COMPUTER INTERGRATED MANUFACTURING

UNIT- I
Introduction to CIM
 Need of CIM (Why CIM!!!)
• In today’s competitive international business environment, companies are
calling for new approaches to manufacturing.

• Moreover, the growth in computer-based technology during the 1980s,

coupled with the emergence of flexible manufacturing systems (FMS) and
just-in-time (JIT) inventory control forced movement away from the
traditional product focused manufacturing paradigms of the mass-
production era to that of a process-focused paradigm.

• Through the use of various computer-aided technologies, computer

integrated manufacturing (CIM) attempts to pull all of the functional areas
of a business into a cohesive, interconnected, interactive, self-aware whole

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 Need of CIM
• CIM includes such activities as product/process design, manufacturing technology,
material acquisition, information resource management and total quality management.

• CIM utilizes enterprise-wide computer-aided technologies to maintain quality, speed, new

product development, minimize costs and maximize flexibility to respond to ever-
changing customer desires

• Thus, the competitive advantage of CIM in industry comes from its ability to:

• Develop a large quantity of new products quickly;

• Produce small production runs of custom-made items efficiently; and

• Maximize the flexibility of the manufacturer in responding quickly to changes in the

environment.

• .
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 Unit 1. Introduction to CIM
Introduction
• 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.

• For example, the product data is created during design. This data has
to be transferred from the modeling software to manufacturing
software without any loss of data.

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 Unit 1. Introduction to CIM
Introduction
• CIM uses a common database wherever feasible and communication
technologies to integrate design, manufacturing and associated business
functions that combine the automated segments of a factory or a
manufacturing facility.

• CIM reduces the human component of manufacturing and thereby relieves

the process of its slow, expensive and error-prone component.

• CIM stands for a holistic and methodological approach to the activities of

the manufacturing enterprise in order to achieve vast improvement in its
performance.

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 Unit 1. Introduction to CIM

• Automation is a dynamic technology that represents a continuous

evolutionary process. It is the process of reducing the human labor by
an automated machines.

• Automation is a technology concerned with the application of

Mechanical, Electrical, Electronic, Computer, Hydraulic and
Pneumatic based system to operate and control production.

• Production systems: A production system is a collection of People,

Equipment and Procedures organized to perform the manufacturing
operations of a company.

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 Evolution of CIM
• Development of numerical control played an important role in the development of CIM.

• In 1947, Parsons Corp. took the challenge of developing a new method of moving the
tool, using numbers and thus numerical control was born.

• Parsons worked with MIT to produce the first NC milling machine in 1954.

• Since then, NC has developed, along with microelectronics and computers, into a

• sophisticated technology that drives modern machining centres, FMSs, etc.

• While NC was evolving on its own, computers were being developed independently.

• They provided an effective tool for carrying out repetitive tasks, storing large amounts of
data and handle various types of mathematical analyses.

• Initially computers were introduced in manufacturing to support payroll and accounting.

• Next computers were extended to inventory control.

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 Evolution of CIM
• Further inroads to manufacturing had to wait until computer graphics matured.
• Today, with enhanced capabilities and lower cost, computers represent an attractive technology.
• Computer-Aided Design (CAD) also played an important role.
• Design involves both creative and repetitive tasks. The repetitive tasks within design are very
appropriate for computerization.
• In the early 1970s, using computers for generating drawings and documentation proved cost-
effective.
• Since then, computer use in design has exploded.
• The computer’s help in designing and drafting is commonly expressed by the term computer-
Aided Design (CAD).
• By this time, NC technology had matured to become cost-effective for applications in machining.
• In the case of components with complex geometries, part programmers had to carry out lengthy
calculations, for which it was logical to use computers. This gave rise to MCUs with built-in
microprocessors.
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 Evolution of CIM
• The use of computers in extending the applications of NC technology to part programming
was earlier termed computer-aided machining (CAM).

• Later CAM became the acronym for computer-aided manufacturing.

• As the use of computers in design and machining broadened under CAD and CAM, it
became evident that certain tasks are common to both.

• Part geometries created during CAD can readily be saved in a database for later use.
• Why re-enter such information again at the MCU?
In the beginning CAD and CAM developed independently of each other.

• Later, when the drawbacks of CAD and CAM compartmentalization were realized, the
logical move from CAD and CAM was to CAD/CAM.

• In the 1970s, another concept – flexible automation – came into being to distinguish this
type of automation from Detroit-type of automation, which is inflexible.
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Evolution of CIM

• CIM is an umbrella term under which all functions of manufacturing

and associated acronyms such as CAD, CAD/CAM, FMS, CAPP find a place.

• Discrete manufacturing has always presented a challenge because of the large

number of factors involved and their interaction.

• CIM is being projected as a panacea for this type of industry, which produces
40% of all goods.

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CIM Hardware

11/1/2023 SNJB's LS K. B. Jain College of Engineering, Chandwad 11

 CIM Hardware
• Manufacturing equipment such as CNC machines or computerized work
centres, robotic work cells, DNC/FMS systems, work handling and tool
handling devices, storage devices, sensors, shop floor data collection devices,
inspection machines etc.

• Computers, controllers, CAD/CAM systems, workstations / terminals, data

entry terminals, bar code readers, RFID tags, printers, plotters and other
peripheral devices, modems, cables, connectors etc.

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CIM Hardware is comprised of the following components:
• Manufacturing equipment:- Workstations, cells, Direct Numerical Control (DNC),

Flexible Manufacturing Systems (FMS), Work, tool handling, and storage devices,

Sensors, and Devices for collecting data from Shop Floor Control (SFC)

• Computer-related hardware items are listed: Computers and computer-related

hardware controllers, printers, plotters, modems, cable, connectors, and workstation

terminals.

• The third part is office equipment.

• Communication hardware items such as: Remote batch terminals are used for

batch processing, Processors in the front end, Transmitters, Acoustic couplers,

Multiplexers, and Concentrators.

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CIM software comprises computer programmes to
carry out the following functions:
• ✓ Modelling and Design • ✓ Business Process
• ✓ Analysis Engineering Network
• ✓ Simulation Management
• ✓ Communications • ✓ Quality Management
• ✓ Monitoring • ✓ Management
• ✓ Production Control Information System
• ✓ Manufacturing Area • ✓ Sales
Control • ✓ Marketing Finance
• ✓ Job Tracking • ✓ Database
• ✓ Inventory Control Management
• ✓ Shop Floor Data
• ✓ Collection Order Entry
• ✓ Materials Handling
• ✓ Process Planning
• ✓ Manufacturing Facilities
Planning
• ✓ Work Flow Automation
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Definition of CIM by (CASA/SME)

CIM is the integration of the total manufacturing enterprise through the

use of computer and data communications coupled with new managerial
philosophies that improve organizational and personnel efficiency. It aims
to integrate all of the

operational and information processing functions in manufacturing

from order receipt, through design and manufacturing, to product
shipment.

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 Unit 1. Introduction to CIM
Automation and Type of Automation

Two categories of automation in the production system:

1. Automation of manufacturing systems in the factory.

2. Computerization of the manufacturing support systems .

• The two categories overlap because manufacturing
support systems are connected to the factory
manufacturing systems.
– Computer-Integrated Manufacturing (CIM).
Computer Integrated Manufacturing
 Automated Manufacturing Systems
Examples:

• Automated machine tools

• Transfer lines

• Automated assembly systems

• Industrial robots that perform processing or assembly operations

• Automated material handling and storage systems to integrate

manufacturing operations

• Automatic inspection systems for quality control

 Automated Manufacturing Systems

Three basic types:

1. Fixed automation
2. Programmable automation
3. Flexible automation
 Fixed Automation

A manufacturing system in which the sequence of processing (or assembly)

operations is fixed by the equipment configuration.

Typical features:

• Suited to high production quantities.

• High initial investment for custom-engineered equipment.

• High production rates.

• Relatively inflexible in accommodating product variety.

 Programmable Automation
A manufacturing system designed with the capability to change the sequence
of operations to accommodate different product configurations.

Typical features:

• High investment in general purpose equipment.

• Lower production rates than fixed automation.

• Flexibility to deal with variations and changes in product configuration.

• Most suitable for batch production.

• Physical setup and part program must be changed between jobs (batches).
 Flexible Automation
An extension of programmable automation in which the system is capable of
changing over from one job to the next with no lost time between jobs.

Typical features:

• High investment for custom-engineered system.

• Continuous production of variable mixes of products.

• Medium production rates.

• Flexibility to deal with soft product variety.

Product Variety and Production Quantity for
Three Automation Types
 Unit 1. Introduction to CIM
Reasons For Automation
1. Increase labor productivity
2. Reduce labor cost
3. Mitigate the effects of labor shortages
4. Reduce or remove routine manual and clerical tasks
5. Improve worker safety
6. Improve product quality
7. Reduce manufacturing lead time
8. Accomplish what cannot be done manually
9. Avoid the high cost of not automating
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 Unit 1. Introduction to CIM
Types of Production
Types of Production system is grouped under two categories :
1. Intermittent Production System
2. Continuous Production System
1. Intermittent Production System
• Intermittent means something that starts (initiates) and stops (halts)
• at irregular (unfixed) intervals (time gaps).
• In the intermittent production system, goods are produced based on customer's
orders.
• These goods are produced on a small scale. The
flow of production is not continuous.
• In this system, large varieties of products are produced. These
• products are of different sizes.
• The design of these products goes on changing according to the design and size of
the product. Therefore, this system is very flexible
 The work of a goldsmith is purely based on the frequency of his customer's

orders. The goldsmith makes goods (ornaments) on a small- scale basis as per his

customer's requirements. Here, ornaments are not done on a continuous basis.

Similarly, the work of a tailor is also based on the number of orders he gets from

his customers. The clothes are stitched for every customer independently by the tailor as per

one's measurement and size. Goods (stitched clothes) are made on a limited scale and is

proportional to the number of orders received from customers. Here, stitching is not done on

a continuous basis.
1. Project Production Flow
2. Jobbing Production Flow
3. Batch Production Flow
1. Project production flows
Here, in project production flows, company accepts a single, complex order
or contract. The order must be completed within a given period of time and at an
estimated cost.

Examples of project production flows mainly include, construction of

airports, dams, roads, buildings, shipbuilding, etc.
2. Jobbing production flows

Here, in jobbing production flows, company accepts a contract to produce either one or

few units of a product strictly as per specifications given by the customer. The product is produced

within a given period and at a fixed cost. This cost is fixed at the time of signing the contract.

Examples of such jobbing production flows include, services given by repair shops,

tailoring shops, manufacturer of special machine tools, etc.

3. Batch production flows

In batch production flows, the production schedule is decided according to

specific orders or are based on the demand forecasts. Here, the production of items takes
place in lots or batches. A product is divided into different jobs. All jobs of one batch of
production must be completed before starting the next batch of production.

Examples of batch production flows include, manufacturing of drugs and

pharmaceuticals, medium and heavy machineries, etc.
Continuous means something that operates constantly without any
irregularities or frequent halts.
In the continuous production system, goods are produced constantly as per
demand forecast.
Goods are produced on a large scale for stocking and selling. They are not
produced on customer's orders. Here, the
inputs and outputs are standardized along with the production
process and sequence.
 The production system of a food industry is purely based on the demand

forecast. Here, a large-scale production of food takes place. It is also a continuous

production.

The production and processing system of a fuel industry is also purely

based on, demand forecast. CRUDE OIL and other raw sources are processed

continuously on a large scale to yield usable form of fuel and compensate global

energy demand.
1.Mass Production Flows
2. Process Production Flows
1. Mass production flows

Here, company produces different types of products on a large- scale and stock them in
warehouses until they are demanded in the market.

The goods are produced either with the help of a single

operation or uses a series of operations.

E.g. of mass production is the production of toothpastes, soaps, pens, etc.

2. Process production flows

Here, a single product is produced and stocked in warehouses until it is

demanded in the market. The flexibility of these plants is almost zero because only one
product can be produced.

Examples of these plants include, steel, cement, paper, sugar, etc

Functions in Manufacturing

For any of the three types of production, there are certain basic functions
that must be carried out to convert raw materials into finished product. For a firm
engaged in making discrete products, the functions are:
1. Processing
2. Assembly
3. Material handling and storage
4. Inspection and test
5. Control

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Functions in Manufacturing

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Functions in Manufacturing
Processing operations
Processing operations transform the product from one state
of completion into a more advanced state of completion.
Processing operations can be classified into one of the
following four categories:
1. Basic processes
2. Secondary processes
3. Operations to enhance physical properties
4. Finishing operations
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 Functions in Manufacturing
• Basic processes are those which give the work material its initial form. Metal
casting and plastic molding are examples. In both cases, the raw materials are
converted into the basic geometry of the desired product.
Secondary processes follow the basic process and are performed to give the work
part its final desired geometry. Examples in this category include machining
(turning, drilling, milling, etc.) and press working operations (blanking, forming,
drawing, etc.).
Operations to enhance physical properties do not perceptibly change the physical
geometry of the work part. Instead, the physical properties of the material are
improved in some way. Heat-treating operations to strengthen metal pans and
preshrinking used in the garment industry are examples in this category.
Finishing operations are the final processes performed on the work part. Their
purpose is, for example, to improve the appearance, or to provide a protective
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Functions in Manufacturing

Above Figure presents an input/output model of a typical

processing operation in manufacturing. Most manufacturing
processes require five inputs:
1. Raw materials
2. Equipment
3. Tooling, fixtures
4. Energy (electrical energy)
5. Labor

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Functions in Manufacturing

Assembly operations
Assembly and joining processes constitute the second major
type of manufacturing operation. In assembly, the
distinguishing feature is that two or more separate components
are joined together. Included in this category are mechanical
fastening operations, which make use of screws, nuts, rivets,
and so on, and joining processes, such as welding, brazing, and
soldering. In the fabrication of a product, the assembly
operations follow the processing operations.
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 Functions in Manufacturing
• Material handling and storage

A means of moving and storing materials between the

processing and assembly operations must be provided. In most
manufacturing plants, materials spend more time being moved
and stored than being processed. In some cases, the majority
of the labor cost in the factory is consumed in handling,
moving, and storing materials. It is important that this
function be carried out as efficiently as possible.

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Functions in Manufacturing

Inspection and testing

Inspection and testing are generally considered part of quality control.
The purpose of inspection is to determine whether the manufactured
product meets the established design standards and specifications. For
example, inspection examines whether the actual
dimensions of a mechanical part are within the tolerances indicated on
the engineering drawing for the part and testing is generally
concerned with the functional specifications of the final product

rather than the individual parts that go into the product.

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Functions in Manufacturing
Control
The control function in manufacturing includes both the regulation of
individual processing and assembly operations, and the management
of plant-level activities. Control at the process level involves the
achievement of certain performance objectives by proper
manipulation of the inputs to the process. Control at the plant level
includes effective use of labor, maintenance of the equipment,
moving materials in the factory, shipping products of good quality on
schedule, and keeping plant operating costs at the minimum level
possible. The manufacturing control function at the plant level
represents the major point of intersection between the physical
operations in the factory and the information-
processing activities that occur in production.

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CIM Wheel

• SME has suggested a framework, the CIM wheel to illustrate the

integration called for in the definition of CIM, and shows the
interrelationship among all the parts of an enterprise.

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CIM Wheel

CASA/SME’s CIM Wheel

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Computerized Elements of CIM

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Computerized Elements of CIM
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 modeling 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.

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Computerized Elements of CIM

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.

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 Computerized Elements of CIM
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.
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Computerized Elements of CIM
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.
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What Exactly Is CIM, and How Does It Function?

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• IGES: Integrated Graphics Exchange Specification
• PDES: Product Data Exchange Standard
• DMIS: Dimensional Measuring Interface Standard
• MAP: Manufacturing Automation Protocol
• STEP: Standard for The Exchange of Product model
data (ISO 10303)
• CASA: Computer and Automated Systems
Association
• SME: Society of Manufacturing Engineers 56
 Advantages 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
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 Advantages of CIM
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.

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 Advantages of CIM
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 %.

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THANK
YOU!!!

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