COMPUTER INTEGRATED

MANUFACTUTRING

VIGIL J VIJAYAN
Dept. of Mechanical Engineering
NIT Calicut
Introduction
Progressive opportunities in international markets have led to significant new
competitive pressures on industry.
 This resulted in changes in organizational structures at the product design
level through the prologue of computer-integrated manufacturing (CIM) and
concurrent engineering (CE) philosophy, and now in changes in industry
structures as companies build worldwide manufacturing relationships.
 Taking these issues into consideration leads to a recognition that the
integration between design and manufacturing needs to be made to ensure
business competitiveness.
If such integration is successful, the product life cycle will decrease, which
leads to low manufacturing costs
 With the increased improvement of CIM systems, a further improvement of
automated design and manufacturing has become an important need.
In order to achieve the integration of design and manufacturing, understanding
how manufacturing information can be obtained directly from CAD system
must be addressed
 CAD and CAM systems are based on modelling geometric data.
Usefulness of CAD/CAM systems is the ability to visualize product design,
support design analysis, and link to the generation of part programmers for
manufacturing.
 Because of the increased development of manufacturing technology, a new
generation of customers has appeared.
These customers have forced organizations to look for new methods and
techniques to improve their business processes and speed up the product
development cycle.
Result - the industry is required to apply new engineering philosophies such as
rapid response to manufacturing (RRM).
RRM concept - uses the knowledge of previously designed products in support
of developing new products.
 Rapid prototyping (RP) is a technique for direct conversion of 3D CAD data
into a physical prototype.
CAD data are interpreted into the stereolithography data format.
Stereolithography or "STL" is the standard data format used by most RP machines
RP allows for automatic construction of physical models and used to reduce the
time for the product development cycle and to improve the final quality of the
designed product.
 RP process - thin horizontal cross sections are used to transform materials into
physical prototypes.
(1) Product Design,
(2) Feature-based Design and Techniques,
(3) Feature-based Process Planning and Techniques, and
(4) Advanced Topics
Product Development Life Cycle
Sequence of all the required activities that a company must perform to develop,
manufacture, and sell a product.
 Activities include marketing, research, engineering design, quality assurance,
manufacturing, and a whole chain of suppliers and
vendors.
Process also comprises all strategic planning, capital investments, management
decisions, and tasks necessary to create a new product.
An important part of product development is the engineering design
process, which can be defined as the process of devising a system,
component, or process to meet desired needs.
What is Design ?
If you search the literature for an answer to that question, you will
find about as many definitions as there are designs.
Perhaps the reason is that the process of design is such a common human
experience
Websters dictionary says that to design is to fashion after a plan, but that
leaves out the essential fact that to design is to create something that has never
been.
Certainly an engineering designer practices design by that definition, but so
does an artist, a sculptor, a composer, a playwright, or any another creative
member of our society
 Although engineers are not the only people who design things, it is true that the
professional practice of engineering is largely concerned with design; it is often
said that design is the essence of engineering.
To design is to pull together something new or to arrange existing things in a
new way to satisfy a recognized need of society.
 Design establishes and defines solutions to and pertinent structures for
problems not solved before, or new solutions to problems which have
previously been solved in a different ways
The ability to design is both a science and an art
 Design should not be confused with discovery.
Discovery is getting the first sight of, or the first knowledge of something, as
when Columbus discovered America or Jack Kilby made the first
microprocessor. We can discover what has already existed but has not been
known before, but a design is the product of planning and work.
 A design may or may not involve invention .
To obtain a legal patent on an invention requires that the design be a step
beyond the limits of the existing knowledge (beyond the state of the art). Some
designs are truly inventive, but most are not.
 Good design requires both analysis and synthesis.
Typically we approach complex problems like design by decomposing the
problem into manageable parts.
Analysis - Because we need to understand how the part will perform in service,
we must be able to calculate as much about the parts expected behaviour as
possible before it exists in physical form by using the appropriate disciplines of
science and engineering and the necessary computational tools.
It usually involves the simplification of the real world through models
 Synthesis involves the identification of the design elements that will comprise
the product, its decomposition into parts, and the combination of the part
solutions into a total workable system.
 A scientist will be lucky if he makes one creative addition to human
knowledge in his whole life, and many never do. A scientist can discover a new
star but he cannot make one. He would have to ask an engineer to do it for him.
Engineering Design Process
The engineering design process can be used to achieve several different
outcomes.
NRC
Types of Design
Original design (innovative design)
Top of the hierarchy. It employs an original, innovative concept to achieve a
need. Sometimes, but rarely, the need itself may be original. A truly original
design involves invention.
Successful original designs occur rarely, but when they do occur they usually
disrupt existing markets because they have in them the seeds of new
technology of far-reaching consequences. The design of the microprocessor
was one such original design
 Adaptive design
This form of design occurs when the design team adapts a known solution to
satisfy a different need to produce a novel application . For example, adapting
the ink-jet printing concept to spray binder to hold particles in place in a rapid
prototyping machine
 Redesign
Much more frequently, engineering design is employed to improve an existing
design.
The task may be to redesign a component in a product that is failing in service, or
to redesign a component so as to reduce its cost of manufacture.
Often redesign is accomplished without any change in the working principle or
concept of the original design. For example, the shape may be changed to reduce
a stress concentration, or a new material substituted to reduce weight or cost.
When redesign is achieved by changing some of the design parameters, it is often
called variant design.
 Selection design
Most designs employ standard components such as bearings, small motors, or
pumps that are supplied by vendors specializing in their manufacture and sale.
Therefore, in this case the design task consists of selecting the components with
the needed performance, quality, and cost from the catalogues of potential
vendors.
Computer Integrated Manufacturing (CIM)
CIM is the integration of the total manufacturing
enterprise through the use of integrated systems and data communications
coupled with new managerial philosophies that improve organizational and
personnel efficiency.

- Society of Manufacturing Engineers (SME)

Term coined by Joseph Harrington in 1974
Use of computer systems to design the products, plan the production, control
the operation and perform various business related functions needed in a
manufacturing firm.
CIM includes all of CAD/CAM and embraces the business functions of a
manufacturing firm.
CIM is the integration of all enterprise operations and activities around a
common corporate data repository.
CIM is not a product that can be purchased and installed. It is a way of thinking
and solving problems.
Evolution of CIM
1909 Fords concept of production line.
1923 Automatic transfer machine in Morris engine
factory.
1952 Generation of punched paper tape.
1954 1st NC milling machine in Parson corporation
of USA by MIT.
1959 1st application of computer control at Texaco
Refinery of USA.
1970s CAD, CAM, GT, Flexible automation & DNC
developed.
1980s FMS & CIM became popular.
CIM Objectives
Simplify production processes, product designs, and factory organization as a
vital foundation to automation and integration.
Automate production processes and the business functions that support them
with computers, machines, and robots.
Integrate all production and support processes using computer networks,
cross-functional business software, and other information technologies.
SME Manufacturing Enterprise Wheel
CIM wheel captures the
concept of total integration
of all industrial functions &
interrelationship among
various segments of the
enterprise.
SME manufacturing enterprise wheel has 6 defined areas
1. Customer -
Success of an enterprise depends on customer and
customer is hub of wheel.
Clear understanding of customer needs and market place is
necessary for enterprise growth.
2. Organisational Structure
Organising people, training, motivation, &
cooperation in teamwork.
Organisational learning, leadership, standards, quality circles
and rewards are techniques to achieve these goals.
3. Shared Knowledge of Enterprise
Includes all databases & archival knowledge &
experience, which can be used to support people and processes.
 4. System Used in Total Enterprise
All processes are mainly grouped into 3 major
categories : Product & Process, Manufacturing & Customer
Support.
Each has components that perform necessary functions.
5. Resource and Responsibilities of the Enterprise
Resources are people, materials, tools,
information, technology & suppliers
Responsibilities will be to employees, investors &
communities that are served while undertaking statutory, ethical
& environmental safeguards.
6. Actual Manufacturing Infrastructure
Includes entire infrastructure such as customers &
their needs, suppliers, distributors, prospective workers, natural
resources, financial markets, educational & research institutions
and competitors.
Factors Lead to CIM
Development of NC, CNC & DNC.
Advent & cost effective computers.
Manufacturing challenges
Global competition
High labor cost
Demand for quality products
Flexibility to meet orders
Lower product cost
Capability to cost attractiveness of microcomputers.
Activities of CIM
Evaluating and developing different product strategies.
Market analysis and forecasting.
Analyzing product / market characteristics & generates concept of possible
manufacturing system (FMS & FMC).
Designing and Analyzing components for machining, inspection, assembly and
other processes.
Evaluating and determining batch sizes, manufacturing capacity, scheduling
and control strategies.
Analysis and feedback for manufacturing processes.
Analysis of system disturbances and economic factors.
Reasons for implementing CIM
To meet competitive pressures
Reduces lead time, inventory, material & cost.
Increased quality, responsiveness to computers.
Links logical, organizational and manufacturing activities.
To coordinate and organize data
Functional, product, operational & performance data.
To eliminate paper and cost associated with its use
To automate communication within factory and increase speed
To facilitate simultaneous engineering
Concurrent engineering restructuring product development activity by cross
functional team.
CIM Systems
Computer-aided manufacturing (CAM) - automate the production process.
Manufacturing execution systems (MES) performance monitoring
information systems for factory floor operations.
Process Control control ongoing physical processes.
Machine Control controls the actions of machines.
Components of CIM Hardware
1. Manufacturing equipments
Workstations
Cells
DNC
FMS
Work, tool handling & storage devices
Sensors
2. Computer related hardwares
Computers, Controllers, Printers, Plotters, Modems, Cables, Connectors,
Workstation terminals
CAD/CAM systems
3. Office equipment

4. Communication hardware
Remote batch terminals, Front end processors,
Transmitters, Acoustic couplers
Multiplexers, Concentrators
Information System
Information systems involve
people, hardware, software,
computer networks, and data
used to manage daily and
long-term operations.
Role of Computer in Manufacturing
Computer has had a substantial impact on almost all activities of factory.
Introduction of the computer changed the organizational structure of a
department and made necessary adoption of new management structures.

The operation of a CIM system gives the user substantial benefits:

Reduction of design costs by 15 - 30%;
Reduction of the in-shop time of a part by 30 - 60%;
Increase of productivity by 40 - 70%;
Better product quality, reduction of scrap 20 - 50%.
Communication Networks
A communication network is the backbone of an enterprise integration.

Networks help to unify a company by linking together all the

computerized devices irrespective of their physical location.

Through networks the whole enterprise can be integrated, including

suppliers and customers.
 For example,
Sales and marketing can send customer requirements for new products to
design engineering.

A CAD generated bill of materials can then be transferred to material

requirements planning(MRP) systems.

Product design information can be transmitted to manufacturing for use in

process planning.
Types of Communication
Networks

There 2 main types of communication networks:

1) Telecommunication Networks;
Telecommunication network is mainly used for voice communication.

2) Computer communication Networks.

Computer communication network is a system of interconnected
computers and other devices capable exchanging information.
COMMUNICATION HIERARCHY
Enterprise level
Globally link various plants/sites and interconnect corporations through electronic
data interchange

Plant level
Connect departments inside plant

Cell level
Connect cells inside departments

Equipment/device level
Connect individual devices such as computers, robots and NC machines
Benefits of CIM
Improved customer service
Improved quality
Shorter time to market with new products
Shorter flow time
Shorter vendor lead time
Reduced inventory levels
Improved schedule performance
Greater flexibility and responsiveness
Improved competitiveness
Lower total cost
Shorter customer lead time
 Creates truly interactive system
Accurate data transferability
Faster responses to data changes
Increased flexibility towards new products
Improved quality and accuracy
Control of data flow
Reduction of lead time
Streamlined manufacturing flow form order to delivery
Easier training and re-training facilities
Increase in manufacturing productivity
Decrease in work-in process inventory
Disadvantages
Very Expensive
High Maintenance Cost
Skilled labors are required
May be outdated as the technology grows day by day
THANK YOU