1、MIL-HDBK-702 1 August 1985 - Military Standardization Hand book ENGINEERING PRACTICES PRODUCTIVITY ENHANCEMENT OF INDUSTRIAL PLANT EQUIPMENT AND PRODUCTION SUPPORT SYSTEMS THIS DOCUMENT CONTAINS / 83 PAGES. DISTRIBUTION STATEMENT A. distribution is unlimited. - Approved for public release; NO DELIVE
2、RABLE DATA REQUIRED BY THIS DOCUMENT AMSI N/A Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-_ - MIL-HDBK-702 34 m 9939970 0041715 B m DEPARTMENT OF DEFENSE WASHINGTON , D C. 20301 MI L- HDB K- 702 Engi neeri ng Practices I Productivity Enhancement
3、of Industrial Plant Equipment and Production Support Systems 1. This standardization handbook was developed by the Department of Defence in accordance with established procedures. 2. This document was approved 1 August 1985, for printing and inclusion in the military Standardization handbook series.
4、 3. This document covers productivity enhancing industrial plant equipment and practices for developing creditable justification and analysis documents related to acquisition. that this handbook be referenced in specifications for the procurement of industrial plant equipment except for information
5、purposes, nor shall it supersede any specification requirement. It is not intended 4. It is intended that this handbook will be reviewed periodically to insure its completeness and currency. Users of this document are encouraged to report any errors discovered and any recommendations for changes or
6、additions to Commander, Defense Industrial Plant Equipment Center, ATTN: DIPEC-SSM, Memphis, Tennessee 38114-5297. t ii Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-FOREWORD Numerical ly control 1 ed i ndustri al pl ant equipment (IPE) and compute
7、r aided manufacturing systems properly selected and utilized will increase investment required to purchase the NC IPE and supportinq systems warrants a premium amount of effort to do a quality job in selection, justification, and post operation analysis. This handbook provides guidelines to DoD oper
8、ating officials on what -constitutes a thorough set of documents related to selection, justifi- cation, and post operation analysis. It also provides DoD personnel basic information on the operating characteristics and technical features avail- able on commercial items and systems. - the productivit
9、y of defense plant operations. The large amount of capital This handbook should be used in conjunction with the references and guidance published by the Military Services covering subjects contained herein. iii Provided by IHSNot for ResaleNo reproduction or networking permitted without license from
10、 IHS-,-,-CHAPTER 1. Paragraph 1. 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 1.3.4 1.4 1.5 1.5.1 1.5.2 1.5,3 1.6 1.6.1 1.6.1.1 1.6.1.2 1,6.1.3 1.6.2 1.6.2.1 1.6.2.2 1.6.3 1.6.3.1 1.6.3.2 1.7 1.7.1 1.7.2 CHAPTER 2 Paragraph 2. 2.1 2.1.1 2.1.2 2.2 2.2.1 2.2.1.1 2.2.2 2.2.2.1 2.3 2.3.1 CONTENTS INTRODUCTION ABSTRACT
11、 Objectives Appl icabil ity References Direct ives Instructions Manuals Regul at ions Definitions General requirements Department of Defense Direct ive Department of Defense Instruction Operating guide1 ines and reporting instructions Bac kground Investment approaches Defensive approach Cost-saving
12、approach Agg r e ss i v e approach Present productivity base Aged industrial pl ant equipment Recognition of unfunded investment opportunities Emphasis on productivity improvement Productivity enhancing capital investment program General Accounting Office studies The role of management Management su
13、pport Staff involvement PRODUCTIVITY ENHANCING INDUSTRIAL PLANT PRODUCTIVITY ENHANC I NG TECHNOLOGY Hi story The advent of numerical control Advancement of manufacturing technology Automat ion Automation systems and processes Automatic conventional /special purpose machines Numerically controlled ma
14、chines Numerical ly control led machine tool consistency Productivity enhancing technology for conventional Productivity enhancing retrofit EQUIPMENT AND MANUFACTURING SUPPORT SYSTEMS mach i nes Page 1-1 1-1 1-1 1-1 1-1 1-2 1-2 1-2 1-2 1-2 1-4 1-4 1-4 1-4 1-4 1-4 1-4 1-5 1-5 1-5 1-5 1-5 1-5 1-5 1-6
15、1-6 1-6 1-6 2-1 2-1 2-1 2-1 2-1 2-1 2-1 2-1 2-2 2-2 2-3 2-3 iv Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-Paragraph CHAP TER Paragraph CHAP TER Paragraph -I 7777770 004L7LB 3 . MI L-H DBK- 702 flIL-HDBK-7UZ 34 CONTENTS - Continued. Page 2.3.2 2.
16、3.3 2.3.4 2.3.4.1 2.3.4.2 2.3.5 2.3.5.1 2.3.6 2.4 2.4.1 2.4.2 2.4.2.1 2.4.2.2 2.4,2.2.1 2.4.2.2.2 2.4.2.3 2.4.2.4 2.4.2.4.1 2.4.2.4.2 2.4.2.5 2.4.2.6 2.4.2.7 Numerical control retrofit to conventional mach i nes 2-3 Candidates for numerical control retrofit 2-3 Digital readout system 2-4 Advantages
17、of digital readouts 2-4 machines 2-4 Manual data input (MDI) numerical controls 2-4 retrofit 2-5 NC controlled axis drive system retrofit 2-5 Computer applications to manufacturing 2-5 Problems inherent with batch manufacturing 2-5 Computer aided manufacturing support systems 2-6 Computer aided desi
18、gn (CAD) 2-6 Group technology 2-6 Data base 2-7 Document at i on 2-7 Distributed numerical control (DNC) .system 2-7 Computer aided process pl anni ng (CAPP) 2-7 Integration with other systems 2-8 Computer aided qual ity control (CAQC) 2-8 Manufacturing management system (MMS) 2-9 Retrofit of digita
19、l readouts to conventional Manual data input (MDI) numerical control System output of CAPP 2-8 Computer aided materi al management system (CAMM) 2-8 3 SELECTION OF NC MACHINE WORK 3. IDENTIFICATION OF OPPORTUNITIES TO APPLY 3.1 Considerations for NC machine production 3.2 Work-mix analysis 3.3 Work-
20、mix analysis procedures 3.3.1 Represent at ive sqpl e 3.3.2 Recordirig information 3.3.3 Productivity improvement data PRODUCTIVITY ENHANCING TECHNOLOGY 3.3.4 3.3.4.1 3.4 3.5 3.5.1 3.5.2 4 4. 4.1 3- 1 3-1 3-1 3- 2 3-3 3-3 3-3 3-3 Break-even analysis 3-4 Comput,at i on procedures 3-4 Selection of the
21、 numerically control led machine Selection of parts of production on existing Application of work-mix study to new part tool 3-6 NC machines 3-7 Product ion 3-7 Process planning 3-7 JUSTIFICATION PROBLEMS OF JUSTIFICATION Data base 4-1 4-1 V Provided by IHSNot for ResaleNo reproduction or networking
22、 permitted without license from IHS-,-,- _ MIL-HDBK-702 3Li W 7777770 0041717 5 = MI L-HUBK- /U2 Paragraph 4.2 4.2.1 4.3 4.3.1 4.3.2 4.3.3 4.4 4.41 4.4.2 4.4.3 4.5 4.5.1 4.5.2 4.5.3 4.6 CHAPTER 5 Paragraph 5. 5.1 5.2 5.3 54 5.5 CHAPTER 6 Paragraph 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12
23、 CONTENTS - Continued page Estimating NC machine savings 4-1 4-3 Direct and indirect savings 4-3 Economic justification 4-3 Ab brev i at ed economi c anal ys i s ( AEA) DD FORM 1106 industrial plant equipment rep1 acement analysis worksheet 4-4 Examples of DD FORM 1106 use for NC IPE just i f i cat
24、i on 4-4 Sources of supply 4-4 Al location from DoD Reserve 4-4 New machine procurement 4-4 Upgrade by rebuild and retrofit 4-4 Justification of computers and systems 4-5 Justification documents 4-5 Present method cost data 4- 5 Vendor I s data 4- 5 Justification of digital readout systems (DRS) 4-5
25、 POST ANALYSIS 5-1 MODERNIZATION PROGRAM 5-1 Bas is for compari cion 5-1 Productivity enhancement measurement 5-1 DD Form 1651 Preparation 5-1 Reporting 5-2 Automated analysis and management system 5-2 POST ANALYSIS OF INDUSTRIAL EQUIPMENT INSURING THE SUCCESS OF YOUR CAM INSTALLATION Insuring the s
26、uccess of your CAM installation Inform and involve your people Select and train personnel Considerat ion of future deve1 opment 6- 1 6-1 6- 1 6- 1 6-2 Plan for adequate tooling and part programming 6-2 Get adequate machine and control unit feature 6-2 Determine environmental and uti 1 ity requiremen
27、ts 6-3 Implement NC into the entire production process 6-3 Dissemination of information on the subject Know the actual machine capabil ities Set goals for NC performance 6-3 6-3 Rely on trained personnel 6-4 Follow the manufacturers advice 6-4 of NCKAM 6-4 vi Provided by IHSNot for ResaleNo reproduc
28、tion or networking permitted without license from IHS-,-,-APPENDIX A MIL-HDBK-702 34 7799770 0043720 I = Paragraph A. 1 A.2 A.2.1 A.2.2 A.2.3 A.2.4 A.2.5 A.2.6 A.2.6.1 A.2.6.2 A.2.6.3 A.2.6.3.1 A.2.6.3.2 A.2.6.3.2.1 A.2.6.4 A.2.6.5 A.2.6.7 A.2.6.8 A.2.6.9 A. 2.6.10 A.2.6.11 A. 2.6.12 A.2.6.13 A.2.6.
29、14 A. 2.5.15 A. 2.6.16 A. 2.6.17 A. 2.6.18 A.2.6.19 A. 2.6.20 A.2.6.21 A. 2.6.22 A. 2.6.23 A. 2.6.24 A. 2.6.25 A. 2.6.26 A. 2.6.27 A. 2.6.28 A. 2.6.28.1 A. 2.6.29 A. 2.6.30 A. 2.6.31 A. 2.6.32 A. 2.6.33 MI L-HDBK-702 CONTENTS - Continued NUMERICALLY CONTROLLED MACHINES Numerically control led machin
30、es Machining center Combined operations Vertical spindle machining center Horizontal spindle machining centers Four and five-axis machining centers Machining center numerical control requirements Numerical control Type I MCU Type II MCU Data input Punched tape data input Flexible diskettti data inpu
31、t Flexible diskette format Data display Control system modes of operation Departure control Absol ut e/i ncremental input Switchable inch/metric input Part program storage St and by battery power Part program edit Feed rate override Spindle speed override . Sequence number search Mirror image Prepar
32、tory funct ion (G-codes) Miscell aneous functions (M-codes) Block delete Buff er st or age Block-by-block read Tool length offsets Cutter compensation Fixture compensation Reversal error compensation Axis calibration Ad d i t i on al fe at ur es Operator control panel Pendant control Reference zero
33、Set zero Program tryout Operat ional software On-line system diagnostics vii Page A- 1 A- 1 A- 1 A- 1 A- 1 A- 3 A- 3 A- 7 A- 7 A- 7 A-a A- 8 A-8 A- 8 A-8 A- 8 A-8 A- 9 A- 9 A- 10 A-10 A- 10 A-10 A- 10 A- 10 A- 10 A- 10 A-11 A-11 A-11 A-11 A-11 A-11 A-11 A-11 A-11 A-12 A-12 A-12 A-12 A-12 A-12 A-12 A
34、-12 A-13 Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-Paragraph A. 2 . 6 33.1 A. 2.6.34 A. 2.6 -35 A. 2.6.36 A. 2.6.37 A. 2.6.37.1 A. 2.6.38 A. 2.6.39 A . 2 . 6 . 40 A.3 A.3.1 A.3.2 A.3.3 A. 3.4 A.3.5 A.3.5.1 A.3.5.2 A.3.5.3 A.4 A.4.1 A.4.2 A.4.3
35、A.4.4 A.4.5 A.4.5.1 A.4.5.2 A.4.6 A.4.6.1 A.4.6.2 A.4.6.2.1 A.4.6.2.2 A.4.6.2.2.1 A.4.6.2.3 A.4.6.3 A.4.6.4 A.4.6.5 A.4.6.6 A.4.6.7 A.4.6.8 A.4.6.9 A.4.6.10 A.4.6.11 CONTENTS - Continued. Page Maintenance di agnostics system A-13 Peripheral equipment interface A-13 Axis jog A-13 Auxiliary functions
36、A-13 Canned cycles A-13 Macro program cycles A- 14 Tape punch unit A-14 Postprocessor A-14 Graphics software A-14 General Electrical erosion machines A- 14 Numerically control led EDM A-1 5 Wire-cut EDM principles A-15 Numerical ly control 1 ed wi re-cut EDM A-17 Control led functions A- 18 Electric
37、al discharge power A-19 Programming and operating requirements A- 19 Boring machines Am20 Single-column, jig boring machine A- 20 Electrical discharge machines (EDM) principles A-14 Numerical control system A-la Double-column, bridge-type, jig boring machine Boring and mil 1 ing machine, precision,
38、Productivity enhanced boring and mil 1 ing machine A-23 A-21 horizontal spindle tab1 e-type A-22 Vertical boring and turning machines A-24 Vertical turret 1 athe A-25 Vertical bori ng mi 1 1 A-26 Numerical control for 1 athes A- 28 Numerical control system A-28 Punched tape data input A-28 Flexible
39、diskette data input A-29 Flexible diskette format A-29 Manual data input A-29 Data display A-30 Control system modes of operation A- 30 Depart ur e con tr o 1 A-30 Absolute/incremental input A-30 Automatic tape code recognition A-30 Switchable inch/metric input A-30 Part program storage A-30 St andb
40、y battery power A- 30 Edit i ng A-31 Data input A- 28 viii Provided by IHSNot for ResaleNo reproduction or networking permitted without license from IHS-,-,-MIL-HDBK-702 34 M 7777770 0041722 5 Paragraph A.4.6.12 A.4.6.13 8.4.6.14 A.4.6.15 A.4.6.16 . A.4.6.17 A. 4.6.18 A.4.6.19 A. 4.6.20 A.4.6.21 A.4
41、.6.22 A.4.6.23 A. 4.6.24 A.4.6.25 A.4.6.26 A.4.6.26.1 A.4.6.27 A.4.6.28 A .4.6.29 A .4.6.30 A.4.6.31 A.4.6.32 A.4.6.33 A .4.6.34 A.4.6.35 A.5 A.5.1 A.5.2 A.5.3 A.5.4 A.5.4.1 A.5.4.1.1 A.5.4.1.2 A.5.4.1.3 A.5.4.1.4 A.5.4.1.5 A.5.4.1.6 A.5.4.1.7 A.5.4.1.8 A.5.4.1.9 A.5.4.1.10 A.5.4.1.11 A.5.4.1.12 A.5
42、.4.1.13 A.5.4.1.14 A.5.4.1.15 A.5.4.1.15.1 A.5.4.1.16 A.5.4.1.17 A.5.4.1.18 MI L-H DBK-702 CONTENTS - Continued. Feed rate override Spindle speed override Sequence number search Mirror image Preparatory function (G-Codes) Mi scel 1 aneous functions (M-Codes) Block delete Buffer stor age Bl oc k - by
43、- b 1 oc k re ad Tool length offset Threadcutti ng Tool radius compensation Lead reversal error compensation Additional features Operator control panel Portable control Reference zero Set zero Absolute axis offset Tape tryout Canned cycles Programmed macro functions Operational software Maintenance
44、diagnostics system Postprocessor Grinding machines Center-type grinding machine Centerless grinding machines Surf ace gr i nder Numerical control for grinders Numerical control Data display Control system modes of operation Switchable i nch/metric input Part program memory St andby battery power Par
45、t program edit Feed rate override Sequence number search Block delete Segment al read Automatic cycle Refversal error compensation Axis calibration Additional features Operator control panel Pendant control Reference zero Set Zero Program tryout ix Page - A-31 A-31 A-31 A-31 A-31 A-31 A-31 A-31 A-32
46、 A-32 A-32 A-32 A-32 A- 32 A-32 A- 33 A-33 A-33 A-33 A- 33 A-33 A-33 A-33 A-33 A-33 A- 34 A- 34 A-37 A- 39 A-40 A-40 A-40 A-40 A-40 A-41 A-41 A-41 A-41 A-41 A-41 A-41 A-41 A-41 A-42 A-42 A-42 A-42 A-42 A-42 A-42 Provided by IHSNot for ResaleNo reproduction or networking permitted without license fro
47、m IHS-,-,-A.5.4.1. 19 A. 5.4 . 1 . 20 A. 5.4.1.21 A.5.4.1 . 22 A. 5 .4.1.23 A.5.4.1.24 A.6 A.6.1 A.6.2 A.6.3 A.6.4 A.6.5 A.7 A.7.1 A.7.2 A.7.3 A.7.3.1 A. 7 . 3.1.1 A. 7.3.1 . 1.1 A.7.3.2 A.7.3.2.1 A.7.3.3 A.7.3.3.1 A.7.3.3.2 A.7.3.3.3 A.7.3.3.4 A.7.3.3.5 A. 7.3.3.6 A.7.3.3.7 A.7.3.4 A.7.3.4.1 A.7.3.
48、4.2 A.7.3.4.3 A. 7 . 3.4.4 A.7.3.4.5 A. 7.3.4.6 A.7.3.5 A.7.3.5.1 A.7.3.5.2 A.7.3.5.3 A.7.3.5.4 A.7.3.5.5 A.7.3.5.6 A.7.3.5.7 A.7.3.5.8 A.7.3.5.9 A. 7.3. . 10 A.7.3.5.11 A.7.3.5.12 7.3.3.a CONTENTS - Continued. On-line system diagnostics Maintenance diagnostics system Peripheral equi pment interface
49、 Ax is jog Auxil iary functions Canned cyc 1 es Lathes Cy1 indrical turning lathe Chucking 1 athe Combination bar and chuck lathe Universal turning 1 athe Numerical control requirements for 1 athes Milling machines Knee-type mi 1 1 i ng machi ne Bed-type mi 1 1 i ng machi nes Milling machine numerical controls Computer numerical control (CNC) Punched tape data input Tape reader Flexible disk
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