Qualitative research methods for STEP NC systems

¶ … NC system

This study focuses on the rise and significance STEP-NC as the most efficient model to transfer knowledge and communication on different CAD and CAM structures to improve the product design and overall project management. The paper will be divided into six chapters: 1) Introduction chapter which will include the statement of the problem, significance of the problem, purpose and scope of the study, the relevant definitions, the assumptions of the study as well as its limitations; 2) Literature Review chapter which will present an analysis of all the prior studies done on similar topics; 3) chapter variables and hypothesis creation where all the variables (dependent and independent) will be listed; 4) methodology chapter which will include data collection processes and the qualitative procedures used; 5) results and presentation of data chapter which will include all statistical calculations and the regression analysis; 6) conclusion chapter which will includes discussion of results and recommendations for the future. Both the statistical and qualitative results of the studies show that there was a very strong connection between the implementation of Step NC and the dependent variables (communication amid machines, transfer of relevant knowledge and product design).

Chapter 1:

Statement of the Problem

The problem being aimed to tackle here is the technological processes needed in the manufacturing process to improve end result. Hence, the study aims to analyze the impact that the implementation of Step NC in the manufacturing process has on the overall company performance in different internal and external factors.

Significance of the Problem

It is not a hidden fact that the use and access of technology and computers has increased globally amongst both the business and industrial sector, nevertheless, there are many analysts who still question whether its use is having more negative effect then positive on overall performance, project development and communication. With the advent and increased advancements in the technological sphere, it is only normal that the business sector employs more technology or computer-based instruments in their medium as well. The use of new and improved technology has obviously seen the consequential increase in the financial expenses like for instance the yearly financial allotment increased from a mere $21 million to a whopping $729 million in a space of six years from 1995 to 2001 (Market Data Retrieval, 2001). Hence, it has become more important to understand the most fruitful processes as well as the best way to apply them. This study will focus on the one of the more popular processes -- Step NC in the manufacturing process.

This particular research will bear considerable worth for the manufacturing departments in the business world, due to the fact that this particular study will encompass the concept of challenges, problems and job performance of these departments under the adoption of newer technologies, the following two points will be focused on:

1) The conclusions deduced from this particular study will extend the notion regarding the developmental manipulations of technology in the manufacturing process.

2) This particular research will also be of immense help for policy formulators in the business sectors in metropolitan centers and smaller vicinities, in making effectual judgment regarding relevant development.

3) The material along with the conclusion of this particular study will certainly enhance and modernize the methodologies of the investigations linked to technological incorporation in the manufacturing process.

Purpose and Scope of the Study

In the modern world where technological advancements lead to newer ways to improve the manufacturing process, it is important to understand how these advancements can be best applied and bring the most benefit. The purpose hence of this study was to analyze the application of one such modern process -- Step NC -- and how it, after implementation in the manufacturing process, impacts the different aspect of the company performance, namely the communication and transfer of knowledge amid machines and the impact thereof on the project outcomes. The scope of the study will hence be one that makes inroads in analyzing the implementation of technological practices in the manufacturing process. It will help in understanding the different processes that will help different companies attain the best end results from the customers' prospects as well as their own.

Definition

STEP (Standard for Exchange of Protocol data) is an ISO certified global standard (10303) created in 1984 but is updated regularly. For instance, it is now capable of transferring all product data along with part geometry. The more sophisticated version of STEP comprises of application protocols (APs) that help in describing how information for a specific function can be exchanged (Gordon, 2007).

The STEP-NC standard is an additional part of STEP which makes it possible for a CAD/CAM design to interact with CNC commands. The STEP-NC file contains three portions; 1. Work plan, 2. Technology description and 3. Geometry description (Calabrese and Celentano, 2007).

Assumptions, Limitations & De limitations

All research studies have been founded on certain assumptions that the researcher takes for granted. These assumptions allow the researcher to view the world from a certain point-of-view, while ignoring other points-of-view. In our study we plan to view the subjects as reasonable human beings who have a logical point-of-view. They are rationale in their thinking and their approach and are by and large in line with scientific thinking. Furthermore, we will assume scientific thinking and common sense thinking are more or less the same process (Trochim, 2007).

The first limitation of this study has been the viewpoint assumed; this study investigates the impact that the implementation of Step NC in the manufacturing process does on the overall company performance in different internal (including employee performance, decision making procedures, HR strategies, amongst others) and external factors (including PR and media influence, competitor advantage, technological investment by the government amongst others). Secondly, since this study is being carried out in (insert chosen city here), therefore, this study is limited to just this location where the cultural and industrial structures will play a huge part along with the investments in technology that the government will be willing to make. Thirdly, the subjects will be limited to the business sector only, not the industrial sector. Lastly, data collection will be limited to interviews and questionnaires to gather information. These restraints will be discussed in detail in chapter 4 when dealing with the methodology section.

Introduction

Due to the rising prominence of a mutual model-based design, it becomes imperative that data can easily pass along through various CAD systems. In programs such as these, 3D solid models hold important information required (like geometry, notes, GD&T data, material properties, etc.) which helps in explaining any particular product from the point of its inception till dumping. This is especially helpful in allowing companies to computerize digital-life-cycle and reduce expenses. To easily transfer files from different CAD systems, the esteemed IGES and STEP standards were used to create neutral file formats. Both of these systems (IGES and STEP) are used in the model-based mixture in a diverse manner (Gordon, 2007).

IGES was developed in the late 1970s for the purpose of replacing geometry. It has not altered very much since then. In 1996 the last version of Initial Graphics Exchange Specification (Version 5.3) was released, while Version 6.0 is currently being developed. Nevertheless, IGES are still predominantly used in the market, particularly for converting 2D drawings. It accepts free-form surfaces, annotations, wire frames and also has just started supporting solid models (Gordon, 2007). A direct contrast of this the STEP and Step NC processes explained before.

AP 203 and AP214 are mostly incorporated in all major CAD systems both of which focus mostly on developing designs for mechanical items. Further APs in the standard procedure contain them for AEC, shipbuilding, NC machining and factory-floor layout, etc. Along with STEP comes along Conformance Classes (CC) which are frameworks on how to create software using STEP (Gordon, 2007).

It is useful to know that all key 3D MCAD programs include a preprocessor or a reader along with a writer, or a postprocessor for IGES and STEP. The initial program's preprocessor analyses the CAD file and develop a version that can be understood with the STEP or IGES protocol which the user has chosen. After this, the system that collects data post-processes the outcome for additional work (Gordon, 2007).

The ISO10303 standard (also known as STEP - Standard for Exchange of Product model data) (ISO, 1994a and 1994b) lay a foundation for recounting production information along the process line, for CAD to 3D CAM, permitting practical usage and sharing of databases (Calabrese and Celentano, 2007).

The plan of procedure is distinguished by a number of executables which are pre-ordered or reliant on the systemizing real life conditions. This of course is only possible if and when conditional controls are being employed. The executables are usually of 3 kinds: working steps, the NC operations as well as the program designs, the most important of them being the working steps because it explains the manufacturing aspects. The working procedure symbolizes 3D (region) machining features and 2.5-D (two5D_manufacturing_feature). Every working step included contains sub-features (such as pocket, step, planar_face, round_hole slot, general_outside_profile, etc.) along with cutting condition data or information (Calabrese and Celentano, 2007).

The complete and thorough explanation related to the working steps is enclosed in the technology description. This full explanation includes information with respect to machining strategies, tools, definitions of the work pieces and the things of similar nature. For instance, an entire technology description contains depth of hole that is required to be machined, diameter of the tool, rotational speed, and feed rate, etc. (Calabrese and Celentano, 2007). The geometry data employed in different components is explained by employing the ISO 10303 structure (Calabrese and Celentano, 2007).

Every STEP-NC program has a PROJECT and a WORK PLAN unit. The former is a top-level unit, which tells the user about the beginning of a program. It also helps in identifying the work plan that needs to be placed on work along with the work piece used for conducting various operations. The latter entity explains the geometry and the materials that would be used for the operation (Calabrese and Celentano, 2007).

Two different versions of the STEP-NC which are in the making include the following: Application Interpreted Model (AIM) of ISO14649 (also known as ISO 10303 AP-238) (ISO, 2003c) and Application Reference Model (ARM) (also known as ISO14649) (ISO, 2003a and 2003b; Calabrese and Celentano, 2007).

A CAD Manager John Gray, who works at International TechneGroup Inc. (ITI), located in the region of Milford, Ohio points out the difficulty associated with translation when using dissimilar CAD systems. This is due to the fact that both the systems may use separate mathematical representations for similar geometry. Two translators, made by the firm, namely IGES and STEP are being used by many powerful programs currently. IGES, for example, categorizes surfaces such as Nubs surfaces and cylinders are categorized to be exclusive. If a postprocessor is unable to recognize an entity that has been sustained by the preprocessor it simply pays no heed to it. This undetected entity could be the cause for the breakdown on the post processor as pointed out by John Gray (Laguionie et al., 2009).

Problems may also arise because of complicated making of the 3D components and then transferring IGES files to CAM systems. The final model could be infected with huge gaps amongst surfaces if the final user doesn't choose the right translator. This problem can be solved on the basis of their understanding. Gray points out this problem when he says that majority of the people who use CAD depend on the default settings. Most blunders related to translation are a result of the users least participation in data exchange until it becomes problematic. Those who make IGES files of their drawing have to choose from over 50 variables when choosing the right flavor. A few may be related to geometry while the rest may be related to annotation (Laguionie et al., 2009).

Gray explains this concept further by relating it to the locks in a house. If the locks are from one brand then one key would be enough to serve the purpose but if on the contrary they are from more than one brand then a solitary key wouldn't be enough. A CAD interoperability consultant, Doug Cheney at ITI points out the difficulty involved in transferring models amongst various MCAD systems. He explains that each of models may use separate ways for modeling. Catia 4, an old system, works by first making the surfaces and then combining them to built 3D models by using steps with the features and parameters. Recent systems make solid models and have a history tree that constitutes of the tabs of all the steps. In this case, an IGES solid part can also become a surface part mainly due to the fact that surfaces have been divided when translation was done (Laguionie et al., 2009).

Because of the fact that history-based systems employ inferential modeling technique in which a component of the software explains the geometry as opposed to the IGES and STEP. The fact is that IGES and STEP make use of specific geometry based on mathematical equations, and if these are used then transferring models between history and non-history-based systems could be problematic as pointed out by Cheney. Hence higher-order geometries should be altered to lower-order geometries when files are transferred to IGES from an inferential system, which in itself can be a source of difficulty. These conversions can give way to gaps in volumes if they are not done properly (Weck, 2003).

Chapter 2: Literature Review

Because STEP-NC is an improvement of STEP when handling NC processes, it greatly adheres to the standard set by STEP. It therefore implies that all the ways employed (ISO, 1994, 1998, 2000a, 2000b, 2001, 2002, 2004a, 2004b) that are explained by STEP for making and transferring of the product models are applicable. The interface mechanism, Part 21 physical le, is the most widely accepted one. The HEADER, for instance, in a STEP-NC consists of the more common type of information about the part of the program which includes the name, author, data and also the organization (OMG, 2003). The major part of the program is the DATA section which consists of all the information of work related to manufacturing and geometries. The data is separated into three major chunks, first being the work plan and executables, second being the description related to the technology and finally the third part is the description of geometry. Also constituting this section is the PROJECT entity that makes up the specific reference required for beginning of the manufacturing work. It consists of a work plan that is essential for creating a series of manufacturing objectives or commands ready to be put to work and the order for this is provided by the order of executables. If an amendment has to be made in the order it is done by altering this segment of the program. The work plan is also responsible for mixing the various executables. The mixing is usually done in a linear format and/or relies on the given situation if the conditional controls are being put to use (Xu, 2006).

The G-code tells the system how exactly to go about the making process. STEP-NC, on the other hand, deals with the problem of what-to-make by specifying individual tasks that depend upon the machining components. Tasks may include pre-drilling, noshing, drilling and even roughing. The purpose of this is to enable the part program to provide the shop with the equipment or by providing data about the machining task and also about the technological data that may be required over authentic geometrical and topological information; this may also be referred to as higher-level information. Consequently, any changes or alteration at the shop can be easily saved and sent back to the department related to the planning stage and would facilitate an enhanced exchange and conservation of experience and the knowledge (Xu, 2006).

To prevent the information from being displaced when moving across various stages, STEP-NC supplies data models, which are complete and structured, connected with the geometrical, as well as technological information. To equal the performance of a specific CAM shop, programming (SEP) or even an NC, the data model can further be used for newer scalable that contain the conformance classes or for newer technology. A need for a postprocessor methodology will be finished because the interface no longer needs to be provided with the machine-specific information. Saving any alterations at the shop and then sending them back to the design division to allow the accomplishment of the bidirectional information from CAD/CAM to CNC machines (Feeney et al., 2003).

Recently a couple of varieties of STEP-NC are being structured which include namely the application reference model (ARM) (ISO, 2003b, 2003c and 2003d) as well as the application interpreted model (AIM). Containing a comprehensive analysis of the standards required for CNC applications, the ARM, ISO 14-649 contains the particular objects that are precisely determined in addition to the connections among them. EXPRESS, a modeling language is used to develop the structure (ISO, 2003b, 2003c and 2003d). The AIM model, on the contrary, allows the user to draft the application requirement data determined within the ARM (ISO 14-649) in a combined ISO 10-303 application protocol. This is done by following predetermined sets of STEP concepts which are known as a "generic resources." Based on the same principles as some of the other STEP application protocols, AP-238 can exchange information smoothly. Readers should go through studies done by Wolf (2003) and (Feeney et al., 2003) in order to obtain more information on the usage and differences (Xu, 2006).

Research in the field of STEP-NC can be observed worldwide where many important projects have been conducted with the combined efforts of many countries living in either the same region or living overseas (Xu et al., 2005). Three kinds of projects are conducted which constitute the following: first one being those that are conducted among countries internationally, secondly those where the countries live in the same region and thirdly where a project is carried out in a single country. The project that falls in the first category was the IMS STEP-NC project (Tech-Rep, 2003), started on November 2001, consisting of research associates from European Union, U.S., Switzerland and Korea (Maeder et al., 2002). They included manufacturers of all the systems that were related to the data interface which included systems like CAD systems, machine tools and even controls. They also included the users and the academic institutions. Example of the second category includes CADCAMMation (Switzerland), STEP Tools (U.S.), ERC-ACI (Korea), and Siemens (EU), who have decided to become regional co-coordinators, the last one being an inter-regional co-coordinator also.

Since the STEP-NC comprises of a Working step-based feature, it has allowed most projects to include a prototype/commercial CAPP or CAM systems that contain functions related to the planning process. Examples of this include the following: Korea (Suh et al., 2003), the AB-CAM system belonging to Wolfson School of Mechanical and Manufacturing Engineering (Suh, Lee, Chung and Cheon, 2003). Some other examples of this format include the following:

STEP turn from Germany;

WZL-SFP initiated from the WZL Aachen, ISW Stuttgart, also from Germany;

ST-Plan from the United States-based corporation name STEP Tools Inc.;

University, Loughborough, U.K. initiated the SFP system from the facilities of the National Research Laboratory for STEP-NC Technology (NRL-SNT), (Newman, 2004; Newman et al., 2003) and STEP CNC Converter from New Zealand, more specifically the University of Auckland (Xu, 2004 and 2006).

Progress in the management techniques, manufacturing techniques, and information technology has facilitated for the making of STEP. STEP has not been designed to cope with a specific technical problems, it, nevertheless, serves a significant purpose in the business drivers, which is making a different and a better environment for the manufacturing industries which would allow for better understanding of the advantages presented by STEP (Fowler, 1995).

The standard is set by the development of STEP. The context given for the standard has got a lot of significance and if context is not provided then any standard is just considered to be a piece of paper. If the businesses find that the standard would result in the better financial performance of the company and would enhance their performance overall then they would adapt the new standards (Fowler, 1995).

Attaining aggressive advantage

Various numbers of challenges are being faced by the manufacturing industry. They are competing in the market while overcoming the challenges. Fowler (1995) states that the companies want to have high market share; they want to introduce new and differentiated products. However, the product life cycles are smaller as the markets have changed now.

Now the competition is not just based on the cost factor and the functions of the products but trends have changed and quality matters to a lot of the consumers. They emphasize on the quality as well as how good the product is made for the ease of the consumer. In 1980's and 1990's the mindset of the users changed and they demanded better products despite the high availability of cheaper ones. The certifications of the quality has made competition tough among the companies and certification like ISO 9000 was being used by companies and this was then set to be a requirement and not just an edge among the companies (Fowler, 1995).

Professors Hamel and Prahalad mentions that to gain a competitive advantage in the market firms need to work on the distinguishing factors from at least before five to ten years. The correlation between the objectives of the company and the utilization of new technology plays a significant role in the development and planning of that developmental structure beforehand for around five to ten years. If the companies forecast the market and the products then is it even possible for them to foretell the technology which will be needed in the next ten years (as cited in Fowler, 1995).

Tactical Concerns

The tactical challenges can be overcome by various solutions. All the management consultants are striving to get rid of these challenges. The solutions that can be used are as explained below: (Fowler, 1995).

• Business process re-engineering: Companies can grow by their concern on continuous and ongoing improvement and figuring out the basic activities of the company and moreover enhancing their capabilities (Fowler, 1995).

• Total Quality Management: Another important solution is that of TQM. The companies need to focus on the quality of product they are providing to their customers. They need to deliver the products with best quality (Fowler, 1995).

• Concurrent Engineering: The development time of the product should be also minimized so that product is produced with less period of time (Fowler, 1995).

• Design for Manufacturing: The design of the product is also very important. Product should be designed in such a way that it is at ease for its customers (Fowler, 1995).

Moreover, offering the above solutions there are some other solutions as well which are now institutionalized. In the U.S. department of Defense programs like "CALS" (Continuous Acquisition and Life cycle Support) are used as one of the potential solutions because it works as bringing the communication between customers and suppliers. It helps in all the stages of the product's life cycle to have contact between each other (Fowler, 1995).

Transformation operatives

The businesses face a better environment and transformations or changes while performing these solutions. It improves their working capability. Another factor is that of information technology as businesses are not much aware of its use. Some are reluctant as they are not used to it but in 1950's relevant changes have been observed and recorded in the domain. Companies are now using this technology and financial rates applied or invested in information technology have increased. There has been progress and advancement in the companies with the use of advanced computer systems. It leads to innovation and creativity along with a drastic change (Fowler, 1995).

Initially many tasks were carried out manually. The typing pool typewriters are replaced with the word processing systems. As the typewriters consumed more time and required more efficiency. Moreover, in the offices drawing boards were replaced with CAD systems as it provided more productivity (Gordon, 2007).

Despite the use of information technology it did not result in the best benefits for the companies because they lacked the high-end level of interaction needed between the businesses and the technology. Moreover, the new business structures were introduced and the companies looked for an "extended enterprise." With such business structures in place, they can join together and incorporate the new and comprehensive ways to cater a larger sector of business. "Functional silos" were identified by the business re-engineering structures as they helped in the communication between the groups and various departments. It raised a conflict against the process-driven approach (Gordon, 2007).

Despite the problems being faced with information technology it is recommended that it should be used in the businesses as it leads to continuous improvement of the company. However, information technology needs to operate in an adequate manner to help the users get rid of the fluctuations they face and help them to raise the standards of the company and maintain the philosophy of growth (Wang, 2002).

The use of information technology can be explained by considering situations that lead to the reorganization of the company in the successful U.S. corporations. This is mostly done at least once a year and the life of the information technology persists for about five to ten years which gives a beneficial state to the company. This system can help the businesses get reorganized two or more times and work well in this period of time (Fowler, 1995).

Integration

When discussing the relationships between business and technology there comes a word "Integration." This word has several meanings like:

• It exhibits the new organization structure of the company along with the activities performed by it to carry out the business. Moreover, the flow of material is also catered by it. Information and control of the business is also operated with enterprise integration (Wang, 2002).

• New and different computer systems are worked together by the integration called Application integration. This helps in the reformation of computer usage (Wang, 2002).

Integration focuses on having a strong communication and increases the effectiveness of the communication that takes place between/amongst people and the computer systems. Enterprise integration mainly creates a communication among the people whereas Application integration fosters communications through the computer systems. This gives space to STEP for its development and raises the communication level between various computer systems as well as among people (Fowler, 1995).

The core issue

The core concern or issue that is caused regarding the sharing and replacing of various data is mainly due to the insufficiency of the computer systems. There are incompatibilities between the systems to get a grip over other systems. Now the trends have changed and computer systems are now designed in such a way that they encourage their capabilities and improve their performance. This period of "information age" has brought about several changes regarding the functions of computer systems. However, computers are still taken as basic machines used to carry out just the operations by using different software's and programs (Fowler, 1995).

The problem arises when there is a need for one system to get support from another one. This causes trouble because the communication level between the two systems is not appropriate. They cannot exchange the data in an adequate manner, but when systems are operating in isolation things go smooth. The use of word processors and spreadsheets also makes the problem familiar to the users. New software has been introduced to overcome this problem and make the data shareable by other systems. Documents should be kept in the file not by copying it but by extracting with the help simple unstructured ASCII file. However, table can be kept in the form of figures and then create a spreadsheet for it (Fowler, 1995).

Issues regarding the data sharing are being tackled in the office automation by developing creative and innovative operating systems. Various types of application software are allocated to improve the overall sharing of data. However, this is not accessible to everyone in the company but some competent employees will be able to use these systems in departments of engineering and manufacturing. In 1960s and 1970s algorithmic approach was used for software designs and development but now the CAD/CAM systems are new attractive systems in the market. Algorithmic approach does not cover the need of the market appropriately and the data is not shared as required which may lead to the problems regarding the swapping of data (Fowler, 1995).