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It is apparent that the pressure of CIM to operate the factory correctly falls on the data integrity. Data integrity requires on-time data collection and on-time data interpretation.

By "data integrity" is meant that raw data are collected in an "on-time" manner to support the appropriate decision. In some cases this may mean real time to control the process directly.

However, most decisions above the process level are not made in a real-time environment. This allows alternative methods to be used. The key in any of these scenarios is integrity.

It means: Bill of materials accuracy of 95% or better Inventory accuracy by part count by location of 95% or better Engineering change accuracy of 99% or better The requirement to allow ...
... a human being to enter data becomes too taxing even for the most dedicated operator.

The future belongs to automated data collection at the source, with strong ties to a statistical process control system that can predict if a process is tending toward an out-of-control situation before it actually goes out of control.

The same integrity is necessary for the station-level material handling and assembly operations, where it is mandatory to know where a part was moved and what operation was performed. Here again, it cannot be left to a human operator. It is paramount to collect accurate raw data at the source.

To address the requirements of integration, means of integration must be defined and built. As we review the levels in the factory hierarchy, there are only a few principles that are evident. One is that information at the center level must tie systems together and flow between systems with ease, yet with control.

The second is that the intermediate ceil-level control functions must link software systems at the center level with material movement and process control at the lower levels. Finally, material flow must be integrated so that parts are handled in known orientations and moved from known locations to known locations. This leads us to the conclusion that there are three means to integrate systems.

(1) Information integration. To achieve the planning, tracking, and control necessary in the FOF, information must be available where needed in the form needed. This often requires various pieces of computer hardware to peruse various databases, all with absolute data integrity.

(2) Controls integration. To achieve the closed-loop process control that can link each processor and operate each process, control strategies and systems must be integrated. This force the control system to know what parameter set is necessary to make a good part and to monitor these parameters to ensure that a good part is made. It also forces the control system to know where the parts are at all times.

(3) Material flow integration. To achieve transfer line speed with job shop flexibility parts must be handled in known orientations through known moves.