Computer Integrated Manufacturing System by (V.K.

Jaiswal) 2015

CIMS
Computer Integrated Manufacturing System

By
V. K. Jaiswal
 Computer Integrated Manufacturing System by (V.K. Jaiswal) 2015

Computer Integrated Manufacturing (CIM)

• Computer-integrated manufacturing (CIM) is the manufacturing approach of
using computers to control the entire production process. 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.
• Computer-integrated manufacturing is used in automotive, aviation, space, and
ship building industries. 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:

1. Means for data storage, retrieval, manipulation and presentation.

2. Mechanisms for sensing state and modifying processes.
3. Algorithms for uniting the data processing component with the
sensor/modification component.
 Computer Integrated Manufacturing System by (V.K. Jaiswal) 2015

Nature & Role of the Elements of CIM System

Nine major elements of a CIM system are in figure they are,

i. Marketing
ii. Product Design
iii. Planning
iv. Purchase
v. Manufacturing Engineering
vi. Factory Automation Hardware
vii. Warehousing
viii. Logistics and Supply Chain Management
ix. Finance
x. Information Management
 Computer Integrated Manufacturing System by (V.K. Jaiswal) 2015

i. Marketing: The need for a product is identified by the marketing division. The
specifications of the product, the projection of manufacturing quantities and the
strategy for marketing the product are also decided by the marketing department.
Marketing also works out the manufacturing costs to assess the economic viability of
the product.

ii. Product Design: The design department of the company establishes the initial
database for production of a proposed product. In a CIM system this is accomplished
through activities such as geometric modelling and computer aided design while
considering the product requirements and concepts generated by the creativity of the
design engineer. Configuration management is an important activity in many designs.
Complex designs are usually carried out by several teams working simultaneously,
located often in different parts of the world. The design process is constrained by the
costs that will be incurred in actual production and by the capabilities of the available
production equipment and processes. The design process creates the database required
to manufacture the part.

iii. Planning: The planning department takes the database established by the design
department and enriches it with production data and information to produce a plan for
the production of the product. Planning involves several subsystems dealing with
materials, facility, process, tools, manpower, capacity, scheduling, outsourcing,
assembly, inspection, logistics etc. In a CIM system, this planning process should be
constrained by the production costs and by the production equipment and process
capability, in order to generate an optimized plan.

iv. Purchase: The purchase departments is responsible for placing the purchase orders
and follow up, ensure quality in the production process of the vendor, receive the
items, arrange for inspection and supply the items to the stores or arrange timely
delivery depending on the production schedule for eventual supply to manufacture and
assembly.
 Computer Integrated Manufacturing System by (V.K. Jaiswal) 2015

v. Manufacturing Engineering: Manufacturing Engineering is the activity of

carrying out the production of the product, involving further enrichment of the
database with performance data and information about the production equipment and
processes. In CIM, this requires activities like CNC programming, simulation and
computer aided scheduling of the production activity. This should include online
dynamic scheduling and control based on the real time performance of the equipment
and processes to assure continuous production activity. Often, the need to meet
fluctuating market demand requires the manufacturing system flexible and agile.

vi. Factory Automation Hardware: Factory automation equipment further enriches

the database with equipment and process data, resident either in the operator or the
equipment to carry out the production process. In CIM system this consists of
computer controlled process machinery such as CNC machine tools, flexible
manufacturing systems (FMS), Computer controlled robots, material handling
systems, computer controlled assembly systems, flexibly automated inspection
systems and so on.

vii. Warehousing: Warehousing is the function involving storage and retrieval of raw
materials, components, finished goods as well as shipment of items. In today's
complex outsourcing scenario and the need for just-in-time supply of components and
subsystems, logistics and supply chain management assume great importance.

viii. Finance: Finance deals with the resources pertaining to money. Planning of
investment, working capital, and cash flow control, realization of receipts, accounting
and allocation of funds are the major tasks of the finance departments.

ix. Information Management: Information Management is perhaps one of the crucial

tasks in CIM. This involves master production scheduling, database management,
communication, manufacturing systems integration and management information
systems.
 Computer Integrated Manufacturing System by (V.K. Jaiswal) 2015

Group Technology

Group technology or GT is a manufacturing technique in which parts having
similarities in geometry, manufacturing process and/or functions are
manufactured in one location using a small number of machines or processes.
GT is based on a general principle that many problems are similar and by
grouping similar problems, a single solution can be found to a set of problems,
thus saving time and effort.

The group of similar parts is known as part family and the group of machineries
used to process an individual part family is known as machine cell. It is not
necessary for each part of a part family to be processed by every machine of
corresponding machine cell. This type of manufacturing in which a part family
is produced by a machine cell is known as cellular manufacturing.

Group technology is an approach in which similar parts are identified and
grouped together in order to take advantage of the similarities in design and
production. Similarities among parts permit them to be classified into part
families.

The advantage of GT can be divided into three groups:

i. Engineering
ii. Manufacturing
iii. Process Planning
Computer Integrated Manufacturing System by (V.K. Jaiswal) 2015

Figure

1. Composite Group Technology 2.Group Technology Flow Line

Computer Integrated Manufacturing System by (V.K. Jaiswal) 2015

Mechatronics

Mechatronics is a multidisciplinary field of engineering that includes a

combination of systems engineering, mechanical engineering, electrical
engineering, telecommunications engineering, control engineering and
computer engineering. As technology advances the subfields of engineering
multiply and adapt.

Mechatronics' aim is a design process that unifies these subfields. Originally,
Mechatronics just included the combination of mechanics and electronics,
hence the word is a combination of mechanics and electronics; however, as
technical systems have become more and more complex the word has been
broadened to include more technical areas.

A mechatronics engineer unites the principles of mechanics, electronics, and
computing to generate a simpler, more economical and reliable system. The
term "mechatronics" was coined by Tetsuro Mori, the senior engineer of the
Japanese company Yaskawa in 1969. An industrial robot is a prime example
of a mechatronics system; it includes aspects of electronics, mechanics, and
computing to do its day-to-day jobs.
Computer Integrated Manufacturing System by (V.K. Jaiswal) 2015

Engineering cybernetics deals with the question of control engineering of

mechatronic systems. It is used to control or regulate such a system (see
control theory). Through collaboration, the mechatronic modules perform the
production goals and inherit flexible and agile manufacturing properties in
the production scheme.

Modern production equipment consists of mechatronic modules that are
integrated according to control architecture. The most known architectures
involve hierarchy, polyarchy, heterarchy, and hybrid. The methods for
achieving a technical effect are described by control algorithms, which might
or might not utilize formal methods in their design.

Hybrid systems important to mechatronics include production systems,
synergy drives, planetary exploration rovers, automotive subsystems such as
anti-lock braking systems and spin-assist, and everyday equipment such as
autofocus cameras, video, hard disks, and CD players.

Application of Mechatronics

Machine vision

Automation and robotics

Servo-mechanics

Sensing and control systems

Automotive engineering, automotive equipment in the design of
subsystems such as anti-lock braking systems

Computer-machine controls, such as computer driven machines like IE
CNC milling machines

Expert systems

Industrial goods

Consumer products

Mechatronics systems

Medical mechatronics, medical imaging systems
 Computer Integrated Manufacturing System by (V.K. Jaiswal) 2015

Structural dynamic systems

Transportation and vehicular systems

Mechatronics as the new language of the automobile

Computer aided and integrated manufacturing systems

Computer-aided design

Engineering and manufacturing systems

Packaging

Microcontrollers / PLCs

Mobile apps

Computer Aided Process Planning

Computer-aided process planning (CAPP) is the use of computer technology to aid in

the process planning of a part or product, in manufacturing. CAPP is the link between
CAD and CAM in that it provides for the planning of the process to be used in
producing a designed part.
 Computer Integrated Manufacturing System by (V.K. Jaiswal) 2015

Process planning is concerned with determining the sequence of individual

manufacturing operations needed to produce a given part or product. The resulting
operation sequence is documented on a form typically referred to as a route sheet (also
called as process sheet/method sheet) containing a listing of the production operations
and associated machine tools for a work part or assembly. Process planning in
manufacturing also refers to the planning of use of blanks, spare parts, packaging
material, user instructions (manuals) etc.

Process planning encompasses the activities and functions to prepare a detailed set of
plans and instructions to produce a part. The planning begins with engineering
drawings, specifications, parts or material lists and a forecast of demand. The results
of the planning are:

Routings which specify operations, operation sequences, work centers,

standards, tooling and fixtures. This routing becomes a major input to the
manufacturing resource planning system to define operations for production
activity control purposes and define required resources for capacity
requirements planning purposes.

Process plans which typically provide more detailed, step-by-step work
instructions including dimensions related to individual operations, machining
parameters, set-up instructions, and quality assurance checkpoints.

Fabrication and assembly drawings to support manufacture (as opposed to
engineering drawings to define the part).
 Computer Integrated Manufacturing System by (V.K. Jaiswal) 2015

Computer Aided Inspection

• Computer-aided inspection (CAI) is the use of computer-based software tools

that assist quality engineers, machinists and inspectors in manufacturing product
components.
• Its primary purpose is to create a faster production process and components with
more precise dimensions and material consistency. CAI is a software tool that
makes it possible to inspect physical models using computer-aided design
(CAD) programs.
• CAM creates real life versions of components designed within a software
package. CAM was first used in 1971 for car body design and tooling.

Steps of Computer Aided Inspection

Step:1 Use CAI as an alternative way to inspect a product. Working together with
CAD, CAI makes for a faster and easier process for comparing products to their
digital counterpart.

1. Using 3D laser scanning, a product can be 3D inspected, and surfaced to

compare the physical part to the design with the use of a color map and point
clouds.
2. Producing point clouds gives the ability to measure everywhere instead of
being limited to certain parts on a drawing.

Step: 2 Note that there are two non-contact measurement systems for CAI: 3D
laser scanners and laser trackers.

1. D scanners are fast and can be mounted to an existing CMM. It works by

measuring the reflected image from an object with a positioning sensor.
2. Laser trackers calculate the relative distance between points on an axis. With
that information and knowing the wavelength of the emitted light, the
distance between two points can be determined.
 Computer Integrated Manufacturing System by (V.K. Jaiswal) 2015

Step: 3 Make comparisons. Using CAI with the CAD database makes it easier
to compare the digital 3D product to the original, helping make the see whether
the deviations are marginal or serious, and ultimately saving the product from
failing inspection.

Flexible Manufacturing System

A flexible manufacturing system (FMS) is a manufacturing system in which

there is some amount of flexibility that allows the system to react in case of
changes, whether predicted or unpredicted. This flexibility is generally
considered to fall into two categories, which both contain numerous
subcategories.

The first category, machine flexibility, covers the system's ability to be changed
to produce new product types, and ability to change the order of operations
executed on a part. The second category is called routing flexibility, which
consists of the ability to use multiple machines to perform the same operation
on a part, as well as the system's ability to absorb large-scale changes, such as in
volume, capacity, or capability.

Most FMS 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 are 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.
 Computer Integrated Manufacturing System by (V.K. Jaiswal) 2015

Advantages:

Reduced manufacturing cost

Lower cost per unit produced,

Greater labour productivity,

Greater machine efficiency,

Improved quality,

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

Complicated system