ME1403 – 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

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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 it’s basically a
computer system.
- Joel Goldhar, Dean, Illinois Institute of Technology
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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. It’s an understanding of the new way to manage.
- Charles Savage, president, Savage Associates
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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 attempt 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 the use of
integrated systems and data communications coupled with new managerial
philosophies that improve organizational and personnel 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 concept 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

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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
company’s purchasing computer and the ordering computer 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

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 • 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

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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.

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

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 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

Facility design using G.T.

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

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

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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.
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

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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
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

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Components of Flexible Manufacturing Systems(FMS)
 Workstations
 Material handling and storage
 Computer control system
 Human resources

Workstations
 Load/unload stations
 Machining stations
 Other processing stations
 Assembly

Material handling and storage systems

 Primary material handling
 Secondary material handling

FMS layout
 In-line layout
 Loop layout
 Ladder layout
 Open field layout
 Robot centered layout

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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

FMS applications and benefits

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UNIT – IV : CIM IMPLEMENTATION AND DATA COMMUNICATION

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 company’s 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.

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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.

Manufacturing enterprise wheel

he new manufacturing enterprise wheel’s 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
 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

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

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  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
 Multi-tier and high speed LANs

Network management and installation

 Security and administration
 Performance

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  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
 Database administrator

The architecture of a database system

 Internal schema

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  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 design and normalization

Database operators
 Union
 Intersection
 Difference
 Product
 Project

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  Select
 Join
 Divide
The advantages of relational databases

Distributed databases

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