Manufacturing data analysis of machine tool errors within a contemporary small manufacturing enterprise

The main focus of this paper is directed at the determination of manufacturing errors within the contemporary smaller manufacturing enterprise sector. These can manifest themselves as machine tool, fixturing or programming errors, experienced during the manufacture of 2 1/2D components on a 3-axis vertical machining centre. The manufacturing error diagnosis is achieved through the manufacturing data analysis of the results obtained from the inspection of the component on a co-ordinate measuring machine. This manufacturing data analysis activity adopts a feature-based approach and is conducted through the application of a forward chaining expert system, termed, the Product Data Analysis Distributed Diagnostic Expert System, which forms part of a larger prototype feedback system entitled the Production Data Analysis framework. This paper introduces the manufacturing error categorisations that are associated with milling type operations, knowledge acquisition and representation, conceptual structure and operating procedure of the prototype manufacturing data analysis facility. The paper concludes with a brief evaluation of the logic employed through the simulation of manufacturing error scenarios. This prototype manufacturing data analysis expert system provides a valuable aid for the rapid diagnosis and elimination of manufacturing errors on a 3-axis vertical machining centre in an environment where operator expertise is limited. (C) 2002 Elsevier Science Ltd. All rights reserved.