1) Explain different functions of CIM

CIM (Computer Integrated Manufacturing) is a system that integrates different

technologies and software applications to automate various aspects of the
manufacturing process. Here are some of the functions of CIM in a flexible
manufacturing system:
1. Design and Engineering: CIM enables the use of computer-aided design
(CAD) and computer-aided engineering (CAE) software to design and simulate
products and manufacturing processes. This helps in reducing errors and
optimizing the design.
2. Planning and Scheduling: CIM facilitates the use of computer-aided
manufacturing (CAM) software to create production plans and schedules. This
helps in optimizing the use of resources and minimizing cycle time.
3. Management and Control: CIM helps in monitoring and controlling the
manufacturing process using various sensors controllers and feedback
mechanisms. This ensures that the process is running smoothly and any deviations
are detected and corrected in real-time.
4. Quality Control: CIM helps in incorporating quality control into the
manufacturing process through the use of sensors inspection systems and data
analysis tools. This helps in ensuring that the final product meets the required
quality standards.
5. Inventory Control: CIM helps in automating inventory management through
the use of barcodes RFID and other technologies. This helps in reducing waste and
optimizing the use of resources.

2) Explain with block diagram the main elements of CIM system

i. Marketing: The need for a product is identified by the marketing division.

The specifications of the product, the projection of manufacturing quantities and
the strategy for marketing the product are also decided by the marketing
department.
Marketing also works out the manufacturing costs to assess the economic viability
of the product.
ii. Product Design: The design department of the company establishes the
initial database for production of a proposed product. In a CIM system this is
accomplished through activities such as geometric modelling and computer aided
design while considering the product requirements and concepts generated by the
creativity of the design engineer. Configuration management is an important
activity in many designs. Complex designs are usually carried out by several teams
working simultaneously, located often in different parts of the world. The design
process is constrained by the costs that will be incurred in actual production and by
the capabilities of the available production equipment and processes. The design
process creates the database required to manufacture the part.
iii. Planning: The planning department takes the database established by the
design department and enriches it with production data and information to produce
a plan for the production of the product. Planning involves several subsystems
dealing with materials, facility, process, tools, manpower, capacity, scheduling,
outsourcing, assembly, inspection, logistics etc. In a CIM system, this planning
process should be constrained by the production costs and by the production
equipment and process capability, in order to generate an optimized plan.
iv. Purchase: The purchase departments is responsible for placing the purchase
orders and follow up, ensure quality in the production process of the vendor,
receive the items, arrange for inspection and supply the items to the stores or
arrange timely delivery depending on the production schedule for eventual supply
to manufacture and assembly.
v. Manufacturing Engineering: Manufacturing Engineering is the activity of
carrying out the production of the product, involving further enrichment of the
database with performance data and information about the production equipment
and processes. In CIM, this requires activities like CNC programming, simulation
and computer aided scheduling of the production activity. This should include
online dynamic scheduling and control based on the real time performance of the
equipment and processes to assure continuous production activity. Often, the need
to meet fluctuating market demand requires the manufacturing system flexible and
agile.
vi. Factory Automation Hardware: Factory automation equipment further
enriches the database with equipment and process data, resident either in the
operator or the equipment to carry out the production process. In CIM system this
consists of computer controlled process machinery such as CNC machine tools,
flexible manufacturing systems (FMS), Computer controlled robots, material
handling systems, computer controlled assembly systems, flexibly automated
inspection systems and so on.
vii. Warehousing: Warehousing is the function involving storage and retrieval of
raw materials, components, finished goods as well as shipment of items. In today's
complex outsourcing scenario and the need for just-in-time supply of components
and subsystems, logistics and supply chain management assume great importance.
viii. Finance: Finance deals with the resources pertaining to money. Planning of
investment, working capital, and cash flow control, realization of receipts,
accounting and allocation of funds are the major tasks of the finance departments.
ix. Information Management: Information Management is perhaps one of the
crucial tasks in CIM. This involves master production scheduling, database
management, communication, manufacturing systems integration and management
information systems

.
3) Explain in brief benefits obtained by CIM
Benefits of CIM

1.CIM improves the short run responsiveness consisting of :

Engineering changes
Processing changes
Machine down time or unavailability
Operator unavailability
Cutting tool failure
Late material delivery

2.CIM improves long run accommodations through quicker and easier assimilation
of :
Changing product volumes
New product additions and introductions
Different part mixes

3.CIM reduces inventory by Reducing

lot sizes
Improving inventory turnovers
Providing the planning tools for Just – in Time manufacturing
4.CIM increase machine utilization by :
Eliminating or reducing machine setup
Utilizing automated features to replace manual intervention to the extent possible
Providing quick transfer devices to keep the machines in the cutting cycle.

Some quantifiable benefits achieved by apply CIM are : Engineering

design costs can be reduced by 15 to 30 %.
The overall lead times can be reduced by 30 to 60 %.
The product quality can be increased dramatically, as measured by the yield of
acceptable product, offering 2 to 5 times the previous level.
Productivity of the manufacturing operations can be increased by 40 to 70 %.
Operating time related productivity can be increased by 2 to 3 times.
The productivity of engineers and engineering managers can be increased by 5 to
35 times, measured in terms of extent and depth of analysis in the same or less
time.
Work in process can be reduced by 30 to 60 %.

4) What is computer aided inspection (CAI)and how can we control quality

with the help of CAI ?

Computer Aided Inspection (CAI) is a new technology that enables one to develop
a comparison of a physical part to a 3D CAD model. This process is faster, more
complete, and more accurate than using a Coordinate Measuring Machine (CMM)
or other more traditional methods. An automatic inspection method and apparatus
using structured light and machine vision camera is used to inspect an object in
conjunction with the geometric model of the object. Camera images of the object
are analyzed by computer to produce the location of points on the object’s surfaces
in three dimensions. Point-cloud data is taken from a laser scanner or other 3-D
scanning device. During a setup phase before object inspection, the points are
analyzed with respect to the geometric model of the object. The software provides
a graphical comparison of the manufactured part compared to the CAD model.
Many points are eliminated to reduce data-taking and analysis time to a minimum
and prevent extraneous reflections from producing errors. When similar objects are
subsequently inspected, points from each surface of interest are spatially averaged
to give high accuracy measurements of object dimensions. The inspection device
uses several multiplexed sensors, each composed of a camera and a structured light
source, to measure all sides of the object in a single pass.
Computer aided inspection (CAI) is a method of automating inspection processes
with the help of computer software and hardware. It enables inspectors to carry out
inspections faster more accurately and with less human error. Here are some ways
CAI can help control quality:
1. Automated inspection: CAI can automate inspection processes reducing the
chances of human error and inconsistencies. Using computerized measuring tools
inspectors can measure and analyze parts with greater precision.
2. Real-time feedback: CAI provides real-time feedback during inspection
allowing for immediate adjustments to be made if necessary. This leads to faster
decisions on whether a part meets the required specifications or not reducing the
risk of faulty products.
3. Improved accuracy: CAI systems can be calibrated to provide accurate
measurements of dimensions tolerances and surface finishes. The results are more
precise compared to manual inspections improving the accuracy of the quality
control process.
4. Increased efficiency: CAI enables inspectors to work more efficiently
reducing the amount of time it takes to complete inspections. This accelerates the
production process reducing lead times and ensuring that products reach customers
faster.
5. Easily store and analyze inspection data: CAI systems can store inspection
results in a digital format making it easy to analyze trends in quality data. This
helps in identifying areas that require improvements reducing potential defects and
non-conformities.
Overall CAI provides numerous benefits for controlling quality in the
manufacturing process. By automating inspections reducing human error and
providing real-time feedback CAI can help improve efficiency accuracy and
consistency in the quality control process.
5) What is a material requirement planning? Explain the various inputs to the
MRP system?
Material Requirement Planning (MRP) is a critical component of a Flexible
Manufacturing System (FMS). It is a computer-based system that uses information
on sales orders inventory levels and production schedules to determine raw
material requirements and ensure that the right materials are available at the right
time.
In an FMS MRP helps to ensure that the production process runs smoothly by
providing a tool for controlling the flow of materials. This is accomplished by
generating material requirements based on the production schedule which in turn is
driven by the customer demand. The MRP system then creates a list of raw
materials and components required for each stage of production.
Once the raw material requirements are established the MRP system can then
determine the timing of purchases and deliveries based on lead times required to
manufacture or purchase the materials required.
Because an FMS is flexible and adaptable the MRP system must be equally
adaptable to be effective. As production schedules and customer demands change
the MRP system must be able to rapidly recalculate material requirements to
ensure that the production process is not interrupted.
In summary MRP is a critical component of an FMS as it ensures that raw
materials are available when they are needed for each stage of production.
Effective MRP enables businesses to achieve higher levels of efficiency and
productivity and ultimately to better meet customer needs.

Inputs to MRP:
1. Supplier lead time: supplier lead time need to be an essential part of how you
plan production.
2. On hand inventory: If resource material is available in inventory, then there is no
necessity to purchase new. This saves money. This helps to optimize on the
materials already in the inventory. Keeping promises of customers is also easy.
3. Current forecasting: if there is knowledge about what you have already
forecasted, then this can alert the organization to make changes that need to be
made. This helps to line up demand and inventory.
4. Work and machine center capacity:
• Knowledge person capacity is a must to do MRP.
• Whenever a customer wants material, we should make it available to the
customer.
• If capacity at work is known, then the planning of material available for dispatch
can be calculated.
• As per such calculation, we can give promises to the customers.
5. Order history and season:
• There should be an idea about seasonal trends.
• This knowledge helps to optimize production rate as per the demands. Also, in
addition to the above, the following are a few more inputs for effective MRP.
6. Price trends of the materials.
7. Import policy of the government.

6) Explain in detail ERP II

ERP II also known as extended ERP or ERP 2.0 is an advancement of traditional
ERP systems. It expands the scope of ERP by integrating additional functionalities
such as customer relationship management (CRM supply chain management (SCM
and business intelligence (BI) tools. ERP II emphasizes collaboration information
sharing and transparency both within and outside the organization.
ERP II offers a more comprehensive view of the organization's operations through
the integration of various departments/vendors/customers with particular emphasis
on the end-to-end supply chain. This makes it easier to exchange information and
collaborate across departments/organizations thus optimizing business processes
and enhancing decision-making.
Unlike traditional ERP systems ERP II leverages advanced technology such as
cloud computing IoT and artificial intelligence to provide real-time visibility into
business operations automate processes and improve supply chain management. It
provides end-users with a rich user experience through intuitive dashboards and
KPIs that enable easy tracking of performance metrics.
Another Significant advantage of ERP II is its ability to support emerging
technologies such as blockchain and virtual reality. For instance blockchain can be
used to improve transparency in supply chain processes by providing a
tamperevident record of all transactions between parties. Virtual reality on the
other hand can be used to enhance training and simulation in manufacturing and
other industries.
ERP II is an advancement of traditional ERP systems offering additional
functionalities such as customer relationship management supply chain
management business intelligence tools and leveraging advanced technology to
optimize business processes and support emerging technologies. It provides
endusers with a comprehensive view of the organization's operations thereby
enhancing decision-making and collaboration across departments and
organizations.

7) Explain about computer aided process planning (CAPP)

CAPP is a link between the CAD and CAM modules.

Process planning is concerned with determining the sequence of individual
manufacturing operations needed to produce a given part or product.
The resulting operation sequence is documented on a form typically referred to as a
" Route Sheet" (also called a process sheet/method sheet) containing a listing of the
production operations and associated machine tools for a work part or assembly.
Process planning in manufacturing also refers to the planning of use of blanks,
spare parts, packaging material, user instructions (manuals), etc.
As the term "computer-aided production planning" is used in different contexts on
different parts of the production process; to some extent, CAPP overlaps with the
term "PIC" (production and inventory control).
As the design process is supported by many computer-aided tools, computer-aided
process planning (CAPP) has evolved to simplify and improve process planning
and achieve more effective use of manufacturing resources.

Process Planning is of two types:

Generative type computer-aided process planning.
Variant type process planning.
Routings that specify operations, operation sequences, work centers, standards,
tooling, and fixtures. This routing becomes a major input to the manufacturing
resource planning system to define operations for production activity control
purposes and define required resources for capacity requirements planning
purposes.
Computer-aided process planning initially evolved as a means to electronically
store a process plan once it was created, retrieve it, modify it for a new part and
print the plan.
Other capabilities were table-driven cost and standard estimating systems, for sales
representatives to create customer quotations and estimate delivery time.

8) How Material Requirement Planning works ?

MRP helps businesses and manufacturers define what is needed, how much is
needed, and when materials are needed and works backward from a production
plan for finished goods.
MRP converts a plan into a list of requirements for the subassemblies, parts, and
raw materials needed to produce a final product within the established schedule.
MRP helps manufacturers get a grasp of inventory requirements while balancing
both supply and demand.
Using MRP, managers can determine their need for labor and supplies and improve
their production efficiency by inputting data into the MRP scheme such as:
Item Name or Nomenclature: The finished good title, sometimes called Level "0"
on BOM.
Master Production Schedule (MPS): How much is required to meet demand? When
is it needed?
Shelf life of stored materials.
Inventory Status File (ISF): Materials available that are in stock and materials on
order from suppliers.
Bills of materials (BOM): Details of materials and components required to make
each product.
Planning data: Restraints and directions like routing, labor and machine standards,
quality and testing standards, and lot sizing techniques.
9) Explain the concept of ERP
Enterprise resource planning (ERP) refers to a type of software that organizations
use to manage day-to-day business activities such as accounting, procurement,
project management, risk management and compliance, and supply chain
operations.
Enterprise resource planning (ERP) is a platform companies use to manage and
integrate the essential parts of their businesses. Many ERP software applications
are critical to companies because they help them implement resource planning by
integrating all the processes needed to run their companies with a single system.
An ERP software system can also integrate planning, purchasing inventory, sales,
marketing, finance, human resources, and more.

KEY TAKEAWAYS
ERP software can integrate all of the processes needed to run a company.
ERP solutions have evolved over the years, and many are now typically web-based
applications that users can access remotely.
Some benefits of ERP include the free flow of communication between business
areas, a single source of information, and accurate, real-time data reporting.
There are hundreds of ERP applications a company can choose from, and most can
be customized.
An ERP system can be ineffective if a company doesn't implement it carefully.

10) Briefly explain Extended Enterprises?

An extended enterprise is a loosely coupled, self-organizing network of firms that

combine their economic output to provide products and services offerings to the
market. Firms in the extended enterprise may operate independently, for example,
through market mechanisms, or cooperatively through agreements and contracts.
They provide value added service or product to the OEM (Original Equipment
Manufacturer).
Extended enterprise is a more descriptive term than supply chain, in that it permits
the notion of different types and degrees and permanence of connectivity.
How an extended enterprise is organized and structured and its policies and
mechanisms for the exchange of information, goods, services and money is
described by the enterprise architecture.[2]
The notion of the extended enterprise has taken on more importance as firms have
become more specialized and inter-connected, trade has become more global,
processes have become more standardized and information. The standardization of
business processes has permitted companies to purchase as services many of the
activities that previously had been provided directly by the business entity. By
outsourcing certain business functions that had been previously self-provided, such
as transportation, warehousing, procurement, public relations, information
technology, firms have been able to concentrate their resources on those
investments and activities that provide them the greatest rate of return.