Computer Integrated

Manufacturing (CIM) System

Dr Atul Sidola

Contents
Flexible manufacturing system
CIM

Dr Atul Sidola

Flexible Manufacturing System(FMS)

A flexible manufacturing system (FMS) is a highly
automated GT machine cell, consisting of a group or
processing workstations (usually CNC machine tools),
interconnected by an automated material handling and
storage system, and controlled by a distributed computer
system.
FMS can be viewed as computer assisted and controlled
shop floor automation.

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 It is called flexible because it is capable of

processing a variety of different part styles

simultaneously at the various workstations, and
the mix of part styles and quantities of production
can be adjusted in response to changing demand
patterns.
The FMS is most suited for the mid-variety, midvolume production range

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Flexibility Requirement of System

A manufacturing system must possess following
characteristics to be a flexible.
1. The ability to identify and distinguish among
the different part styles processed by the
system.
2. Quick changeover of operating instructions,
and
3. Quick changeover of physical setup.

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A typical FMS
system

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System Flexibility Check

To qualify as being flexible, a manufacturing system should
satisfy several criteria. The following are four reasonable tests
of flexibility in an automated manufacturing system:
1. Part variety test. Can the system process different part
styles in a non batch mode?
2. Schedule change test. Can the system readily accept
changes in production schedule, and changes in either
part mix or production quantity?

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3. Error recovery test. Can the system recover quickly

from equipment breakdowns, so that the

production is not completely disrupted?
4. New part test. Can new part designs be introduced
into the existing product mix with relative ease?
If the answer to all of these questions is YES for a
given manufacturing system, then the system can be
considered flexible.

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Classification of Flexibility in Manufacturing

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Comparison of four Criteria of Flexibility in a Manufacturing

System and the Seven Types of Flexibility

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Classification of FMS (basis: number

of machines)
Flexible manufacturing systems can be distinguished
according to the number of machines in the system. The
following are typical categories:
1. Single machine cell
2. Flexible manufacturing cell
3. Flexible manufacturing system

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Single Machine Cell (SMC)

A single machine cell consists of one CNC machining
center combined with a parts storage system for
unattended operation.
Completed parts are periodically unloaded from the
parts storage unit, and raw workparts are loaded into
it

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Flexible Manufacturing Cell (FMC)

A flexible manufacturing cell consists of two or three
processing workstations (typically CNC machining
centers) plus a part handling system.
The part handling system is connected to a
load/unload station.

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Dr Atul Sidola

Flexible Manufacturing System (FMS)

A flexible manufacturing system has four or more
processing workstations connected mechanically by a
common part handling system and electronically by a
distributed computer system.

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Some of the distinguishing characteristics of the three categories of

flexible manufacturing cells and systems are summarized as per figure
shown.

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Flexibility Criteria Applied to the Three Types of Manufacturing Cells

and Systems

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Classification of FMS (basis: Level of

Flexibility
Another classification of FMS is according to
the level of flexibility designed into the
system. Two categories are distinguished
here:
Dedicated FMS
Random-order FMS

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 A dedicated FMS is designed to produce a limited variety of

part styles, and the complete universe of parts to be made

on the system is known in advance.
A random-order FMS is more appropriate when
1. The part family is large.
2. There are substantial variations in part configurations.
3. There will be new part designs introduced into the
system and engineering changes in parts currently
produced, and
4. The production schedule is subjected to change from
day-to-day.

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A Comparison of Dedicated and

Random-order FMS types

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Flexibility Criteria Applied to Dedicated

FMS and Random-order FMS

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Components of FMS
There are several basic components of an
FMS:
1. Workstations.
2. Material handling and storage systems.
3. Computer control system.
4. Human resource.

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Dr Atul Sidola

1. Workstations
The types of workstations typically found in an FMS:
1. Load/Unload Stations.
2. Machining Stations.
3. Other processing Stations. (punching, shearing,
welding, etc.)
4. Assembly Station.
5. Other Stations and Equipment. (Inspection,
Vision, etc)

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2. Material Handling and Storage

System

1.
2.
3.
4.
5.

Functions of the Handling System

Independent movement of workparts between
stations.
Handle a variety of workpart configurations.
Temporary storage.
Convenient access for loading and unloading
workparts.
Compatible with computer control.

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Material Handling Equipment

Automated material handling system (AMHS)

Automated guided vehicles (AGV)

Conveyors

Automated storage and retrieval systems

(AS/RS)

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3. Computer Control System

The FMS includes a distributed computer system that is interfaced
to
the workstations,
Material handling system, and
Other hardware components.
A typical FMS computer system consists of a central computer and
microcomputers.
Microcomputers controlling the individual machines and other
components.
The central computer coordinates the activities of the
components to achieve smooth overall operation of the system

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4. Human Resources

Human are needed to manage the operations of the FMS.

Functions typically performed by human includes:
Loading raw workparts into the system,
Unloading finished parts (or assemblies) from the system,
Changing and setting tools,
Equipment maintenance and repair,
NC part programming in a machining system, and
Programming and operation the computer system.

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Applications of FMS

Metal-cutting (machining)
Metal forming
Assembly
Joining-welding (arc , spot), gluing
Surface treatment
Inspection
Testing

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Advantages of FMS
1.
2.
3.
4.
5.
6.
7.
8.
9.

To reduce set up and queue times

Improve efficiency
Reduce time for product completion
Utilize human workers better
Improve product routing
Produce a variety of Items under one roof
Improve product quality
Serve a variety of vendors simultaneously
Produce more product more quickly

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Disadvantage of using FMS

1. Limited ability to adapt to changes in product or product

2.

3.
4.

5.

mix (Ex: machines are of limited capacity and the

tooling necessary for products, even of the same family,
is not always feasible in a given FMS)
Substantial pre-planning activity
Expensive
Technological problems of exact component positioning
and precise timing necessary to process a component
Sophisticated manufacturing systems
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Computer Integrated Manufacturing

(CIM)
CIM involves a fundamental strategy of integrating

manufacturing facilities and systems in an enterprise

through the computer and its peripheral.
CIM system integrates the computer automation of FMS
with other computer assisted automation activities in a
factory or a manufacturing organization.
CIM is the integration of total manufacturing enterprise
through the use of integrated system and data
communication mixed with new managerial philosophies
which results in the improvement of personnel or
organizational efficiencies.
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Building Blocks of CIMS

Computer aided design(CAD)
Computer aided manufacturing(CAM)

Flexible manufacturing system(FMS)

Business data processing system(BDPS)

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BDPS activities
1.
2.
3.
4.
5.
6.
7.
8.
9.

Sales order processing

Marketing and forecasting
Sales estimating
Master scheduling
MRP
Budgeting
Ledger keeping and
accounting
Inventory management
Stock control and forecasting

10.
11.
12.
13.
14.
15.
16.
17.

Purchasing
Manufacturing costs
Personal and payrolls
Plant maintenance
Preparation of bill of material.
Routines, time study, reports
Shipping of products
Etc.

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Benefits of CIMS
1.
2.
3.
4.
5.
6.

7.

Products quality
improvement.
Shorter time in launching
new product in the market.
Flow time minimized.
Inventory level reduced.
Competitiveness increases.
Improved scheduling
performance.
Shorter vendor lead time.

8.
9.
10.
11.
12.
13.
14.

Improved customer service.

Increase in flexibility and
responsiveness.
Total cost minimized.
Long term profitability
increases.
Customers lead time
minimized.
Manufacturing productivity
increases.
Work in process inventory
decreases.

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Good Luck for Examination

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Type of flexibility

Definition

Machine

Capability to adopt a given

machine (work station) in the
systems to a wide range
production operation and part
styles. The greater the range of
operations and part style s , the
greater the machine flexibility.

Production

The range or universe of part

styles that can be produced on
the system.

Mix

Ability to change the product

mix while maintaining the same
total production quantity ; that
is ,producing the same parts only
on different proportions.

Depends on
factors

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