programs

b-In Manufacturing Control

Manufacturing control is concerned with managing and controlling the physicaloperation in the factory Process control, quality control, shop floor control, and processmonitoring are included within the scope of this function

Shop floor control refers to production management techniques for collecting datafrom factory operations and using the data to help control production and inventory in thefactory

All of these concepts sever as basic understanding for the study, because we findthem official, and suitable to the objectives of the study and Vietnamese situation than theother ones

2.4 The CAT Applications in Thailand and South Korea

In Thailand

Thailand, a neighbor country that has the similar geography, population and nationalcharacteristics to Vietnam Thailand has a high economic growth Now, Thailand is moreadvanced than Vietnam in applying high technology in manufacturing The learningexperiences of Thailand is beneficial for Vietnam

In Thailand now, no one uses NC machine tools ( no computer involved) morebecause of its inconvenient Instead of NC, DNC is used widely DNC is the system of manyCNC machines directly controlled by one computer DNC has advantages cutting up the step

of making punched steps There are more than 50 factories having some kind of DNCs intheir factories There is circumstance that factories have the machines but occasional usethem There is no experiences operators who can fluently make control programs andoperate these machines (UNIDO/ ESCAP, Thailand report, 1987)

Computer aided design system (CAD ) have not been widely used in small and

medium scaled companies Only large organizations for example Thai Oil, Siam CementGroup, Thai International Airline, Petroleum Authority of Thailand have CAD system.Educational institutes namely Asian Institute of Technology and Chulalongkorn University,College of engineering have CAD system for research.( UNIDO/ ESCAP Thailand report,1987)

Some factories have small CAD systems such as Auto CAD in use for drafting.AutoCAD create many conveniences but it can not efficiently perform calculations for furtherdesign Auto CAD must be linked with other specific software in order to do calculations

CAM system used to centrally control DNC machines CAM is also used to control aindependent CNC machine The fully integrated CAM system, which do scheduling, planningand control of operations, are not in use in Thailand

Most CAM users are not quite successful in having introduced CAM system, they arenot able to utilize CAM full capacity Although, they can generate volume, have precision,reduce setup time, they can not achieve full utilization of CAM

There are many CAD/CAM systems in the use in both private and publicorganizations CAD/CAM system is system in which CAD and CAM are integrated in theuniform manufacturing system There are three available for public access Asian Institute ofTechnology (AIT) has a IBM computer aided design system with comprehensive collections

of software The AIT's system is mainly used for academic research Chulalongkorn, College

of Engineering are the other public organizations having complete CAD system TheMetalworking and Machinery Industries Development Institute (MIDI) has 4 computer aidedmanufacturing machines as follows 1.Makino Wirecut machine, 2 Makino Electro dischargemachine (EDM), 3.Mazak Computer Numerical control Lathe with FUNAC control, 4.Toshiba

Computer control machine center with TOSNAC control MIDI personnel are learning how tooperate machines Machines will be use for manufacturing prototype, and for demonstration.(UNIDO/ESCAP Thailand report, 1987).

Obstacles of introduction of CAD/CAM are lack of personnel who fluently understandCAM There is no further development of personnel in intermediate and advance levels Allsuch pitfalls of applying CNC machines, CAD, and CAM systems may be good lessons forVietnam in introduction of such applications

CAT in South Korea

In 70s, the economic growth in South Korea was seen as a phenomenon So Korea isevaluated as one of the four Asian dragons in term of economic growths South Koreabelongs to the new industrial countries Therefore the reviewing the introduction of CAT inSouth Korea would be useful for Vietnam

South Korea machine tool industry was in an embryonic stage before the early 1970sreflecting the generally underdeveloped stage of the machinery, material and part industries.After the mid-1970s the industry expanded rapidly, aided by the government' machineryindustry In 1978, the government began to actively assist general machinery, specialproducts, materials and part-producing companies During the fifth Five-year Economic Plan,government designated the machine tool industry as a main exporting sector and it simplifiedthe export procedures In additional machine tool fairs both at home and abroad have beenhelp to exchange advanced technology and to increase importer 's confidence in SouthKorean machinery

The first CAD/CAM system was introduced to South Korea in mid 1970s, number ofcompanies utilized CAD/CAM system Seventy three (73)companies have used largesystems, and 79 companies have utilized small-sized (under 16 bits) systems However, most

of the hardware and software systems are imported The CAD/CAM introduction increasedrate of over 50% annum Due to the high demand of small and medium sized companies forCAD/CAM systems, the supply of small CAD/CAM system in domestic market is expected toincrease greatly (Jang, Seung Hwan, 1988)

Large domestic entrepreneurs have actively been introducing a computer aideddesign (CAD) and computer aided manufacturing (CAM) in their production to saveproduction costs CAD and CAM have been utilized in shipbuilding, automobiles, the electricand electronic field to enhance the productivity Samsung has saved manpower and designcosts by 60% Hundai Motor Co., which introduced the system with a total investment of 7billion won since 1982, has applied the computer system in the design of autos and themanufacture of mold presses.(Jang, Seung Hwan, 1988)

Chapter III Development of a model for analysing major factors in

introduction of CAT

This chapter aims at designing an analytical model,which will help us, on the onehand, to understand what are the principal requirements to introduce CNC machine, CAD,and CAM systems into a machine tool company, and on the other hand, to assess the actualcapability of the company to introduce these technologies

3.1 Background for the Analytical Framework

There are different approaches in developing a model to show the requirements inintroduction of Computer Aided Technology (CAT) at a firm level

Chalmet (1987) developed a model for the introduction of a new production

technology in the factory, which consists of five steps as follows:

1- Orientation: Analyzing strengths and weakness of organization and technical-economical

opportunities of factories

2- Pre-design: Implementing the feasibility studies

3- Design: Specification for tasks of the technical sub-systems

4- Test: Realization of technical sub-systems

5- Implementation: Adjustments of the technical sub-systems.

The model of Chalmet mostly concerns the procedures for implementation ofintroduction of a new technology This model is not so relevant to the objectives of this study

In the CAT "91 conference in Bangkok", Pierr Meceir presented a framework in whichall factors impacting the introduction of a new technology are divided into five main groups.They are:

3.2 Knowledge Infrastructure

The knowledge required for each technology - CNC machines, CAD, and CAMsystems are different due to their distinctive functions The knowledge infrastructure is one ofthe most important factors for the application of new technologies.

3.2.1 Knowledge Required For CNC machines

As mentioned in the previous chapter, CNC machines are used to manufacture a part

or machine Machine operators, programmers, and process planners are people directlyinvolved in the process of operating CNC machines

In CNC machine, the process planner does not directly run the production process.

He would decide which machine is to be used to satisfy the technical requirements of a part.The decisions are made based on the capacity of different machines

To do so the process planner should have general knowledge on the operation andthe ability of different CNC machine tools He has to understand how the parts are to beproduced The process planner usually is a mechanical engineer who has experiences inworking with CNC machines (E.Bohez, 1994)

The task of a programmer is writing part-machining programs for CNC machines to

manufacture Based on drawings, and with the help of the part-coordinate-system, theprogrammer has to establish a process plan How a part is to be made, what tools andsequence of operations are to be followed, and at what feed rate and speeds a machine is tooperate, are all included in the process plan The programmer then writes down theinstructions in the G-code language to build the part program To be able to make the partprogram, the programmer obviously has to master the G-code language and perfect inmachining technology The mechanical engineers may be good candidates for programmers(E.Bohez, 1994) In reality, one person can do the jobs of both the programmer and theprocess planner The division between them is very relative

CNC machine operators are people who directly control the working process of

machines The machine operators will stand by the machines When the production is going

on, the instructions are normally displayed on the graphic screen of CNC control Themachine operator should be able to read them so that he can monitor the machining processand suggest modification to the program which he can be permitted to do himself or with thepermission of the supervisor Another important function of the CNC operator is to monitorthe quality of parts, such as surface and tolerances If the part is out of tolerance, theoperator will have to adjust the tool offset value or change the tool inserted (E Bohez, 1994)

INTERNAL ASSETS

Knowledge Infrastructure

CAM

Mach Operating

TARGET PRODUCTS

EXTERNAL FACTORS

MANAGEMENT

CAD

CNC Machine

The CNC machine operators have to monitor the CNC machines during production.They should understand G-code language, and operations of CNC machines That isbecause the instructions, commands, and descriptions on screen are written in G-codelanguage Knowledge regarding standards, tolerance, and tools is also required for CNCoperators.

3.2.2 The Required Knowledge of CAD Users

CAD, as we already knew, is a software used in designing, drafting, and simulations.Designers and drafters are the people directly involve in the process of using CAD system

The tasks of designers are to create parts, or machines They have to understand

how a part or machine is configured or shaped Therefore, they have to know engineeringdrawings, operating principles of different machines, and dimensions More specifically, therequired tolerance, precision, how parts can be assembled, uses of different materials, etc.have to be well understood by designers

In addition, the designers are required to understand how to draw different shapes onscreen of computer That means the CAD operators have to know how to create a point, line,

or curve using computer

The tasks of the drafters are more simple than that of the designers They have to

draw a part or machine that are initiated by designers They also can have to modify andmake the designs clearer in technical terms So the drafters have to know about theengineering drawing

3.2.3 Knowledge Required for CAM Users

CAM system is software assisting the programming and controlling jobs WithoutCAM, a programmer in CNC machine has to program a machining process manually beforerecording it into the machine So CAM is a further computer application that helps people toprogram by computer and then automatically projects the process plan Then the machiningcommands are transferred directly into CNC machines using digital signals Similarly, CAMsystem can be used to program the process of quality control, or for Direct Numerical Control(DNC), etc Therefore, the CAM operator should have knowledge of both the programmerand process planner of CNC machines as mentioned above That is because the CAMoperator has to understand how and when each stage of manufacturing is done or performedand then uses CAM system to control this process

In addition, the CAM operator also has to understand the related areas where CAMsystem is used to program for For example, if a CAM system is used to control the quality ofproducts, the CAM operator has to know about the quality control That is why in reality theCAM operators are different depending on which fields CAM systems are used for

3.2.4 Computer Knowledge and English Skills

Computer literacy is the first requirement for users of CNC machines, CAD, and CAMsystems However, the basic requirement on computer knowledge may be different from one

use to other depending on his or her works in such systems For example, a programmershould have the ability to program a process by computer is required A programmer has tomaster G-code language to write a program An operator may only need understanding of G-code at the level allowing him to communicate effectively with the machine CAD and CAMusers need computer skills at high levels of specialization In the other words, they have towell run the specialized software used in CAD and CAM systems.

As in all IT applications, English is the major language used to all documentation,manuals and instructions of CAT IT is imperative Therefore, that future users of thetechnologies be provided with basic communication skills in English

3.2.5 Maintenance Related Knowledge Required

Maintenance aims at maintaining long working capability of a machine, and reducingmachine breakdown as much as possible For the advanced technologies, such as CNCmachine, CAD, and CAM systems, the maintenance is very important That is because suchhigh-tech related machines require very strict working conditions, such as workingtemperature, stability, cleaning, etc Otherwise, their precision level would be reduced Thatwould cause production bottlenecks due to persistent downtime

Most CNC machines offer good diagnostic routines which vary from simple erroralarms to logic analysis, program testing, and external testing of modules

In order to fulfill the maintenance tasks, the maintenance technicians have to posseknowledge and experience in a number of areas The following qualifications are essential.1- A knowledge of electronics both theory and practice

2- Practical experience with NC, CNC

3- A knowledge of digital technology

4- Experience in working with electronic measuring equipment

5- A desire to enhance knowledge through continuous training

6- Knowledge of basic micro computer fundamentals

3.2.6 Training

All of what mentioned above indicate a wide range of needs for training, when acompany decides to introduce the information technology in its manufacturing process

Suppliers of such technologies usually provide with the following training courses:

1- Traditional training program: Programs provided by certified, experienced

instructors from the vendors, and carried out at the supplier's training sites

2- Media services training: Training course through video- and audio-tape provided by

the suppliers

3- On-Site training: Under certain circumstances, a customer training instructor from

the vendor can travel to your site to conduct classroom-instructions for courses listed in thevendor catalog

4- Train-the-trainer: For users who have a large start-up training requirement on-site,

most vendors offer a "train-the-trainer" program Its purpose to train the customer personnel

to offer basic system instructions on site If a company has more than 20 people to train, thiskind of training may be a cost effective alternative for the company

Such training courses are usually be included in the purchasing contracts In the casethat training courses are excluded in the contracts the purchasers may get training from theinstitutes specializing in CNC machine, CAD, and CAM systems

3.3 Internal Assets

Decisions to apply CNC machines, CAD, or CAM systems heavily depend on internalassets of a company Internal assets here refer to capital, the existing machines, buildings,workshops, and the work-force in the company

3.3.1 Capital Consideration

Capital here refers to funds that a company can use for introduction of CNCmachines, CAD, and CAM systems These technologies always involve long terminvestments

The costs for introductions of CNC machine, CAD, CAM systems include hardware,software, maintenance, training, and site preparation costs The total investment would be abig amount of money

The capital barrier is found more often in small and medium size companies than inlarge enterprises Capital may particularly be a big hurdle for a Vietnamese enterprise toinvest in high technologies That is because finding capital source with reasonable costs inVietnam is very difficult

3.3.2 Existing Machines

The machines which are being used by a company also would affect the decisions tointroduce the new manufacturing technology That is because the existing machines wouldstand for the opportunity cost of introductions of such applications, and hence reducing theirprofitability If the company is using new machines profitably which have been littledepreciated, it would hesitate to liquidate them to install new technologies The real benefitsoffered by such new technologies are not as much as in the case the company is using old,most fully depreciated machinery

3.3.3 Buildings and Workshops

The working conditions required by CNC machines, CAD and CAM systems are verydifferent from that for conventional machines CNC machines, CAD and CAM systems should

be placed in air-conditioned and damp-proof rooms

Electricity supply should also be stable and continuous All these may be trivial in anydeveloped countries but at present, they are crucial and not-easy-to implement conditions inmost advanced manufacturing companies in Vietnam

3.3.4 Work-Force

Work-fore here refers to the number of workers who are working for a company Workforce may mean an other consideration when the company applies the new technologies Atmost of stated-own-enterprises in Vietnam, lay-off is almost impossible decision Given thefear the high productivity induced by the new technology will lead to mass lay off, especially

of unskilled employees, the labor union may put high pressure on management to create newbarriers to the introduction of the CAT

3.4 Target Products

Target products here refer to the product quality intended, volume, variability, andtarget market for products Target products indicated the needs, or motives of a company toapply new technologies Target markets ensure that the company has customers, and henceincrease feasibility of introducing CNC machines, CAD, and CAM systems

If management of companies pursuing high quality products aware of the benefitsoffered by CNC machines, CAD, and CAM systems, that would facilitate and accelerate theprocess of introductions of these technologies in the companies

Many companies aim at diversifying their products, broadening the product line tomeet customer demands, or to create new customer base To achieve this objective, acertain level of flexibility in manufacturing capability should be attained

CNC machines, CAD, and CAM systems are particularly needed for companies inwhich the products are variable and innovative

CNC machines, CAD, and CAM systems also can help companies with a strategy ofhigh volume and lower costs That is because they can considerably improve productivity ofthe companies High volume of product can save fixed costs for the companies in applyingnew technologies, such as cost of design, installation, etc

Different companies may have different target markets The characteristics andbuying behaviors of target customers would affect very much on the decisions to apply newtechnologies of a company Obviously, the different demands of target customers and thebenefits of specific technologies should be matched when a company applies CNCmachines, CAD, or CAM system

3.5 Management

The overall objectives and strategies of a company would be very important for

introductions of CNC machines, CAD, or CAM system because they serve as directions forevery activity in the company What are seen as good or bad in the view of top managementwould affect strongly on the applications of new technologies Dynamic, risk- taking

management with a philosophy of "technology is a key success factor" would facilitate and

encourage the process of applying new technologies, like CNC machines, CAD, and CAMsystems Otherwise, the process would be slower, or impossible to undertake

Introducing CNC machines, CAD, and CAM systems may be strategic investmentdecision, involving a big amount of capital It can result in many considerable consequences,such as changes in organization, firing people, etc In the other words, it is a big,fundamental change in a company Moreover, it takes a long time to implement suchprojects, and it cannot be revoked if it is undergone Therefore the process of introducingCNC machines, CAD, and CAM systems would require high commitment of management,especially top managers

The nature of the process also requires top management serving as "change agent".That means top management has to make people in the company understand, hencesupport and get involve in the process

At the operational level, new technologies like CNC machines, CAD, and CAMsystems also require different management skills Applying such applications involves a wideset of activities, from evaluating technologies, training to operating them Managers should

be capable to project a plan that shows the priority order of actions

People in the company are inexperienced in running such new technologies.Therefore, managers may have to use different ways to motivate employees, which mayallow errors and autonomy Supervisors in workshops also need different set of skills Theyhave to access to the knowledge concerning CNC machines, CAD, and CAM systems That

is only way to understand what the employees are doing, and thus responding timely to theproblems arisen

Team-work is normally organized in CNC machines, CAD, CAM systems Theresponsibilities of the team include training, overseeing system backup managing plotters,evaluating new hardware and software, managing system development, etc

Project management skills are strongly needed The top management must make a selection of the most profitable projects among those proposed The task of selection is a

critical one, since CNC machine, CAD, CAM projects will involve a large initial investment.They have a major effect on the company in the long-term, not be easy stopped oncestarted, or call for major upheavals in the company (John Stark, 1988) Management'sapproval of a given project will partly base on its own knowledge of long-term companyobjectives It will, however, also need to have a detailed description and justification of thecosts and benefits of each potential project