ME1403 COMPUTER INTEGRATED MANUFACTURING

IV year Mechanical Engg Notes on Lesson UNIT I ! INTRODUCTION In"r#$%c"i#n 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 Computer "le#ible Computer

ided

!esign (C !) ("M$)

ided Manufacturing (C M) ided %rocess %lanning (C %%)

Manufacturing $ystems

CIM is being pro&ected as a panacea for !iscrete manufacturing type of industry, which produces '() 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 (CA )! It is not using computers to aid the

de!elopment of part programs to dri!e machine tools. That is computer aided manufacturing (CAM)! It is not materials re"uirement planning (M#$) or %ust&in&time ('IT) or any other method of de!eloping the production schedule. It is not automated identification( data collection( or data ac"uisition. It is not simulation or modeling of any materials handling or robots or anything else li)e that. Ta)en by themsel!es( they are the application of computer technology to the process of manufacturing. *ut ta)en by themsel!es they only crate the islands of automation.+ + De&ini"i#n #& CIM! It describes integrated applications of computers in manufacturing. observers have attempted to refine its meaning/ ,ne needs to thin) of CIM as a computer system in -hich the peripherals( instead of being printers( plotters( terminals and memory dis)s are robots( machine tools and other processing e"uipment. It is a little noisier and a little messier( but it.s basically a computer system. + 0oel 1oldhar, !ean, Illinois Institute of 2echnology + CIM is a management philosophy ( not a turn)ey computer product. It is a philosophy crucial to the sur!i!al of most manufacturers because it pro!ides the le!els of product design and production control and shop fle/ibility to compete in future domestic and international mar)ets. %resident, ! C3M, Inc. CIM is an opportunity for realigning your t-o most fundamental resources0 people and technology. CIM is a lot more than the integration of mechanical( electrical( and e!en informational systems. It.s an understanding of the new way to manage. + Charles $avage, president, $avage ssociates + & !an ppleton, number of ,eo -oth .lein, Manufacturing Control systems, Inc.

CIM is nothing but a data management and networking problem. + 0ac5 Conaway, CIM mar5eting manager, !6C

2he 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. + 1hrens)er( Computer Automated 1ystems Association of the 1ociety of Manufacturing ngineers (CA1A21M ) Concept or echnology 7$ome people view CIM as a concept, while others merely as a technology. It is actually both. good analogy of CIM is man, for what we mean by the word man presupposes both the mind and the body. $imilarly, CIM represents both the concept and the technology. 2he concept leads to the technology which, in turn, broadens the concept.8 + ccording to 9a&payee

The 'eaning an$ #rigin #& CIM 2he CIM will be used to mean the integration of business, engineering, manufacturing and management information that spans company functions from mar5eting to product distribution. The changing an$ 'an%&ac"%ring an$ 'anage'en" (cene( 2he state of manufacturing developments aims to establish the conte#t within which CIM e#ists and to which CIM must be relevant. gile manufacturing, operating through a global factory or to world class standards may all operate alongside CIM. CIM :

is deliberately classed with the technologies because, as will be seen, it has significant technological elements. ;ut it is inappropriate to classify CIM as a single technology, li5e computer aided design or computer numerical control. E)"ernal c#''%nica"i#n( 6lectronic data interchange involves having data lin5s between a buying company<s purchasing computer and the ordering computer in the supplying company. !ata lin5s may private but they are more li5ely to use facilities provided by telephone utility companies. I(lan$( #& a%"#'a"i#n an$ (#&"*are In many instances the software and hardware have been isolated. =hen such computers have been used to control machines, the combination has been termed an island of automation. =hen software is similarly restricted in its ability to lin5 to other software, this can be called an island of software.

De$ica"e$ an$ #+en (y("e'( 2he opposite of dedicated in communication terms is open. 3pen systems enable any type of computer system to communicate with any other. Man%&ac"%ring a%"#'a"i#n +r#"#c#l ,MAP2he launch of the M % initiates the use of open systems and the movement towards the integrated enterprise. Pr#$%c" rela"e$ ac"i.i"ie( #& a c#'+any 1 Mar/e"ing $ales and customer order serviceing

0 Engineering -esearch and product development Manufacturing development '

!esign 6ngineering release and control Manufacturing engineering "acilities engineering Industrial engineering

3 Pr#$%c"i#n +lanning Master production scheduling Material planning and resource planning %urchasing %roduction control

4 Plan" #+era"i#n( %roduction management and control Material receiving $torage and inventory Manufacturing processes 2est and inspection Material transfer %ac5ing, dispatch and shipping %lant site service and maintenance

1 Phy(ical $i("ri2%"i#n %hysical distribution planning %hysical distribution operations =arranties, servicing and spares

3 4%(ine(( an$ &inancial 'anage'en" Company services %ayroll ccounts payable, billing and accounts receivable

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UNIT II ! GROUP TEC5NO6OG7 AND COMPUTER AIDED PROCE88 P6ANNING Gr#%+ "echn#l#gy 1roup technology is a manufacturing philosophy in which similar parts are identified and grouped together to ta5e the advantage of their similarities in design and manufacturing. !roup echnology or ! is a manufacturing philosophy in which the parts having similarities (1eometry, manufacturing process and?or function) are grouped together to achieve higher level of integration between the design and manufacturing functions of a firm. 2he aim is to reduce wor5+in+progress and improve delivery performance by reducing lead times. 12 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. 2he group of similar parts is 5nown as part family and the group of machineries used to process an individual part family is 5nown as machine cell. It is not necessary for each part of a part family to be processed by every machine of corresponding machine cell. 2his type of manufacturing in which a part family is produced by a machine cell is 5nown as cellular manufacturing. 2he manufacturing efficiencies are generally increased by employing 12 because the required operations may be confined to only a small cell and thus avoiding the need for transportation of in+ process parts R#le #& GT in CAD9CAM in"egra"i#n *. Identifying the part families. 4. -earranging production machines into machine cells Par" &a'ily part family is a collection of parts having similarities based on design or shape or similar manufacturing sequence.

C#'+ari(#n #& F%nc"i#nal lay#%" *i"h GT lay#%" Me"h#$( #& Gr#%+ing #& +ar"( *. visual inspection 4. parts classification and coding system :. production flow analysis Par"( cla((i&ica"i#n an$ c#$ing (y("e' *. system based on part design attributes 4. system based on manufacturing attributes :. system based on design and manufacturing attributes Me"h#$( #& c#$ing *. hierarchical coding 4. poly code :. decision tree coding C#$ing (y("e' *. 3%I2A system 4. !C, $$ :. MIC, $$ etc. Pr#$%c"i#n &l#* analy(i( ,PFA9arious steps of %" *. !ata collection 4. %art sorting and routing :. %" chart '. nalysis

Pr#$%c"i#n Fl#* Analy(i(

During the past ten years the people behind QDC Business Engineering have performed several Production Flow Analyses (PFA in manufacturing industries! B

"n short# PFA provides well$established# efficient and analytical engineering method for planning the change from %process organisation& to %product organisation&! 'his means that traditional production layouts are transformed into production groups# which each ma(e a particular set of parts and is e)uipped with a particular set of machines and e)uipment enabling them to complete the assigned parts! 'he following figure illustrates the conventional process layout and its corresponding product based layout after PFA has been applied!
The resulting overall material flow between functional cells. Traditional Process Layout

Product Layout

The resulting smooth material flow between dedicated product groups.

Comple* material flow systems resulting from process based production layouts have long throughput times# high inventories and wor( in progress# which increase cost and reduce profitability! From the organisation+s point of view# delegation and control are difficult to implement# which leads to bureaucratic and centralised management structures# thus increasing overhead! Applying PFA produces a plan to change the layout and organisation in such a way that production throughput times can be reduced radically# while at the same time inventories go down and delivery punctuality and )uality improve to a completely new level! QDC has applied the method successfully in several manufacturing industries# especially in ,ob$shops and electronics industries# but good results have also been obtained in service industries! -nce the layout has been changed to a product based one# new and simple production scheduling routines have been implemented to ensure e*cellent delivery performance! An"ici+a"e$ re(%l"( C

Companies that have gone through PFA and the resulting change to product based layout# have e*perienced the following positive effects. in operations management. reduced production throughput times# significantly less capital tied into the material flow and improved delivery performance/ in general management. ma(es it possible to delegate the responsibility for component )uality# cost and completion by due$date to the group level# which in turn reduced overhead/ in wor(er+s motivation. clearer responsibilities and decision ma(ing on the spot increase ,ob satisfaction/ in the point of information technology. simplified material flow speeds up the implementation of factory automation and simplifies software applications used to support efficient operations!

The c#n"en" #& Pr#$%c"i#n Fl#* Analy(i( 'he main method of the PFA is a )uantitative analysis of all the material flows ta(ing place in the factory# and using this information and the alternative routings to form manufacturing groups that are able to finish a set parts with the resources dedicated to it! Depending on the scale of the pro,ect this logic is applied on company# factory# group# line and tooling level respectively! 0hichever the case# the wor( brea(s down into the following steps. to identify and classify all production resources# machines and e)uipment/ to trac( the all product and part routes that the company# factory or group produces/ to analyse the manufacturing networ( through the main flows formed by the ma,ority of parts/ to study alternative routings and grouping of the machines to fit parts into a simplified material flow system/ to further study those e*ceptional parts not fitting into the grouping of production resources/ to validate the new material flow system and implementing the scheduling system based on single$piece flow!

1ost production units and their layouts are the result of organic growth# during which the products have e*perienced many changes affecting the arsenal of the e)uipment in the wor(shop! 'his continuously evolving change process leads in conventional factories into comple* material flow systems! PFA reveals the natural grouping of production resources li(e the following small$scale yet real$ world e*ample shows!
The Machine:Par" 'a"ri) a( ra* $a"a ga"here$ in "he &ir(" ("e+( #& "he PFA

'he 1achine$Part matri* reorganised into natural groups that finish parts!

1ost of our previous cases have focused on the forming of groups in ,ob$shops# which are part of a larger production facility! 'hese test cases have been used as eye$openers for the rest of the organisation! -ur recommendation# however# is to continue with PFA on higher level! Product and component allocation in the whole supply chain combined with product and customer segmentation is an area where not only vast savings in operating costs can be achieved# but also competitive advantage can be created! 1anufacturing science (nows numerous cases where complete product$oriented re$organisation of the company has produced staggering results in productivity# throughput times and competitive advantage! PFA is one of the few systematic engineering methods for achieving these results! Production Flow Analysis was developed by Professor 2ohn 3! Burbidge of the Cranfield "nstitute of 'echnology!

Facili"y $e(ign %(ing G T *. ,ine layout 4. 1roup layout, machines grouped by part family :. "unctional layout, machines grouped by process

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4ene&i"( #& gr#%+ "echn#l#gy *. !esign 4. 2ooling and setups :. Material handling '. %roduction and inventory control >. %rocess planning @. 6mployee satisfaction Cell%lar 'an%&ac"%ring Machine cell $e(ign The c#'+#(i"e +ar" c#nce+"

Ty+e( #& cell $e(ign *. $ingle machine cell 4. 1roup machine cell with manual handling :. 1roup machine cell with semi+integrated handling '. "le#ible manufacturing system De"er'ining "he 2e(" 'achine arrange'en" "actors to be considered/ 9olume of wor5 to be done by the cell 9ariations in process routings of the parts %art siEe, shape, weight and other physical attributes

;ey 'achine c#nce+" R#le #& +r#ce(( +lanning *. Interpretation of product design data

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4. $election of machining processes. :. $election of machine tools. '. !etermination of fi#tures and datum surfaces. >. $equencing the operations. @. $election of inspection devices. B. !etermination of production tolerances. C. !etermination of the proper cutting conditions. D. Calculation of the overall times. *(. 1eneration of process sheets including FC data. A++r#ache( "# Pr#ce(( +lanning *. Manual approach 4. 9ariant or retrieval type C %% system :. 1enerative C %% system CAPP an$ CMPP ,C#'+%"er Manage$ Pr#ce(( PlanningUNIT III ! 85OP F6OOR CONTRO6 AND INTRODUCTION OF FM8 8h#+ &l##r c#n"r#l 2he three phases of shop floor control *. 3rder release 4. 3rder scheduling :. 3rder progress Fac"#ry Da"a C#llec"i#n 8y("e' 3n+line versus batch systems !ata input techniques 0ob traveler 6mployee time sheets 3peration tear strips %repunched cards *4

%roviding 5ey board based terminals o 3ne centraliEed terminal o $atellite terminals o =or5station terminals

A%"#'a"ic i$en"i&ica"i#n 'e"h#$( ;ar codes -adio frequency systems Magnetic stripe 3ptical character recognition Machine vision

A%"#'a"e$ $a"a c#llec"i#n (y("e'( !ata acquisition systems Multilevel scanning

C#'+#nen"( #& Fle)i2le Man%&ac"%ring 8y("e'(,FM8 =or5stations Material handling and storage Computer control system Guman resources

fle"i#le manufacturing system ($M%) is a manufacturing system in which there is some amount of fle#ibility that allows the system to react in the case of changes, whether predicted or unpredicted. 2his fle#ibility is generally considered to fall into two categories, which both contain numerous subcategories. 2he first category, machine fle/ibility, covers the systemHs ability to be changed to produce new product types, and ability to change the order of operations e#ecuted on a part. 2he second category is called routing fle/ibility, which consists of the ability to use multiple machines to perform the same operation on a part, as well as the systemHs ability to absorb large+scale changes, such as in volume, capacity, or capability. Most $M% systems consist of three main systems. 2he wor5 machines which are often automated CFC machines are connected by a material handling system to optimiEe parts

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flow and the central control computer which controls material movements and machine flow. 2he main advantages of an "M$ is its high fle#ibility in managing manufacturing resources li5e time and effort in order to manufacture a new product. 2he best application of an "M$ is found in the production of small sets of products li5e those from a mass production.

Advantages
"aster, ,ower+ cost?unit, 1reater labor productivity, 1reater machine efficiency, Improved quality, Increased system reliability, -educed parts inventories, daptability to C !?C M operations. $horter lead times &isadvantages Cost to implement.

Industrial FMS Communication

2raining "M$ with learning robot $C3-;32+6- 'u, wor5bench CFC Mill and CFC ,athe n Industrial $le"i#le Manufacturing %ystem ("M$) consists of robots, Computer+ controlled Machines, Fumerical controlled machines (CFC), instrumentation devices, computers, sensors, and other stand alone systems such as inspection machines. 2he use of robots in the production segment of manufacturing industries promises a variety of benefits ranging from high utiliEation to high volume of productivity. 6ach -obotic cell or node will be located along a material handling system such as a conveyor or automatic guided vehicle. 2he production of each part or wor5+piece will require a different combination of manufacturing nodes. 2he movement of parts from one node to another is done through the material handling system. t the end of part processing, the finished parts will be routed to an automatic inspection node, and subsequently unloaded from the "le#ible Manufacturing $ystem.

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CFC machine he $M% data traffic consists of large files and short messages, and mostly come from nodes, devices and instruments. 2he message siEe ranges between a few bytes to several hundreds of bytes. 6#ecutive software and other data, for e#ample, are files with a large siEe, while messages for machining data, instrument to instrument communications, status monitoring, and data reporting are transmitted in small siEe. 2here is also some variation on response time. ,arge program files from a main computer usually ta5e about @( seconds to be down loaded into each instrument or node at the beginning of "M$ operation. Messages for instrument data need to be sent in a periodic time with deterministic time delay. 3ther type of messages used for emergency reporting is quite short in siEe and must be transmitted and received with almost instantaneous response. 2he demands for relia#le $M% protocol that support all the "M$ data characteristics are now urgent. 2he e#isting I666 standard protocols do not fully satisfy the real time communication requirements in this environment. 2he delay of C$M ?C! is unbounded as the number of nodes increases due to the message collisions. 2o5en ;us has a deterministic message delay, but it does not support prioritiEed access scheme which is needed in "M$ communications. 2o5en -ing provides prioritiEed access and has a low message delay, however, its data transmission is unreliable. single node failure which may occur quite often in "M$ causes transmission errors of passing message in that node. In addition, the topology of 2o5en -ing results in high wiring installation and cost. design of $M% communication protocol that supports a real time communication with bounded message delay and reacts promptly to any emergency signal is needed. ;ecause of machine failure and malfunction due to heat, dust, and electromagnetic interference is common, a prioritiEed mechanism and immediate transmission of emergency messages are needed so that a suitable recovery procedure can be applied. modification of standard 2o5en ;us to implement a prioritiEed access scheme was proposed to allow transmission of short and periodic messages with a low delay compared to the one for long messages.

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Flexibility
"le#ibility in manufacturing means the ability to deal with slightly or greatly mi#ed 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. <#r/("a"i#n( ,oad?unload stations Machining stations 3ther processing stations ssembly

Ma"erial han$ling an$ ("#rage (y("e'( FM8 lay#%" In+line layout ,oop layout ,adder layout 3pen field layout -obot centered layout %rimary material handling $econdary material handling

C#'+%"er c#n"r#l (y("e' =or5station control !istribution of control instructions to wor5stations %roduction control 2raffic control $huttle control =or5piece monitoring 2ool control

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%erformance monitoring and reporting !iagnostics

UNIT IV ! CIM IMP6EMENTATION AND DATA COMMUNICATION CIM an$ c#'+any ("ra"egy !oes that mean the starting point for CIM is a networ5 to lin5 all the e#isting islands of automation and softwareI 3r is it the integration of the e#isting departmental functions and activities as suggested by the CIM wheelI 2he answer to both the questions &ust 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 companys business strategy. 8y("e' '#$eling "##l( It is helpful if the modeling tool is of sufficient sophistication that it e#ists in three forms/ s a representation of the system s a dynamic model s an e#ecutable model

IDEF an$ IDEF0 I!6" initially provided three modeling methods I!6"( is used for describing the activities and functions of a system I!6"* is used for describing the information and its relationships

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I!6"4 is used for describing the dynamics of a system

Ac"i.i"y cycle $iagra'( 2his modeling approach follows the notation of I!6"( by having activities represented as rectangles and by having the activity names specified inside the rectangle. ll resources which are to be represented in the model are classified as entity classes. CIM #+en (y("e' archi"ec"%re,CIMO8ACIM3$ was produced as generic reference architecture for CIM integration as part of an 6$%-I2 pro&ect. 2he architecture is designed to yield e#ecutable models or parts of models leading to computeriEed implementations for managing an enterprise. Man%&ac"%ring en"er+ri(e *heel he new manufacturing enterprise wheel<s focus is now the customer at level *, and it identifies *> 5ey processes circumferentially at level '. 2hese are grouped under the headings of customer support, product?process and manufacturing. CIM archi"ec"%re

CIM A'C(I )C *')

+., CIM Architecture -verview

2o develop a comprehensive CIM strategy and solutions, an enterprise must begin with .solid foundations such as CIM architecture. CIM architecture is an information systems structure that enables industrial enterprises integrate information and business processes It accomplishes this first by establishing the direction integration will ta5eJ and second, by defining the interfaces between the users and the providers of this integration function.2he chart ("igure 4.*) illustrates how a CIM architecture answers the enterprise<s integration needs. s you can see here, a CIM architecture provides a core of common services. 2hese services support every other area of the enterpriseKfrom its common support functions to its highly specialiEed business processes. +.,., hree .ey #uilding #loc.s 2he information environment of an industrial enterprise is sub&ect to frequent changes

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in systems configuration and technologies.

CIM architecture can offer a fle#ible

structure that enables it to react to these changes. 2his structure relies on a number of modular elements that allow systems to change more easily to grow along with enterprise needs. nd as you can see from the chart on the facing page, the modular elements that give a CIM architecture its fle#ible structure are based on three 5ey building bloc5s/ L CommunicationsKthe communication and distribution of data. L Data managementKthe definition, storage and use of data L $resentationKthe presentation of this data to people and devices throughout the enterprise

!ata dictionary !ata repository and store layered structure -epository builder

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Pr#$%c" $a"a 'anage'en" ,PDM-! CIM i'+le'en"a"i#n (#&"*are 2he four ma&or modules typically contained within the %!M software are %rocess models %rocess pro&ect management !ata management !ata and information 5itting

2he %!M environment provides lin5s to a number of software pac5ages used by a company. 2hey are C ! pac5age manufacturing?production management pac5age word processing pac5age !atabases for various applications ,ife+cycle data

C#''%nica"i#n &%n$a'en"al( frequency n amplitude phase which continuously changes bandwidth n introduction to baseband and broadband 2elephone terminology !igital communications

6#cal area ne"*#r/( $ignal transmission, baseband and broadband Interconnection media

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T#+#l#gy $tar topology -ing topology ;us topology 2ree topology

6AN i'+le'en"a"i#n( Client server architecture Fetwor5s and distributed systems Multi+tier and high speed , Fs

Ne"*#r/ 'anage'en" an$ in("alla"i#n $ecurity and administration %erformance "le#ibility Mser interface Installation

UNIT V ! OPEN 878TEM AND DATA4A8E FOR CIM O+en (y("e' in"erc#nnec"i#n ,O8I- '#$el 2he physical layer 2he data lin5 layer 2he networ5 layer 2he transport layer 2he session layer 2he presentation layer 2he application layer

Man%&ac"%ring a%"#'a"i#n +r#"#c#l an$ "echnical #&&ice +r#"#c#l

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4a(ic $a"a2a(e "er'in#l#gy !atabase management system !atabase system !ata model 2ransaction $chema !ata definition language !ata manipulation language pplications program Gost language !atabase administrator

The archi"ec"%re #& a $a"a2a(e (y("e' Internal schema 6#ternal schema Conceptual schema

Da"a '#$eling an$ $a"a a((#cia"i#n( !ata modeling is carried out by using a data modeling method and one of a number of graphic representations to depict data groupings and the relationship between groupings. Da"a '#$eling $iagra' En"i"y:Rela"i#n(hi+ $iagra' Da"a a((#cia"i#n( 3ne+to+3ne 3ne+to+Many Many+to+3ne Many+to+Many

Rela"i#nal $a"a2a(e( 44

2he terms illustrated are relation, tuple, attribute, domain, primary 5ey and foreign 5ey. Da"a2a(e #+era"#r( Mnion Intersection !ifference %roduct %ro&ect $elect 0oin !ivide

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