Computer Integrated Manufacturing (CIM) System:

A comprehensive approach that integrates all manufacturing activities through the use of
computer systems.

The CIM Wheel is a visual model showing four key functional elements working together with
centralized data flow.

---

1. Product Design:

The starting point of the manufacturing process.

Involves Computer-Aided Design (CAD) tools to create 3D models, drawings, specifications,

Includes design analysis, tolerance studies, and design validation.

Output used directly in downstream CIM functions.

Strongly linked with Product Data Management (PDM) systems.

---

2. Process Planning:

Translates product designs into step-by-step manufacturing plans.

Uses Computer-Aided Process Planning (CAPP) systems.

Determines machines, tools, operation sequences, and setup instructions.

Optimizes cost, time, and resource usage.

Bridges the gap between design and actual manufacturing.

---

3. Process Control:

Ensures production is executed as per the plan, maintaining quality and precision.

Involves real-time monitoring and control of machines using CNC, PLCs, and sensors.
Implements feedback loops, statistical process control (SPC), and automated inspection
systems.

Maintains consistency, reduces defects, and improves efficiency.

---

4. Business Function:

Supports overall manufacturing with administrative and strategic activities.

Includes Enterprise Resource Planning (ERP), Materials Requirement Planning (MRP), costing,
inventory, and customer management.

Integrates marketing, sales, HR, and finance with the production floor.

Ensures data-driven decision-making and synchronization of operations.

---

CIM Wheel Concept:

Shows all four elements (Product Design, Process Planning, Process Control, Business
Function) as interconnected spokes around a central database.

Central data communication system enables seamless flow and integration.

Leads to automation, flexibility, and increased productivity in manufacturing.

___________________________________________

Part Programming:

The process of preparing a set of coded instructions (program) that directs a CNC machine to
perform specific operations.

The program defines tool paths, cutting speeds, feed rates, and operation sequences.

Instructions are written in G-codes and M-codes, which are interpreted by the machine
controller.

---

Manual Part Programming:

Programmer must have detailed knowledge of:

Machine tool functions

CNC codes (G/M codes)

Coordinate systems

Machining process and tooling

Suitable for simple parts and 2-axis machining operations.

Time-consuming and prone to human error.

Example:

N10 G00 X0 Y0
N20 G01 X20 Y20 F100
N30 M30

---

Computer-Assisted Part Programming (CAPP):

Uses software tools and CAD/CAM systems to generate CNC programs automatically.

Programmer inputs design and machining parameters, and the system generates optimized
G-code.

Advantages:

Faster and more accurate than manual programming

3D visualization and simulation of tool paths

Easy to handle complex geometries and multi-axis operations

Common tools: Mastercam, NX, CATIA, Fusion 360, SolidCAM

___________________________________________

NC (Numerical Control) Machines:

Machines controlled by a set of programmed instructions using numbers, letters, and symbols.
Offer higher precision, repeatability, and automation than conventional (manual) machines.

Advantages of NC Machines over Conventional Machines:

1. Higher Accuracy:

Precise control over motion and dimensions through programmed instructions.

Reduces human error.

2. Improved Repeatability:

Can produce identical parts in large quantities with consistent quality.

3. Increased Productivity:

Faster operation due to automated control, reduced setup, and lower idle time.

4. Reduced Operator Skill Requirement:

Basic machine operation knowledge is sufficient; no need for skilled manual machining.

5. Greater Flexibility:

Easy to change programs for different parts—ideal for low-volume, high-variety production.

6. Complex Geometry Handling:

Capable of machining intricate shapes and multi-axis profiles not feasible on manual machines.

7. Lower Scrap and Rework Rates:

Due to consistent accuracy and fewer manual interventions.

8. Integration with CAD/CAM:

Supports automated manufacturing through seamless data transfer.

9. Reduced Setup Time:

Pre-set tooling and stored programs speed up machine setup.

10. Better Safety and Ergonomics:

Less manual handling reduces operator fatigue and enhances workplace safety
___________________________________________

Modern CNC (Computer Numerical Control) Machines:

Equipped with state-of-the-art technologies for improved accuracy, flexibility, and automation.

Key Features of Modern CNC Machines:

1. Multi-Axis Control:

Support for 3, 4, 5 or more axes to perform complex machining operations in one setup.

2. High-Speed Machining (HSM):

Capable of operating at very high spindle speeds and feed rates for increased productivity.

3. Automatic Tool Changer (ATC):

Enables automatic switching between different tools without stopping the machine.

4. Precision Feedback Systems:

Use of linear encoders and rotary encoders for real-time position accuracy.

5. Closed-Loop Control System:

Continuously compares actual machine output with programmed input and corrects deviations.

6. Integration with CAD/CAM:

Direct import of part designs and tool paths from CAD/CAM software.

7. Touchscreen and GUI Interfaces:

User-friendly controls with graphical displays, touch input, and simulation.

8. On-Machine Probing:

For in-process inspection and automatic adjustment of tool offsets.

9. Network and IoT Connectivity:

Supports remote monitoring, data logging, and smart factory integration (Industry 4.0).

10. Adaptive Control:

Adjusts cutting conditions automatically based on tool wear or material behavior.

Equipped with automatic interlocks, error detection, and real-time diagnostics.

Automated Storage System (ASS):

A computer-controlled system that automatically handles, stores, and retrieves materials or

Commonly used in warehousing, manufacturing, and distribution centers.

Includes components like storage racks, shuttles, conveyors, and robotic arms.

Types of Automated Storage Systems:

Automated Storage and Retrieval System (AS/RS)

Carousel Systems (Vertical/Horizontal)

Shuttle-Based Systems

Mini Load and Unit Load Systems

Advantages of Automated Storage Systems:

1. Space Efficiency:

Maximizes vertical and horizontal space usage, reducing facility footprint.

2. Increased Throughput:

Fast and precise retrieval and storage operations, improving productivity.

3. Reduced Labor Costs:

Minimizes reliance on manual labor for storage and material handling.

4. Improved Inventory Accuracy:

Real-time inventory tracking and error reduction through automation.

5. Enhanced Safety:

Reduces accidents by limiting human interaction with heavy or high-stacked items.

6. Better Material Handling:

7. Integration with ERP Systems:

Seamless communication with enterprise systems for inventory control and order management.

8. Reduced Lead Time:

Speeds up order processing and shipping, improving customer service.

9. 24/7 Operation:

Capable of continuous operation without fatigue or downtime

Cellular Manufacturing:

A lean manufacturing approach that arranges machines and workstations into cells, each
designed to produce a family of similar parts or products.

Each cell is a small, self-contained production unit with all necessary equipment and labor.

Based on the principles of Group Technology (GT), which groups similar parts to streamline
production.

Enhances flow efficiency, reduces material handling, and encourages team responsibility.

___________________________________________

Optiz Coding System:

A hybrid coding system used in Group Technology (GT) to classify and code parts based on
design and manufacturing attributes.

Developed in Germany by H. Opitz.

Code structure: 9-digit alphanumeric code divided into form code and supplementary code.

General format: XXXXX – XXXX

First 5 digits: Form code – Describes design features (shape, dimensions, holes, etc.).

Last 4 digits: Supplementary code – Includes manufacturing-related info (material type,

Advantages:

Useful in part classification, machine grouping, inventory control.

Supports design retrieval and standardization.

M1 Class Coding System:

A hierarchical coding system used to classify parts based on their geometry and manufacturing
characteristics.

Commonly applied in industries using group technology.

The code is structured hierarchically, where each digit represents a specific feature or category.

Emphasis is placed on manufacturing aspects like type of operation, sequence, and tools
required.

Helps in organizing parts into families for process planning and production control.

Advantages:

Facilitates efficient machine grouping and routing.

Aids in automated process planning.

Useful for similarity analysis of components.