ME2402 COMPUTER INTEGRATED MANUFACTURING

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 just-in-time
(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 its 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. Its 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 atte mpt 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 ne w 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
companys 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

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 inprocess parts

Role of GT in CAD/CAM integration

1. Identifying the part families.
2. 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

1. visual inspection
2. parts classification and coding system
3. production flow analysis

Parts classification and coding system

1. system based on part design attributes
2. system based on manufacturing attributes
3. system based on design and manufacturing attributes

Methods of coding
1. hierarchical coding
2. poly code
3. decision tree coding
Coding system
1. OPITZ system
2. DCLASS
3. MICLASS etc.

Production flow analysis (PFA)

Various steps of PFA
1. Data collection
2. Part sorting and routing
3. PFA chart
4. 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 organisations 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 workers 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
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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 realworld example shows.
The Machine-Part matrix as raw data gathered in the first
steps of the PFA

The Machine-Part matrix reorganised

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.

1. Line layout
2. Group layout, machines grouped by part family
3. Functional layout, machines grouped by process

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Benefits of group technology

1. Design
2. Tooling and setups
3. Material handling
4. Production and inventory control
5. Process planning
6. Employee satisfaction

Cellular manufacturing
Machine cell design
The composite part concept

Types of cell design

1. Single machine cell
2. Group machine cell with manual handling
3. Group machine cell with semi- integrated handling
4. 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

1. Interpretation of product design data
2. Selection of machining processes.
3. Selection of machine tools.
4. Determination of fixtures and datum surfaces.

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5. Sequencing the operations.

6. Selection of inspection devices.
7. Determination of production tolerances.
8. Determination of the proper cutting conditions.
9. Calculation of the overall times.
10. Generation of process sheets including NC data.

Approaches to Process planning

1. Manual approach
2. Variant or retrieval type CAPP system
3. 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
1. Order release
2. Order scheduling
3. 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

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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.

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Advantages
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.

Industrial FMS Communication

Training FMS with learning robot SCORBOT-ER 4u, workbench CNC Mill and CNC
Lathe
An Industrial Flexible Manufacturing System (FMS) consists of robots, Computercontrolled 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 volume 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.

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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
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

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Assembly

Material handling and storage systems

Primary material handling

Secondary material handling

In- line layout

Loop layout

Ladder layout

Open field layout

Robot centered layout

FMS 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

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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 companys 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.

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Manufacturing enterprise wheel

he new manufacturing enterprise wheels 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
enterprises integration needs. As you can see here, a CIM architecture provides a core of
common services. These services support every other area of the enterprisefrom 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:
Communicationsthe communication and distribution of data.
Data managementthe definition, storage and use of data
Presentationthe presentation of this data to people and devices throughout the
enterprise

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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

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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

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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

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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

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