PRODUCTION OPREATION AND MANAGEMENT PROJECT REPORT ON

CAD,CAM,CIM,FMS AND ITS APPLICATION IN NISSAN COMPANY

Submitted by JEFF THOMAS L (3511210236) JOSEPH BEN FRANCIS(3511210237) JIJO GEORGE (3511210238)
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INDEX
INTRODUCTION 3

OBJECTIVE

Definition

CAM

CAD

Working with CAD CAM

15

CIM

22

FMS

27

Application of CAD CAM

31

Application of CIM

31

Application of FMS

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What is CAD,CAM
Computer-aided manufacturing (CAM)
Computer-aided manufacturing (CAM) is the use of computer software to control machine tools and related machinery in themanufacturing of workpieces. This is not the only definition for CAM, but it is the most common; CAM may also refer to the use of a computer to assist in all operations of a manufacturing plant, including planning, management, transportation and storage. Its primary purpose is to create a faster production process and components and tooling with more precise dimensions and material consistency, which in some cases, uses only the required amount of raw material (thus minimizing waste), while simultaneously reducing energy consumptionCAM is now a system used in schools and lower educational purposes CAM is a subsequent computer-aided process after computer-aided design (CAD) and sometimes computeraided engineering (CAE), as the model generated in CAD and verified in CAE can be input into CAM software, which then controls the machine tool.

Chrome-cobalt disc with crowns fordental implants, manufactured using WorkNCCAM Traditionally, CAM has been considered as a numerical control (NC) programming tool, wherein two-dimensional (2-D) or three-dimensional (3-D) models of components generated in CAD software are used to generate G-code to drive computer numerically controlled (CNC) machine tools. Simple designs such as bolt circles or basic contours do not necessitate importing a CAD file. As with other Computer-Aided technologies, CAM does not eliminate the need for skilled professionals such as manufacturing engineers, NC programmers, or machinists. CAM, in fact, leverages both the value of the most skilled manufacturing professionals through advanced productivity tools, while building the skills of new professionals through visualization, simulation and optimization tools.

History
An early commercial applications of CAM was in large companies in the automotive and aerospace industries for example Pierre Bzierswork developing the CAD/CAM application UNISURF in the 60's for car body design and tooling at Renault. Historically, CAM software was seen to have several shortcomings that necessitated an overly high level of involvement by skilled CNC machinists. Fallows created the first CAM software but this had severe shortcomings and was promptly taken back into the developing stage CAM software would output code for the least capable machine, as each machine tool control added on to the standard G-code set for increased flexibility. In some cases, such as improperly set up CAM software or specific tools, the CNC machine required manual editing before the program will run properly. None of these issues were so insurmountable that a thoughtful engineer or skilled machine operator could not overcome for prototyping or small production runs; G-Code is a simple language. In high production or high precision shops, a different set of problems were encountered where an experienced CNC machinist must both hand-code programs and run CAM software. Integration of CAD with other components of CAD/CAM/CAE Product lifecycle management (PLM) environment requires an effective CAD data exchange. Usually it had been necessary to force the CAD operator to export the data in one of the common data formats, such as IGES or STL, that are supported by a wide variety of software. The output from the CAM software is usually a simple text file of G-code, sometimes many thousands of commands long, that is then transferred to a machine tool using a direct numerical control(DNC) program. CAM packages could not, and still cannot, reason as a machinist can. They could not optimize toolpaths to the extent required of mass production. Users would select the type of tool, machining process and paths to be used. While an engineer may have a working knowledge of G-code programming, small optimization and wear issues compound over time. Mass-produced items that require machining are often initially created through casting or some other non-machine method. This enables hand-written, short, and highly optimised G-code that could not be produced in a CAM package. At least in the United States, there is a shortage of young, skilled machinists entering the workforce able to perform at the extremes of manufacturing; high precision and mass production[citation needed]. As CAM software and machines become more complicated, the skills required of a machinist or machine operator advance to approach that of a computer programmer and engineer rather than eliminating the CNC machinist from the workforce.

Typical areas of concern:

High Speed Machining, including streamlining of tool paths Multi-function Machining 5 Axis Machining Feature recognition and machining Automation of Machining processes

Overcoming historical shortcomings

Over time, the historical shortcomings of CAM are being attenuated, both by providers of niche solutions and by providers of high-end solutions. This is occurring primarily in three arenas: 1. 2. 3. Ease of use Manufacturing complexity Integration with PLM and the extended enterprise

Ease in use
For the user who is just getting started as a CAM user, out-of-the-box capabilities providing Process Wizards, templates, libraries, machine tool kits, automated feature based machining and job function specific tailorable user interfaces build user confidence and speed the learning curve. User confidence is further built on 3D visualization through a closer integration with the 3D CAD environment, including error-avoiding simulations and optimizations.

Manufacturing complexity
The manufacturing environment is increasingly complex. The need for CAM and PLM tools by the manufacturing engineer, NC programmer or machinist is similar to the need for computer assistance by the pilot of modern aircraft systems. The modern machinery cannot be properly used without this assistance. Today's CAM systems support the full range of machine tools including: turning, 5 axis machining and wire EDM. Todays CAM user can easily generate streamlined tool paths, optimized tool axis tilt for higher feed rates and optimized Z axis depth cuts as well as driving non-cutting operations such as the specification of probing motions. Integration with PLM and the extended enterpriseLM to integrate manufacturing with enterprise operations from concept through field support of the finished product. To ensure ease of use appropriate to user objectives, modern CAM solutions are scalable from a stand-alone CAM system to a fully integrated multi-CAD 3D solution-set. These solutions are created to meet the full needs of manufacturing personnel including part planning, shop documentation, resource management and data management and exchange. To prevent these solutions from detailed tool specific information a dedicated tool management

Machining process
Most machining progresses through many stages, each of which is implemented by a variety of basic and sophisticated strategies, depending on the material and the software available. The stages are:

Roughing
This process begins with raw stock, known as billet, and cuts it very roughly to shape of the final model. In milling, the result often gives the appearance of terraces, because the strategy has taken advantage of the ability to cut the model horizontally. Common strategies are zig-zag clearing, offset clearing, plunge roughing, rest-roughing.

Semi-finishing
This process begins with a roughed part that unevenly approximates the model and cuts to within a fixed offset distance from the model. The semi-finishing pass must leave a small amount of material so the tool can cut accurately while finishing, but not so little that the tool and material deflect instead of shearing. Common strategies are raster passes, waterline passes, constant step-over passes, pencil milling.

Finishing
Finishing involves a slow pass across the material in very fine steps to produce the finished part. In finishing, the step between one pass and another is minimal. Feed rates are low and spindle speeds are raised to produce an accurate surface. Contour milling In milling applications on hardware with five or more axes, a separate finishing process called contouring can be performed. Instead of stepping down in fine-grained increments to approximate a surface, the workpiece is rotated to make the cutting surfaces of the tool tangent to the ideal part features. This produces an excellent surface finish with high dimensional accuracy.

Computer-aided design (CAD)

Computer-aided design (CAD) is the use of computer systems to assist in the creation, modification, analysis, or optimization of adesign. CAD software is used to increase the productivity of the designer, improve the quality of design, improve communications through documentation, and to create a database for manufacturing. CAD output is often in the form of electronic files for print, machining, or other manufacturing operations. Computer-aided design is used in many fields. Its use in electronic design is known as Electronic Design Automation, or EDA. In mechanical design, it is also known as computer-aided drafting (CAD) or computer-aided design and drafting (CADD), which describes the process of creating a technical drawing with the use of computer software. CAD software for mechanical design uses either vector based graphics to depict the objects of traditional drafting, or may also produceraster graphics showing the overall appearance of designed objects. However, it involves more than just shapes. As in the manual draftingof technical and engineering drawings, the output of CAD must convey information, such as materials, processes, dimensions, andtolerances, according to application-specific conventions. CAD may be used to design curves and figures in two-dimensional (2D) space; or curves, surfaces, and solids in three-dimensional (3D) space. CAD is an important industrial art extensively used in many applications, including automotive, shipbuilding, and aerospace industries, industrial and architectural design, prosthetics, and many more. CAD is also widely used to produce computer animation for special effects in movies, advertising and technical manuals. The modern ubiquity and power of computers means that even perfume bottles and shampoo dispensers are designed using techniques unheard of by engineers of the 1960s. Because of its enormous economic importance, CAD has been a major driving force for research in computational geometry, computer graphics (both hardware and software), and discrete differential geometry. The design of geometric models for object shapes, in particular, is occasionally called computer-aided geometric design (CAGD). While the goal of automated CAD systems is to increase efficiency, they are not necessarily the best way to allow newcomers to understand the geometrical principles of Solid Modeling. For this, scripting languages such as PLaSM (Programming Language of Solid Modeling) are more suitable.[citation needed]

Overview
Beginning in the 1980s computer-aided design programs reduced the need of draftsmen significantly, especially in small to mid-sized companies. Their affordability and ability to run on personal computers also allowed engineers to do their own drafting work, 9

eliminating the need for entire departments. In today's world, many students in universities do not learn manual drafting techniques because they are not required to do so. The days of hand drawing for final drawings are virtually over. Universities no longer require the use of protractors and compasses to create drawings, instead there are several classes that focus on the use of CAD software. Current computer-aided design software packages range from 2D vector-based drafting systems to 3D solid and surface modelers. Modern CAD packages can also frequently allow rotations in three dimensions, allowing viewing of a designed object from any desired angle, even from the inside looking out. Some CAD software is capable of dynamic mathematical modeling, in which case it may be marketed as CADD. CAD is used in the design of tools and machinery and in the drafting and design of all types of buildings, from small residential types (houses) to the largest commercial and industrial structures (hospitals and factories). CAD is mainly used for detailed engineering of 3D models and/or 2D drawings of physical components, but it is also used throughout the engineering process from conceptual design and layout of products, through strength and dynamic analysis of assemblies to definition of manufacturing methods of components. It can also be used to design objects. Furthermore many CAD applications now offer advanced rendering and animation capabilities so engineers can better visualize their product designs. CAD has become an especially important technology within the scope of computer-aided technologies, with benefits such as lower product development costs and a greatly shortened design cycle. CAD enables designers to layout and develop work on screen, print it out and save it for future editing, saving time on their drawings.

Uses
Computer-aided design is one of the many tools used by engineers and designers and is used in many ways depending on the profession of the user and the type of software in question. CAD is one part of the whole Digital Product Development (DPD) activity within the Product Lifecycle Management (PLM) processes, and as such is used together with other tools, which are either integrated modules or stand-alone products, such as:

Computer-aided engineering (CAE) and Finite element analysis (FEA) Computer-aided manufacturing (CAM) including instructions to Computer Numerical Control (CNC) machines Photo realistic rendering Document management and revision control using Product Data Management (PDM).

CAD is also used for the accurate creation of photo simulations that are often required in the preparation of Environmental Impact Reports, in which computer-aided designs of intended buildings are superimposed into photographs of existing environments to

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represent what that locale will be like were the proposed facilities allowed to be built. Potential blockage of view corridors and shadow studies are also frequently analyzed through the use of CAD. CAD has been proven to be useful to engineers as well. Using four properties which are history, features, parameterization, and high level constraints. The construction history can be used to look back into the model's personal features and work on the single area rather than the whole model. Parameters and constraints can be used to determine the size, shape, and the different modeling elements. The features in the CAD system can be used for the variety of tools for measurement such as tensile strength, yield strength, also its stress and strain and how the element gets affected in certain temperatures.

Types
There are several different types of CAD, each requiring the operator to think differently about how to use them and design their virtual components in a different manner for each. There are many producers of the lower-end 2D systems, including a number of free and open source programs. These provide an approach to the drawing process without all the fuss over scale and placement on the drawing sheet that accompanied hand drafting, since these can be adjusted as required during the creation of the final draft. 3D wireframe is basically an extension of 2D drafting (not often used today). Each line has to be manually inserted into the drawing. The final product has no mass properties associated with it and cannot have features directly added to it, such as holes. The operator approaches these in a similar fashion to the 2D systems, although many 3D systems allow using the wireframe model to make the final engineering drawing views. 3D "dumb" solids are created in a way analogous to manipulations of real world objects (not often used today). Basic three-dimensional geometric forms (prisms, cylinders, spheres, and so on) have solid volumes added or subtracted from them, as if assembling or cutting real-world objects. Two-dimensional projected views can easily be generated from the models. Basic 3D solids don't usually include tools to easily allow motion of components, set limits to their motion, or identify interference between components. 3D parametric solid modeling requires the operator to use what is referred to as "design intent". The objects and features created are adjustable. Any future modifications will be simple, difficult, or nearly impossible, depending on how the original part was created. One must think of this as being a "perfect world" representation of the component. If a feature was intended to be located from the center of the part, the operator needs to locate it from the center of the model, not, perhaps, from a more convenient edge or an arbitrary point, as he could when using "dumb" solids. Parametric solids require the operator to consider the consequences of his actions carefully. Some software packages provide the ability to edit parametric and non-parametric geometry without the need to understand or undo the design intent history of the geometry by use of direct modeling functionality. This ability may also include the additional ability to infer the correct relationships between selected geometry (e.g., 11

tangency, concentricity) which makes the editing process less time and labor intensive while still freeing the engineer from the burden of understanding the models. These kind of non-history based systems are called Explicit Modellers or Direct CAD Modelers. Top end systems offer the capabilities to incorporate more organic, aesthetics and ergonomic features into designs. Freeform surface modeling is often combined with solids to allow the designer to create products that fit the human form and visual requirements as well as they interface with the machine.

Technology

A CAD model of a computer mouse. Originally software for Computer-Aided Design systems was developed with computer languages such as Fortran, but with the advancement of object-oriented programming methods this has radically changed. Typical modern parametric feature based modeler andfreeform surface systems are built around a number of key C modules with their own APIs. A CAD system can be seen as built up from the interaction of a graphical user interface (GUI) with NURBS geometry and/or boundary representation (B-rep) data via a geometric modeling kernel. A geometry constraint engine may also be employed to manage the associative relationships between geometry, such as wireframe geometry in a sketch or components in an assembly. Unexpected capabilities of these associative relationships have led to a new form of prototyping called digital prototyping. In contrast to physical prototypes, which entail manufacturing time in the design. That said, CAD models can be generated by a computer after the physical prototype has been scanned using an industrial CT scanning machine. Depending on the nature of the business, digital or physical prototypes can be initially chosen according to specific needs. Today, CAD systems exist for all the major platforms (Windows, Linux, UNIX and Mac OS X); some packages even support multiple platforms. Right now, no special hardware is required for most CAD software. However, some CAD systems can do graphically and computationally intensive tasks, so a modern graphics card, high speed (and possibly multiple) CPUs and large amounts of RAM may be recommended.

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The human-machine interface is generally via a computer mouse but can also be via a pen and digitizing graphics tablet. Manipulation of the view of the model on the screen is also sometimes done with the use of a Spacemouse/SpaceBall. Some systems also support stereoscopic glasses for viewing the 3D model.

History
Designers have long used computers for their calculations. Initial developments were carried out in the 1960s within the aircraft and automotive industries in the area of 3D surface construction and NC programming, most of it independent of one another and often not publicly published until much later. Some of the mathematical description work on curves was developed in the early 1940s by Robert Issac Newton from Pawtucket, Rhode Island. Robert A. Heinlein in his 1957 novel The Door into Summer suggested the possibility of a robotic Drafting Dan. However, probably the most important work on polynomial curves and sculptured surface was done by Pierre Bzier (Renault), Paul de Casteljau (Citroen), Steven Anson Coons (MIT, Ford), James Ferguson (Boeing), Carl de Boor (GM), Birkhoff (GM) and Garibedian (GM) in the 1960s and W. Gordon (GM) and R. Riesenfeld in the 1970s. It is argued that a turning point was the development of the SKETCHPAD system at MIT in 1963 by Ivan Sutherland (who later created a graphics technology company with Dr. David Evans). The distinctive feature of SKETCHPAD was that it allowed the designer to interact with his computer graphically: the design can be fed into the computer by drawing on a CRT monitor with a light pen. Effectively, it was a prototype of graphical user interface, an indispensable feature of modern CAD. The first commercial applications of CAD were in large companies in the automotive and aerospace industries, as well as in electronics. Only large corporations could afford the computers capable of performing the calculations. Notable company projects were at GM (Dr. Patrick J.Hanratty) with DAC-1 (Design Augmented by Computer) 1964; Lockheed projects; Bell GRAPHIC 1 and at Renault (Bzier) UNISURF 1971 car body design and tooling. One of the most influential events in the development of CAD was the founding of MCS (Manufacturing and Consulting Services Inc.) in 1971 by Dr. P. J. Hanratty, who wrote the system ADAM (Automated Drafting And Machining) but more importantly supplied code to companies such as McDonnell Douglas (Unigraphics), Computervision (CADDS), Calma, Gerber, Autotrol and Control

Data.
As computers became more affordable, the application areas have gradually expanded. The development of CAD software for personal desktop computers was the impetus for almost universal application in all areas of construction. Other key points in the 1960s and 1970s would be the foundation of CAD systems United Computing, Intergraph, IBM, Intergraph IGDS in 1974 (which led to Bentley SystemsMicroStation in 1984)

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CAD implementations have evolved dramatically since then. Initially, with 3D in the 1970s, it was typically limited to producing drawings similar to hand-drafted drawings. Advances in programming and computer hardware, notably solid modeling in the 1980s, have allowed more versatile applications of computers in design activities. Key products for 1981 were the solid modelling packages -Romulus (ShapeData) and Uni-Solid (Unigraphics) based on PADL-2 and the release of the surface modeler CATIA(Dassault Systemes). Autodesk was founded 1982 by John Walker, which led to the 2D system AutoCAD. The next milestone was the release of Pro/ENGINEER in 1988, which heralded greater usage of feature-based modeling methods and parametric linking of the parameters of features. Also of importance to the development of CAD was the development of the B-rep solid modeling kernels (engines for manipulating geometrically and topologically consistent 3D objects) Parasolid (ShapeData) and ACIS (Spatial Technology Inc.) at the end of the 1980s and beginning of the 1990s, both inspired by the work of Ian Braid. This led to the release of mid-range packages such as SolidWorks in 1995, Solid Edge(then Intergraph) in 1996 and Autodesk Inventor in 1999.

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WORKING WITH CAD/CAM/CAE TECHNOLOGY

Essentially design is a decision making process where the discretion and knowledge of the designer play a great role. While man still finally controls decisionmaking, the computer has served to ease the designers task.

CAD

CAM

CAE

MASTER MODELER

TOOL PATH GENERATION

SIMULATION

SHEET METAL DESIGN

MOLD DESIGN

PIPE DESIGN

STATIC ANALYSIS (WHEN BODY IS IN STATE OF REST)

DYNAMIC ANALYSIS (WHEN BODY IS IN STATE OF MOTION)

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GEOMETRIC MODELLING: Design involves the development of the shape and dimensions of a component. During designing several factors are to be considered simultaneously. Some of them are stress requirements, method of manufacture. Geometric modeling is the first step in CAD. A geometric model is created on the screen using different techniques. Once creating this model can be easily altered in geometry and configuration to yield a satisfactory shape. The next step is deciding on the exact dimensions. The results of geometric modeling will further be use by CAM in the preparation of NC tapes for the component.

ENGINEERING ANALYSIS: The most important function of CAD is engineering analysis. Engineering analysis basically involves deciding the exact dimensions of the component. These values have to be arrived at by analyzing the component in terms of the loads it has to withstand in function. CAD provides sophisticated method like the finite element technique. Unsatisfactory design may require several iteration of the whole process. The computer scores over the human in its capabilities of rapid information retrieval, numerical processing and repeating a process without fatigue.

SIMULATION: Simulation, in the CAD/CAM context, means duplicating on the video screen a replica of the actual physical situation the designed component is likely to be in. for instance, an aeroplane will be subjected to wind loads. In the conventional method, the aeroplane will be tested in a wind tunnel using a prototype. This is an expensive and inflexible process, expensive because of the physical construction of the wind tunnel and the prototype, inflexible because it may not be possible to test various sizes and shape under a set of test condition. Computer simulation gets rid of both these limitations. It involves the testing of a graphic model whose size and shape can be varied at will. Computer simulation does not completely do away with prototype testing. A near perfect shape can be determined using simulation, which can later be tested with a prototype under test conditions.

DRAFTING: The logical step would be to produce a drawing of the component. A drawing is dispensable for the production of the component. Not only the components designed by engineering analysis, but also complex layouts, assemblies can be created interactively and plotted in about one tenth of the normal time. Automated drafting has resulted in enormous productivity gains in terms of time, labour and expenses.

EXPERT SYSTEMS: The latest development in CAD is the use of Expert systems. An Expert system has an intelligent data-base called knowledge base and reasoning logic. It may contain, for example, the details of the breakdowns that occurred in the industry. On a later date, the user has only to feed in the conditions under which a breakdown occurred. The expert system discovers the reason for the breakdown. This is only one application of expert 16

systems. Wherever decision making under multiple constraints is involved expert systems are used as logic support systems.

SYSTEM DESIGN CYCLE (Conventional design cycle)

For solving any design problem or engineering problem, the general procedure may be followed. RECOGNITION OF A NEED SPECIFICATION AND REQUIREMENTS FEASIBILITY STUDY CREATIVE DESIGN SYNTHESIS PRELIMINARY DESIGN AND DEVELOPEMENT DETAILED DESIGN PROTOTYPE BUILDING AND TESTING DESIGN FOR PRODUCTION

PRODUCT RELEASE

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RECOGNITION OF A NEED
This aspect of design can have its origin in many numbers of sources. Customer reports on the product function and quality may force a redesign. The starting point of a design project is a hypothetical need which may have been observed in socio-economic scene. The need may be existing or may not yet exist, but the evidence may be existing that the need is latent. The following points will help at this stage: 1. 2. 3. 4. aspects. Study the nature of the need. Establish the need reasonably well to the extent possible. Make primitive statement of need. Do reconnaissance study with respect to qualitative and quantitative

SPECIFICATION AND REQUIREMENTS

Once a need has been established, its requirements must be carefully spelled out. Very often the specifications are stated in such general terms as to indicate that the consumer has only a vague idea of what he wants. In these requirements design and performance requirements are carefully stated. Also, the specifications are prepared keeping in mind the production competence and capability of the company.

FEASIBILITY STUDY
Once the problems need has been established and the specifications have been prepared, accepted and submitted, the feasibility study is done. The purpose of this study is to check the possibility of success or failure of the purposed project both from technical and economic standpoint. In this study, various questions are to be answered. 1. Is any natural law being defied? 2. Are some of the specifications beyond what is technically available at present? 3. Is there any dependence on source materials? 4. Will the cost of the end product be too high? The persons doing the feasibility study will be the engineers with strong design background, knowledge of engineering science, a good knowledge of material usage, knowledge of production methods and requirements of the sales department.

CREATIVE DESIGN SYNTHESIS

Once the feasibility of the design is established, the creative design synthesis has to be done. Here, the designer can act as engineer, inventor, artist all in one, because now he is called upon to create. The quantities of the new design will be: 1. The quality of newness or uniqueness. 2. Things, which are either useful or appreciated, are called creative. Creative things are sometimes either purposeful or beautiful or both. 18

3. The third quality in the design solution will be that it will have simplicity. A solution having the qualities of newness and useful or appreciated but complex would not be known as a creative solution.

PRELIMINARY DESIGN AND DEVELOPMENT

After the process of creativity design is complete, there will be one or more possible designs that satisfy the given set of specifications and requirements. It then becomes necessary to decide which of the solutions to choose for the preliminary design and development stage. Note, this stage is primarily concerned with checking the validity of the functional and overall size requirements of the specifications. The stages of the preliminary design can be summarized as below: 1. Selection of the most useful solution from the several suggested solutions. 2. Formulation of useful model preferably mathematical for this selected solution. 3. Analysis of this model. 4. Prediction of performance. 5. Preparing layout of the selected solution, making a check for its function.

DETAILED DESIGN
Many designers often miss many of the activities of the detailed design phase of the design process, particularly for smaller jobs, because so much of the detailing in the sense of component design is already done in the preliminary design phase. This phase of the design work consists of two major activities: (1) Detailing the parts, component and their assembly. (2) Going into sufficient details of manufacture in implementing the design. The second phase as indicated earlier requires a good knowledge of manufacturing process. The method of manufacturing should be such that the following are avoided. (1) Heavy weight of material (2) Reclamping of work (3) Special purpose tools (4) Finishing operations

PROTOTYPE BUILDING AND TESTING

After completing all the details, the sub-assemblies and assembly drawings including the materials and parts list, the completed design is sent to the prototype or model shop for fabrication. At this juncture the parts are fabricated, commercial components are purchased, and the machine or system, after having been assembled, is ready for evolution and testing. This testing can help in: 1. Producing acceptable performance 2. To generate new design information 3. To develop improved design concepts 4. To increase validity of the results.

DESIGN FOR PRODUCTION

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In addition to being functionally sound, a product must have sales appeal and must be competitive in price. In order for a product to be made economically, it must be designed so that the most appropriate material and processes will be utilized. This is called design for production. For large scale manufacturing, any of these processes may be more economical than individual part machining.

PRODUCT RELEASE
Production prototype are usually made and tested, and any drawback that can be easily corrected is generally referred back to preliminary design and development or to detailed design for alteration.

ADVANTAGES OF CAD
CAD can make a draft men much more efficient. Depending upon the drafting task, two to ten times productivity improvement is not uncommon when using a CAD system .The following are the advantages of using CAD over manual drafting: -

REVISIONS: One of the most time-consuming tasks that a draft man performs is making changes to existing drawings. With a CAD system, revisions are much faster than manual methods. After a drawing has been completed, it is stored and can be recalled at any time to make changes easily.

REPITITION: Simple symbols or more complex ones , are created by drawing them with the CAD system and storing them away to be used at any time. Once a drawing has been produced and stored in the computers memory, it does not have to be drawn again if it is part of another drawing. Parts of previous drawings can be combined to produce new drawings.

ACCURACY: Dimensions are keyed-in using the computer keyboard or menu instead of reading a scale. Mating parts can be checked for fit by having the computer match the parts on the screen before hard copies are produced.

SPEED: In almost all areas of drafting, CAD is faster than manual drawing. This is especially true as the operator becomes more proficient through continued use of the system

NEATNESS: After the drawing has been produced on screen, it can be drawn on paper with a plotter. The mechanical plotting of a drawing produces clean, accurate and neat drawings using proper line weight and consistency, and sharp, consistent lettering. 20

COST: In the past, CAD systems were an expensive alternative to manual drafting, and only major industrial corporations could afford them. Now, because of reduced cost of memory, increased competition, and improved software and computer technology CAD systems are affordable to most drafting-design offices.

DIFFERENT TYPES OF CAD/CAM SOFTWARE

1. INTEGRATED CAD/CAM SYSTEM - Pro/engineer, I-DEAS CATIA, UNIGRAPHICS are integrated CAD/CAM system. We can do design/ analysis/ generation of tool path in same environment. 2. Point/Standalone solution- Softwares, which give only one solution out of DESIGN, MANUFACTURING & ANALYSIS are called point solution software. Like AUTO-CAD gives only drafting solution, master cam gives manufacturing solution& ANSYS, NASTRAN, ADAMS, ABAQUS gives only analysis solution.

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Computer-integrated manufacturing
Computer-integrated manufacturing (CIM) is the manufacturing approach of using computers to control the entire productionprocess.[1][2] This integration allows individual processes to exchange information with each other and initiate actions. Through the integration of computers, manufacturing can be faster and less error-prone, although the main advantage is the ability to create automated manufacturing processes. Typically CIM relies on closed-loop control processes, based on real-time input from sensors. It is also known as flexible design and manufacturing.[citation needed]

Manufacturing Systems Integration Program,NIST 2008.

Overview
The term "computer-integrated manufacturing" is both a method of manufacturing and the name of a computer-automated system in which individual engineering, production, marketing, and support functions of a manufacturing enterprise are organized. In a CIM system functional areas such as design, analysis, planning, purchasing, cost accounting, inventory control, and distribution are linked through the computer with factory floor functions such as materials handling and management, providing direct control and monitoring of all the operations. As a method of manufacturing, three components distinguish CIM from other manufacturing methodologies:

Means for data storage, retrieval, manipulation and presentation; Mechanisms for sensing state and modifying processes;

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Algorithms for uniting the data processing component with the sensor/modification component.

CIM is an example of the implementation of information and communication technologies (ICTs) in manufacturing. CIM implies that there are at least two computers exchanging information, e.g. the controller of an arm robot and a micro-controller of a CNC machine. Some factors involved when considering a CIM implementation are the production volume, the experience of the company or personnel to make the integration, the level of the integration into the product itself and the integration of the production processes. CIM is most useful where a high level of ICT is used in the company or facility, such as CAD/CAM systems, the availability of process planning and its data.

History
The idea of "digital manufacturing" was prominent the 1980s, when computer-integrated manufacturing was developed and promoted by machine tool manufacturers and theComputer and Automated Systems Association and Society of Manufacturing Engineers (CASA/SME). "CIM is the integration of total manufacturing enterprise by using integrated systems and data communication coupled with new managerial philosophies that improve organizational and personnel efficiency." ERHUM

Computer-integrated manufacturing topics

CIM & production control system: Computer Integrated Manufacturing is used to describe the complete automation of a manufacturing plant, with all processes running under computer control and digital information tying them together.[3]

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Key challenges
There are three major challenges to development of a smoothly operating computerintegrated manufacturing system:

Integration of components from different suppliers: When different machines, such as CNC, conveyors and robots, are using different communications protocols. In the case of AGVs, even differing lengths of time for charging the batteries may cause problems.

Data integrity: The higher the degree of automation, the more critical is the integrity of the data used to control the machines. While the CIM system saves on labor of operating the machines, it requires extra human labor in ensuring that there are proper safeguards for the data signals that are used to control the machines.

Process control: Computers may be used to assist the human operators of the manufacturing facility, but there must always be a competent engineer on hand to handle circumstances which could not be foreseen by the designers of the control software.

Subsystems in computer-integrated manufacturing

A computer-integrated manufacturing system is not the same as a "lights-out" factory, which would run completely independent of human intervention, although it is a big step in that direction. Part of the system involves flexible manufacturing, where the factory can be quickly modified to produce different products, or where the volume of products can be changed quickly with the aid of computers. Some or all of the following subsystems may be found in a CIM operation: Computer-aided techniques:

CAD (computer-aided design) CAE (computer-aided engineering) CAM (computer-aided manufacturing) CAPP (computer-aided process planning) CAQ (computer-aided quality assurance) PPC (production planning and control) ERP (enterprise resource planning) 24

A business system integrated by a common database.

Devices and equipment required:

CNC, Computer numerical controlled machine tools DNC, Direct numerical control machine tools PLCs, Programmable logic controllers Robotics Computers Software Controllers Networks Interfacing Monitoring equipment

Technologies:

FMS, (flexible manufacturing system)

ASRS, automated storage and retrieval system AGV, automated guided vehicle Robotics Automated conveyance systems

Others:

Lean manufacturing

CIMOSA
CIMOSA (Computer Integrated Manufacturing Open System Architecture), is a 1990s European proposal for an open system architecture for CIM developed by the AMICE Consortium as a series of ESPRIT projects. The goal of CIMOSA was "to help companies to manage change and integrate their facilities and operations to face world wide competition. It provides a consistent architectural framework for both enterprise modeling and enterprise integration as required in CIM environments". CIMOSA provides a solution for business integration with four types of products:

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The CIMOSA Enterprise Modeling Framework, which provides a reference architecture for enterprise architecture

CIMOSA IIS, a standard for physical and application integration. CIMOSA Systems Life Cycle, is a life cycle model for CIM development and deployment. Inputs to standardization, basics for international standard development. CIMOSA according to Vernadat (1996), coined the term business process and introduced the process-based approach for integrated enterprise modeling based on a cross-boundaries approach, which opposed to traditional function or activity-based approaches. With CIMOSA also the concept of an "Open System Architecture" (OSA) for CIM was introduced, which was designed to be vendor-independent, and constructed with standardised CIM modules. Here to the OSA is "described in terms of their function, information, resource, and organizational aspects. This should be designed with structured engineering methods and made operational in a modular and evolutionary architecture for operational use"

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Flexible manufacturing system

A typical FMS. 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 multiplemachines 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 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.

Advantages

Reduced manufacturing times, Lower cost per unit produced, Greater labor productivity, Greater machine efficiency, Improved quality,

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Increased system reliability, Reduced parts inventories, Adaptability to CAD/CAM operations. Shorter lead times

Disadvantages

Cost to implement, Substantial pre-planning Requirement of skilled labour

Industrial FMS Communication

Training FMS with learning robotSCORBOT-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 almost 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 29

proposed to allow transmission of short and periodic messages with a low delay compared to the one for long messages.[1]

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.

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APPLICATION OF CAD, CAM, CIM, FMS IN NISSANCOMPANY

Application of cad cam
Nissan has selected UGS to be the provider of the new global PLM system that Nissan and Nissan affiliates will deploy to design and build its next generation of vehicles. UGS expects the selection to represent its largest win in 2005. Nissan will use UGS' NX CAD software to digitally design its vehicles on a global basis and UGS' Teamcenter collaborative Product Development Management (cPDM) software to digitally manage product data and enable digital prototyping for all Nissan vehicles across the world. The company will deploy the software as part of a fully integrated, common R&D infrastructure for use inside Nissan. "Nissan is one of the world's most innovative and successful companies, and UGS is proud to help strengthen its strong automotive industry leadership by providing the new technology foundation for its innovative, knowledgeenabled vehicle development process," said Tony Affuso, chairman, CEO and president of UGS. "No other PLM company combines superior technology, ability to scale the product across multiple global sites and proven strength in supporting large global customers, and our expert UGS delivery team is gearing-up to deploy its unmatched track record for customer success on Nissan's behalf." Application of CIM

CIM (COMUPUTER INTEGRATED MANUFACTURING) Computer Integrated Manufacturing is a management tool that ties all departments within 31

a corporation (i.e. sales, management, manufacturing, R&D) to an automated production system through a network and host computer. After recognizing the potential of this approach, NKC pioneered the field by developing it for practical use. Already in use at some major manufacturing companies, NKC's Computer Integrated Manufacturing system is drawing a great deal of interest from the automotive and appliance industries. The evolution of this concept continues as we build upon our success with the CIM system and make full use of advanced technologies.

Application of FMS
Nissan has been able to facilitate a complete financial turnaround in 2008-09 based on optimum manufacturing efficiency and cost effectiveness achieved through extended use of FMS. Nissan uses common assembly lines and FMS to keep production fluid. In the body shop they have one body main and respot line, which is fed by various floor and body-side lines. Emil Hassan, senior vice president of manufacturing, purchasing, quality and logistics for Nissan North America Inc , explains that the benefits of this are obvious reduced floor space, reduced capital investment for changeovers and a more agile response to changing market conditions.[19] They acknowledge that FMS enables them to cut lead time and investment in half when launching new models, allowing them to respond to changing market conditions quickly and flexibly. Nissan has developed its own Nissan Integrated Manufacturing System (NIMS). In India they are implementing the same NIMS at their Chennai plant using the name AIMS - Alliance Integrated Manufacturing System[20]. AIMS is a flexible manufacturing system which creates common assembly processes between plants and, in this case, between companies (Nissan and Renault) so that similar platforms can be shifted easily and cost-effectively. The system incorporates welding, painting and final assembly operations along with injection molding and stamping.

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