– COMP U TER INTEGRA TED MANUFAC T URING
IV year Mechanical Engg .Notes on Lesson
UNIT – I : INTRODUCTION
Introduction
Computer integrated manufacturing(CIM) is a broad term covering all technologies and
soft automation used to manage the resources for cost effective production of tangible
goods.
Integration – capital, human, technology and equipment
CIM – which orchestrates the factors of production and its management.
Computer Aided Design (CAD)
Computer Aided Manufacturing (CAM)
Flexible Manufacturing Systems (FMS)
Computer Aided Process Planning (CAPP)
CIM is being projected as a panacea for Discrete manufacturing type of industry, which
produces 40% of all goods.
“CIM is not applying computers to the design of the products of the company. That is
computer aided design (CAD)! It is not using them as tools for part and assembly analysis. That
is computer aided engineering (CAE)! It is not using computers to aid the
development of part programs to drive machine
tools. That is computer aided manufacturing
(CAM)! It is not materials requirement planning
(MRP) or justintime (JIT) or any other method of
developing the production schedule. It is not
automated identification, data collection, or data
acquisition. It is not simulation or modeling of any
materials handling or robots or anything else like
that. Taken by themselves, they are the application
of computer technology to the process of
manufacturing. But taken by themselves they only
crate the islands of automation.”
- Leo Roth Klein, Manufacturing Control systems, Inc.
Definition of CIM:
It describes integrated applications of computers in manufacturing. A number of
observers have attempted to refine its meaning:
One needs to think of CIM as a computer system in which the peripherals, instead of
being printers, plotters, terminals and memory disks are robots, machine tools and other
processing equipment. It is a little noisier and a little messier, but it’s basically a
computer system.
Joel Goldhar, Dean, Illinois Institute of Technology
CIM is a management philosophy, not a turnkey computer product. It is a philosophy crucial to
the survival of most manufacturers because it provides the levels of product design and
production control and shop flexibility to compete in future domestic and
international markets. Dan Appleton,
President, DACOM, Inc.
CIM is an opportunity for realigning your two most fundamental resources: people and
technology. CIM is a lot more than the integration of mechanical, electrical, and even
informational systems. It’s an understanding of the new way to manage.
Charles Savage, president, Savage Associates
CIM is nothing but a data management and networking problem.
Jack Conaway, CIM marketing manager, DEC
The preceding comments on CIM have different emphases (as highlighted).
An attempt to define CIM is analogous to a group of blind persons trying to
describe an elephant by touching it.
“CIM is the integration of the total manufacturing enterprise through t he use of
integrated systems and data communications coupled with new managerial
philosophies that improve organizational and pe rsonnel efficiency.”
- Shrensker, Computer Automated Systems Association of the Society of Manufacturing
Engineers (CASA/SME)
Concept or Technology
―Some people view CIM as a concept, while others merely as a technology. It is
actually both. A good analogy of CIM is man, for what we mean by the word man
presupposes both the mind and the body. Similarly, CIM represents both the co ncept
and the technology. The concept leads to the technology which, in turn, broadens the
concept.‖
- According to Vajpayee
The meaning and origin of CIM
The CIM will be used to mean the integration of business, engineering, manufacturing
and management information that spans company functions from marketing to product
distribution.
The changing and manufacturing and management scenes
The state of manufacturing developments aims to establish the context within which CIM exists
and to which CIM must be relevant. Agile manufacturing, operating through a global factory or to
world class standards may all operate alongside CIM. CIM
is deliberately classed with the technologies because, as will be seen, it has significant
technological elements. But it is inappropriate to classify CIM as a single technology, like
computer aided design or computer numerical control.
External communications
Electronic data interchange involves having data links between a buying company’s
purchasing computer and the ordering co mputer in the supplying company. Data links
may private but they are more likely to use facilities provided by telephone utility
companies.
Islands of automation and software
In many instances the software and hardware have been isolated. When such
computers have been used to control machines, the combination has been termed an
island of automation. When software is similarly restricted in its ability to link to other
software, this can be called an island of software.
Dedicated and open systems
The opposite of dedicated in communication terms is open. Open systems enable any
type of computer system to communicate with any other.
Manufacturing automation protocol (MAP)
The launch of the MAP initiates the use of open systems and the movement towards the
integrated enterprise.
Product related activities of a company 1. Marketing
Sales and customer order serviceing
2. Engineering
Research and product development
Manufacturing development
Fatima Michael College of Engineering & Technology
Design
Engineering release and control
Manufacturing engineering
Facilities engineering
Industrial engineering
3. Production planning
Master production scheduling
Material planning and resource planning
Purchasing
Production control
4. Plant operations
Production management and control
Material receiving
Storage and inventory
Manufacturing processes
Test and inspection
Material transfer
Packing, dispatch and shipping
Plant site service and maintenance
5. Physical distribution
Physical distribution planning
Physical distribution operations
Warranties, servicing and spares
6. Business and financial management
Company services
Payroll
Accounts payable, billing and accounts receivable
UNIT – II : GROUP TECHNOLOGY AND COMPUTER AIDED
PROCESS PLANNING
Group technology
Group technology is a manufacturing philosophy in which similar parts are
identified and grouped together to take the advantage of their similarities in
design and manufacturing.
Group Technology or GT is a manufacturing philosophy in which the parts having
similarities (Geometry, manufacturing process and/or function) are grouped
together to achieve higher level of integration between the design and
manufacturing functions of a firm. The aim is to reduce work- in-progress and
improve delivery performance by reducing lead times. GT is based on a general
principle that many problems are similar and by grouping similar problems, a single
solution can be found to a set of problems, thus saving time and effort. The group
of similar parts is known as part family and the group of machineries used to
process an individual part family is known as machine cell. It is not necessary for
each part of a part family to be processed by every machine of corresponding
machine cell. This type of manufacturing in which a part family is produced by a
machine cell is known as cellular manufacturing. The manufacturing efficiencies
are generally increased by employing GT because the required operations may be
confined to only a small cell and thus avoiding the need for transportation of in-
process parts
Role of GT in CAD/CAM integration
Identifying the part families.
Rearranging production machines into machine cells
Part family
A part family is a collection of parts having similarities based on design or
shape or similar manufacturing sequence.
Comparison of Functional layout with GT layout
Methods of Grouping of parts
visual inspection
parts classification and coding system
production flow analysis
Parts classification and coding system
system based on part design attributes
system based on manufacturing attributes
system based on design and manufacturing attributes
Methods of coding
hierarchical coding
poly code
decision tree coding
Coding system
OPITZ system
DCLASS
MICLASS etc.
Production flow analysis (PFA)
Various steps of PFA
Data collection
Part sorting and routing
PFA chart
Analysis
Production Flow Analysis
During the past ten years the people behind QDC Business Engineering have
performed several Production Flow Analyses (PFA) in manufacturing industries. In
short, PFA provides well-established, efficient and analytical engineering method
for planning the change from “process organisation” to “product
organisation”. This means that traditional production layouts are transformed into
production groups, which each make a particular set of parts and is equipped with
a particular set of machines and equipment enabling them to complete the
assigned parts. The following figure illustrates the conventional process layout and
its corresponding product based layout after PFA has been applied.
The resulting overall material flow between functional cells.
Traditional Process Layout
Product Layout
The resulting smooth material
flow between dedicated product
groups.
Complex material flow systems resulting from process based production
layouts have long throughput times, high inventories and work in progress ,
which increase cost and reduce profitability. From the organisation’s point of
view, delegation and control are difficult to implement, which leads to
bureaucratic and centralised management structures, thus increasing
overhead. Applying PFA produces a plan to change the layout and organisation
in such a way that production throughput times can be reduced radically, while
at the same time inventories go down and delivery punctuality and quality
improve to a completely new level. QDC has applied the method successfully in
several manufacturing industries, especially in job-shops and electronics
industries, but good results have also been obtained in service industries. Once
the layout has been changed to a product based one, new and simple
production scheduling routines have been implemented to ensure excellent
delivery performance.
Anticipated results
Companies that have gone through PFA and the resulting change to product
based layout, have experienced the following positive effects:
in operations management: reduced production throughput times, significantly
less capital tied into the material flow and improved delivery performance;
in general management: makes it possible to delegate the responsibility for
component quality, cost and completion by due-date to the group level, which in
turn reduced overhead;
in worker’s motivation: clearer responsibilities and decision making on the spot
increase job satisfaction;
in the point of information technology: simplified material flow speeds up the
implementation of factory automation and simplifies software applications used
to support efficient operations.
The content of Production Flow Analysis
The main method of the PFA is a quantitative analysis of all the material flows
taking place in the factory, and using this information and the alternative
routings to form manufacturing groups that are able to finish a set parts with the
resources dedicated to it. Depending on the scale of the project this logic is
applied on company, factory, group, line and tooling level respectively.
Whichever the case, the work breaks down into the following steps:
to identify and classify all production resources, machines and equipment;
to track the all product and part routes that the company, factory or group
produces;
to analyse the manufacturing network through the main flows formed by the
majority of parts;
to study alternative routings and grouping of the machines to fit parts into a
simplified material flow system;
to further study those exceptional parts not fitting into the grouping of
production resources;
to validate the new material flow system and implementing the scheduling
system based on single -piece flow.
Most production units and their layouts are the result of organic growth, during
which the products have experienced many changes affecting the arsenal of the
equipment in the workshop. This continuously evolving change process leads in
conventional factories into complex material flow systems. PFA reveals the
natural grouping of production resources like the following small-scale yet real-
world example shows.
The Machine-Part matrix as raw data gathered in The Machine-Part matrix reorganised
the first steps of the PFA
into natural groups that finish parts.
Most of our previous cases have focused on the forming of groups in job-
shops, which are part of a larger production facility. These test cases have
been used as eye-openers for the rest of the organisation. Our
recommendation, however, is to continue with PFA on higher level. Product
and component allocation in the whole supply chain combined with product
and customer segmentation is an area where not only vast savings in
operating costs can be achieved, but also competitive advantage can be
created.
Manufacturing science knows numerous cases where complete product-
oriented re-organisation of the company has produced staggering results in
productivity, throughput times and competitive advantage. PFA is one of
the few systematic engineering methods for achieving these results.
Production Flow Analysis was developed by Professor John L. Burbidge of
the Cranfield Institute of Technology.
Facility design using G.T.
Line layout
Group layout, machines grouped by part family
Functional layout, machines grouped by process
Benefits of group technology
Design
Tooling and setups
Material handling
Production and inventory control
Process planning
Employee satisfaction
Cellular manufacturing
Machine cell design
The composite part concept
Types of cell design
Single machine cell
Group machine cell with manual handling
Group machine cell with semi- integrated handling
Flexible manufacturing system
Determining the best machine arrangement
Factors to be considered:
Volume of work to be done by the cell
Variations in process routings of the parts
Part size, shape, weight and other physical attributes
Key machine concept
Role of process planning
Interpretation of product design data
Selection of machining processes.
Selection of machine tools.
Determination of fixtures and datum surfaces.
Sequencing the operations.
Selection of inspection devices.
Determination of production tolerances.
Determination of the proper cutting conditions.
Calculation of the overall times.
Generation of process sheets including NC data.
Approaches to Process planning
Manual approach
Variant or retrieval type CAPP system
Generative CAPP system
CAPP and CMPP (Computer Managed Process Planning)
UNIT – III : SHOP FLOOR CONTROL AND INTRODUCTION OF
FMS
Shop floor control
The three phases of shop floor control
Order release
Order scheduling
Order progress
Factory Data Collection System
On-line versus batch systems
Data input techniques
Job traveler
Employee time sheets
Operation tear strips
Prepunched cards
Providing key board based terminals
o One centralized terminal o Satellite terminals
o Workstation terminals
Automatic identification methods
Bar codes
Radio frequency systems
Magnetic stripe
Optical character recognition
Machine vision
Automated data collection systems
Data acquisition systems
Multilevel scanning
Components of Flexible Manufacturing Systems(FMS)
Workstations
Material handling and storage
Computer control system
Human resources
A flexible manufacturing system (FMS) is a manufacturing system in which
there is some amount of flexibility that allows the system to react in the case of
changes, whether predicted or unpredicted. This flexibility is generally
considered to fall into two categories, which both contain numerous
subcategories.
The first category, machine flexibility, covers the system's ability to be changed to
produce new product types, and ability to change the order of operations
executed on a part. The second category is called routing flexibility , which
consists of the ability to use multiple machines to perform the same operation on
a part, as well as the system's ability to absorb large-scale changes, such as in
volume, capacity, or capability.
Most FMS systems consist of three main systems. The work machines
which are often automated CNC machines are connected by a material
handling system to optimize parts flow and the central control computer
which controls material movements and machine flow.
The main advantages of an FMS is its high flexibility in managing
manufacturing resources like time and effort in order to manufacture a new
product. The best application of an FMS is found in the production of small
sets of products like those from a mass production.
Faster, Lower- cost/unit, Greater labor productivity, Greater machine
efficiency, Improved quality, Increased system reliability, Reduced parts
inventories, Adaptab ility to CAD/CAM operations. Shorter lead times
Disadvantages
Cost to implement.
Training FMS with learning robot SCORBOT-ER 4u, workbench CNC Mill
and CNC Lathe
An Industrial Flexible Manufacturing System (FMS) consists of robots, Computer-
controlled Machines, Numerical controlled machines (CNC), instrumentation
devices, computers, sensors, and other stand alone systems such as inspection
machines. The use of robots in the production segment of manufacturing
industries promises a variety of benefits ranging from high utilization to high vo
lume of productivity. Each Robotic cell or node will be located along a material
handling system such as a conveyor or automatic guided vehicle. The production
of each part or work-piece will require a different combination of manufacturing
nodes. The movement of parts from one node to another is done through the
material handling system. At the end of part processing, the finished parts will be
routed to an automatic inspection node, and subsequently unloaded from the
Flexible Manufacturing System.
CNC machine
The FMS data traffic consists of large files and short messages, and mostly come
from nodes, devices and instruments. The message size ranges between a few
bytes to several hundreds of bytes. Executive software and other data, for
example, are files with a large size, while messages for machining data,
instrument to instrument communications, status monitoring, and data reporting
are transmitted in small size.
There is also some variation on response time. Large program files from a
main computer usually take about 60 seconds to be down loaded into each
instrument or node at the beginning of FMS operation. Messages for
instrument data need to be sent in a periodic time with deterministic time
delay. Other type of messages used for emergency reporting is quite short
in size and must be transmitted and received with almos t instantaneous
response.
The demands for reliable FMS protocol that support all the FMS data
characteristics are now urgent. The existing IEEE standard protocols do not fully
satisfy the real time communication requirements in this environment. The delay
of CSMA/CD is unbounded as the number of nodes increases due to the
message collisions. Token Bus has a deterministic message delay, but it does not
support prioritized access scheme which is needed in FMS communications.
Token Ring provides prioritized access and has a low message delay, however, its
data transmission is unreliable. A single node failure which may occur quite often
in FMS causes transmission errors of passing message in that node. In addition,
the topology of Token Ring results in high wiring installation and cost.
A design of FMS communication protocol that supports a real time
communication with bounded message delay and reacts promptly to any
emergency signal is needed. Because of machine failure and malfunction due
to heat, dust, and electromagnetic interference is common, a prioritized
mechanism and immediate transmission of emergency messages are needed
so that a suitable recovery procedure can be applied. A modification of
standard Token Bus to implement a prioritized access scheme was proposed
to allow transmission of short and periodic messages with a low delay
compared to the one for long messages.
Flexibility in manufacturing means the ability to deal with slightly or greatly mixed
parts, to allow variation in parts assembly and variations in process sequence,
change the production volume and change the design of certain product being
manufactured.
Workstations
Load/unload stations
Machining stations
Other processing stations
Assembly
Material handling and storage systems
Primary material handling
Secondary material handling
FMS layout
In- line layout
Loop layout
Ladder layout
Open field layout
Robot centered layout
Computer control system
Workstation control
Distribution of control instructions to workstations
Production control
Traffic control
Shuttle control
Workpiece monitoring
Tool control
Performance monitoring and reporting
Diagnostics
UNIT – II : COMPONENTS OF CIM
CIM and company strategy
Does that mean the starting point for CIM is a network to link all the
existing islands of automation and software? Or is it the integration of the
existing departmental functions and activities as suggested by the CIM
wheel?
The answer to both the questions just posed is no. the starting point for
CIM is not islands of automation or software, not is it the structure
presented by the CIM wheel, rather it is a company’s business strategy.
System modeling tools
It is helpful if the modeling tool is of sufficient sophistication that it exists in three
forms:
As a representation of the system
As a dynamic model
As an executable model
IDEF and IDEF0
IDEF initially provided three modeling methods
IDEF0 is used for describing the activities and functions of a system
IDEF1 is used for describing the information and its relationships
IDEF2 is used for describing the dynamics of a system
Activity cycle diagrams
This modeling approach follows the notation of IDEF0 by having activities represented
as rectangles and by having the activity names specified inside the rectangle. All
resources which are to be represented in the model are classified as entity classes.
CIM open system architecture(CIMOSA)
CIMOSA was produced as generic reference architecture for CIM integration as
part of an ESPRIT project. The architecture is designed to yield executable
models or parts of models leading to computerized implementations for managing
an enterprise.
Manufacturing enterprise wheel
he new manufacturing enterprise wheel’s focus is now the customer at level 1,
and it identifies 15 key processes circumferentially at level 4. These are
grouped under the headings of customer support, product/process and
manufacturing.
CIM architecture
CIM ARCHITECTURE
CIM Architecture Overview
To develop a comprehensive CIM strategy and solutions, an enterprise must begin
with .solid foundations such as CIM architecture. A CIM architecture is an information
systems structure that enables industrial enterprises integrate information and
business
processes It accomplishes this first by establishing the direction integration will
take; and second, by defining the interfaces between the users and the providers
of this integration function.The chart (Figure 2.1) illustrates how a CIM
architecture answers the enterprise’s integration needs. As you can see here, a
CIM architecture provides a core of common services. These services support
every other area of the enterprise—from its common support functions to its highly
specialized business processes.
2.1.1 Three key building blocks
The information environment of an industrial enterprise is subject to freque nt
changes
in systems configuration and technologies. A CIM architecture can offer a flexible
structure that enables it to react to these changes. This structure relies on a number
of modular elements that allow systems to change more easily to grow along with
enterprise needs. And as you can see from the chart on the facing page, the modular
elements that give a CIM architecture its flexible structure are based on three key
building blocks:
Communications—the communication and distribution of data.
Data management—the definition, storage and use of data
Presentation—the presentation of this data to people and devices
throughout the enterprise
Data dictionary
Data repository and store
A layered structure
Repository builder
Product data management (PDM): CIM implementation
software
The four major modules typically contained within the PDM software are
Process models
Process project management
Data management
Data and information kitting
The PDM environment provides links to a number of software packages
used by a company. They are
A CAD package
A manufacturing/production management package
A word processing package
Databases for various applications
Life-cycle data
Communication fundamentals
A frequency
An amplitude
A phase which continuously changes
A bandwidth
An introduction to baseband and broadband
Telephone terminology
Digital communications
Local area networks
Signal transmission, baseband and broadband
Interconnection media
Topology
Star topology
Ring topology
Bus topology
Tree topology
LAN implementations
Client server architecture
Networks and distributed systems
Multi-tier and high speed LANs
Network management and installation
Security and administration
Performance
Flexibility
User interface
Installation
UNIT – V : OPEN SYSTEM AND DATABASE FOR CIM
Open system interconnection (OSI) model
The physical layer
The data link layer
The network layer
The transport layer
The session layer
The presentation layer
The application layer
Manufacturing automation protocol and technical office
protocol
Basic database terminology
Database management system
Database system
Data model
Transaction
Schema
Data definition language
Data manipulation language
Applications program
Host language
Database administrator
The architecture of a database system
Internal schema
External schema
Conceptual schema
Data modeling and data associations
Data modeling is carried out by using a data modeling method and one of a
number of graphic representations to depict data groupings and the
relationship between groupings.
Data modeling diagram – Entity-Relationship diagram
Data associations
One-to-One
One-to-Many
Many-to-One
Many-to-Many
Relational databases
The terms illustrated are relation, tuple, attribute, domain, primary key and
foreign key.
Database operators
Union
Intersection
Difference
Product
Project
Select
Join
Divide
