Automation (21-541)

Advanced Manufacturing Laboratory

Department of Industrial Engineering
Sharif University of Technology

Session # 2
Session Schedule

 Automation & CIM relation with enterprise information systems (ERP,

Accounting, Inventory, marketing…)
 Automation and CIM development history

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 2

Automation (21541), Session # 2
Introduction to manufacturing automation and CIM (Computer Integrated Manufacturing)

 Automation:
 set of all measures aiming at replacing human work through machines
(e.g. automation is applied science)
 the technology used for this purpose
(e.g. this company has an automation department)
 Automation:
 replacement of human work through machines
(e.g. the automatisation of the textile factory caused uproar of the workers)
 replacement of conscious activity by reflexes
(e.g. drill of the sailors allows the automatisation of ship handling)
 Automation:
 The use of computers and machines instead of people to do a job

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 3

Automation (21541), Session #2
Introduction to manufacturing automation and CIM (Computer Integrated Manufacturing)

 Automation:
 Set of all measures aiming at replacing human work through machines
(e.g. automation is applied science)
 The technology used for this purpose
(e.g. this company has an automation department)
 Automation:
 Replacement of human work through machines
(e.g. the automatisation of the textile factory caused uproar of the workers)
 Replacement of conscious activity by reflexes
(e.g. drill of the sailors allows the automatisation of ship handling)
 Automation:
 The use of computers and machines instead of people to do a job

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 4

Automation (21541), Session #2
Introduction to manufacturing automation and CIM (Computer Integrated Manufacturing)

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 5

Automation (21541), Session #2
Introduction to manufacturing automation and CIM (Computer Integrated Manufacturing)

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 6

Automation (21541), Session #2
Automation engineer characteristics
 Curiosity: I want to understand
 Learn-hungry: I learn fast – my knowledge is volatile
 Basic Physics: I can make a model of my world
 Mathematics I know how to calculate
 Programming: I can structure
 Systematic Work: I can plan …
 Initiative: I can try….

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 7

Automation (21541), Session #2
Introduction to manufacturing automation and CIM (Computer Integrated Manufacturing)

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 8

Automation (21541), Session #2
Introduction to manufacturing automation and CIM (Computer Integrated Manufacturing)

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 9

Automation (21541), Session #2
Introduction to manufacturing automation and CIM (Computer Integrated Manufacturing)

 Computer Integrated Manufacturing (CIM) encompasses

 The entire range of product development and manufacturing activities with all the functions being carried
out
 With the help of dedicated software packages.
 The data required for various functions are passed from one application software to another in a seamless
manner
 CIM considers
 All activities from the design of the product to customer support in an integrated way,
 Using various methods, means and techniques in order to achieve
 Production improvement,
 Cost reduction,
 Fulfillment of scheduled delivery dates,
 Quality improvement
 Total flexibility in the manufacturing system.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 10
Automation (21541), Session #2
Introduction to manufacturing automation and CIM (Computer Integrated Manufacturing)

 Types of manufacturing systems

 Project shop
 Job shop
 Batch production system
 Flow line

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 11

Automation (21541), Session #2
 Project shop

 Characteristics
 product's position remains fixed during manufacturing
because of its size and/or weight

 Materials, people, and machines are brought to the

product as needed.

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 12

Automation (21541), Session #2
 Job shop
 Characteristics
 Machines with the same or similar material processing capabilities
are grouped together

 The machines are usually general-purpose machines, which can

accommodate a large variety of part types

 Material handling is very flexible in order to accommodate many

different part types

 Within each work center, a number of machines can be used for a

particular operation.

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 13

Automation (21541), Session #2
 Job shop
 Characteristics
 Each operation can be assigned to a machine, which yields the best
quality or the best production rate

 Machines can be evenly loaded

 Machine breakdowns can be accommodated easily.

 Requires making and implementing complex decisions in real time.

 Parts spending a long time on the job shop

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 14

Automation (21541), Session #2
 Batch production
 Characteristics
 The equipment or machinery is grouped according to the
process combinations that occur in families of parts

 Each cell contains machines that can produce a certain family

of parts

 Intra-cellular material flow can be performed either

automatically or manually

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 15

Automation (21541), Session #2
 Flow line
 Characteristics
 machines and other equipment are ordered according to the
process sequences of the parts to be manufactured

 Only one part type is produced at a time

 The machines are linked by automated material handling

devices, such as conveyors.

 lot size of each part is high enough to guarantee that the

capacity of the equipment will be fully exploited and not wasted
on the setups

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 16

Automation (21541), Session #2
Manufacturing Systems

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 17

Automation (21541), Session #2
Manufacturing Systems
Type Job shop Batch Production Flow line

Machine allocation same or similar material grouped according to the process ordered according to the
processing capabilities are combinations that occur in families process sequences of the parts
grouped together of parts to be manufactured

Machine Types general-purpose machines machines produce a certain family of

parts

Material handling flexible Intra-cellular material automated material handling

flow can be performed either devices,
automatically or manually

Product Variety High Medium Low

Product Quantity Low Medium High

WIP High Medium Low

Material Flow Complicated material flow within the Smooth

cell may differ for different parts of a
part family

Product type specialized and customized Family Part One type of product

Labor highly skilled Medium Not skill

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 18

Automation (21541), Session #2
Automation and CIM development history
 Fixed automation
 Uses mechanical, electrical, pneumatic and hydraulic systems
 Is widely used in automobile manufacturing

 Fixed automation examples

 Single spindle automatic lathe
 Multi spindle automatic lathe
 Transfer lines

 Fixed automation limitations

 It is designed for a particular product
 Any product change will require extensive modifications to the automation system.

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 19

Automation (21541), Session # 2
Automation and CIM development history (continue …)
 Programmable automation
 Electrically controlled systems
 Programs were stored in punched cards and punched tapes

 Programmable automation examples

 Electrical programmed controlled milling machines
 Hydraulically operated Automatic lathes with programmable control drum
 Sequencing machines with punched card control /plug board control

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 20

Automation (21541), Session # 2
Introduction to manufacturing automation and CIM (Computer Integrated Manufacturing)

 Computer Integrated Manufacturing (CIM) encompasses

 The entire range of product development and manufacturing activities with all the functions being carried
out
 With the help of dedicated software packages.
 The data required for various functions are passed from one application software to another in a seamless
manner
 CIM considers
 All activities from the design of the product to customer support in an integrated way,
 Using various methods, means and techniques in order to achieve
 Production improvement,
 Cost reduction,
 Fulfillment of scheduled delivery dates,
 Quality improvement
 Total flexibility in the manufacturing system.
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 21
Automation (21541), Session # 2
Automation & CIM
 The advances in automation have enabled industries to develop
“Islands of automation”
 Islands of automation examples are :
 Flexible manufacturing cells
 Robotized work cells
 Flexible inspection cells

 CIM tries to achieve the consolidation and integration of these islands of automation.

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 22

Automation (21541), Session # 2
Automation & CIM (Continued… )
 Consolidation and integration of “Islands of automation” requires:
 Sharing of information among different applications or sections of a factory (Collaboration)
 Accessing incompatible and heterogeneous data and devices (Interoperability)

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 23

Automation (21541), Session # 2
Automation & CIM (Continued… )
 Advantages of Automated Manufacturing:
 Improved work flow

 Reduced handling

 Simplification of production

 Reduced lead time

 Increased moral in workers (after a wise implementation)

 More responsive to quality, and other problems

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 24

Automation (21541), Session # 2
CIM history
 Computer-Aided Design (CAD) & Computer-Aided Manufacturing (CAM) were the
first areas for “Automation islands integration”

 Massachusetts Institute of Technology (MIT, USA) is credited with pioneering the

development in both CAD and CAM

 The need to meet the design and manufacturing requirements of aerospace industries
after the Second World War necessitated the development CIM technologies.

 US Air Force approaches MIT to develop suitable control systems, drives and
programming techniques for machine tools using electronic control

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 25

Automation (21541), Session # 2
CIM history (Continued… )
 CAD in fact owes its development to the APT language project at MIT in early 50’s.
 APT (Automatically Programmed Tool)

 P1 = POINT / 50, 50, 0

 P2 = POINT / 20, -20, 0
 C1 = CIRCLE / CENTER, P2, RADIUS, 30
 P3 = POINT / -50, -50, 0
 …
 SPINDL / 3000, CW
 FEDRAT / 100, 0
 …
 GOFWD / C1, TANTO, L2
 GOFWD / L2, PAST, L3
Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 26
Automation (21541), Session # 2
CIM history (Continued… )
 By 80’s, the automation in design was well progressed.

 In the case of manufacture, CNC machines, DNC systems, FMC, FMS … provide
tightly controlled automation systems

 Also computer control has been implemented in several areas like

 Manufacturing resource planning
 Accounting
 Sales
 Marketing
 Purchase

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 27

Automation (21541), Session # 2
CIM history (Continued… )
 CIM scope within the enterprises:
 Marketing
 Product Design
 Planning
 Purchase
 Manufacturing Engineering
 Factory Automation Hardware
 Warehousing
 Logistics and Supply Chain Management
 Finance
 Information Management

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 28

Automation (21541), Session # 2
CIM history (Continued… )

Advanced Manufacturing Laboratory, Department of Industrial Engineering, Sharif University of Technology 29

Automation (21541), Session # 2