COMPUTER INTEGRATED MANUFACTURING. UNIT -1 COMPUTER INTEGRATED MANUFACTURING SYSTEMS 1, INTRODUCTION Computer Integrated Manufacturing (CIM) encompasses the entire range of product development and manufacturing activities with all the functions being carried out with the help of dedicated software packages. The data required for various functions are passed from one application software to another in a seamless manner. For example, the product data is created during design. This data has to be transferred from the modeling software to manufacturing software without any loss of data. CIM uses a common database wherever feasible and communication technologies to integrate design, manufacturing and associated business functions that combine the automated segments of a factory or a manufacturing facility. CIM reduces the human component of manufacturing and thereby relieves the process of its slow, expensive and error-prone component. CIM stands for a holistic and methodological approach to the activities of the manufacturing enterprise in order to achieve vast improvement in its performance. This methodological approach is applied to all activities from the design of the product to customer support in an integrated way, using various methods, means and techniques in order to achieve production improvement, cost reduction, fulfillment of scheduled delivery dates, quality improvement and total flexibility in the manufacturing system. CIM requires all those associated with a company to involve totally in the process of product development and manufacture. In such a holistic approach, economic, social and human aspects have the same importance as technical aspects, CIM also encompasses the whole lot of enabling technologies including total quality management, business process reengineering, concurrent engineering, workflow automation, enterprise resource planning and flexible manufacturing ‘The challenge before the manufacturing engineers is illustrated in Fig. 1 t uauiry /\ saan cm DELIVERY cost TIME, | | Figure 1 Challenges in manufacturing Dept. Mechanical Engineering, ACE, Bangalore SANDEEP TR.COMPUTER INTEGRATED MANUFACTURING. SANDEEP TR. ‘Manufacturing industries strive to reduce the cost of the product continuously to remain competitive in the face of global competition. In addition, there is the need to improve the quality and performance levels on a continuing basis, Another important requirement is on time delivery. In the context of global outsourcing and long supply chains cutting across several intemational borders, the task of continuously reducing delivery times is really an arduous task. CIM has several software tools to address the above needs, Manufacturing engineers are required to achieve the following objectives to be competitive in a global context. + Reduction in inventory + Lower the cost of the product + Reduce waste + Improve quality + Increase flexibility in manufacturing to achieve immediate and rapid response to" Product changes + Production changes + Process change + Equipment change Change of personnel CIM technology is an enabling technology to meet the above challenges to the manufacturing. 2. EVOLUTION OF COMPUTER INTEGRATED MANUFACTURING Computer Integrated Manufacturing (CIM) is considered a natural evolution of the technology of CAD/CAM which by itself evolved by the integration of CAD and CAM. Massachusetts Institute of Technology (MIT, USA) is credited with pioneering the development in both CAD and CAM. The need to meet the design and manufacturing requirements of aerospace industries after the Second World War necessitated the development these technologies. The manufacturing technology available during late 40's and early 50's could not meet the design and manufacturing challenges arising out of the need to develop sophisticated aircraft and satellite launch vehicles. This prompted the US Air Force to approach MIT to develop suitable control systems, drives and programming techniques for ‘machine tools using electronic control. Dept. Mechanical Engineering, ACE, BangaloreCOMPUTER INTEGRATED MANUFACTURING. SANDEEP TR. The first major innovation in machine control is the Numerical Control (NC), demonstrated at MIT in 1952. Early Numerical Control Systems were all basically hardwired systems, since these were built with disctete systems or with later first generation integrated chips. Early NC machines used paper tape as an input medium. Every NC machine was fitted with a tape reader to read paper tape and transfer the program to the memory of the machine tool block by block. Mainframe computers were used to control a group of NC machines by mid 66's. This arrangement was then called Direct Numerical Control (DNC) as the computer bypassed the tape reader to transfer the program data to the machine controller. By late 60's mini computers were being commonly used to control NC machines. At this stage NC became truly soft wired with the facilities of mass program storage, offline editing and software logic control and processing. This development is called Computer Numerical Control (CNC), Since 70's, numerical controllers are being designed around microprocessors, resulting in compact CNC systems. A further development to this technology is the distributed numerical control (also called DNC) in which processing of NC program is carried out in different computers operating at different hierarchical levels - typically from mainframe host computers to plant computers to the machine controller. Today the CNC systems are built around powerful 32 bit and 64 bit microprocessors. PC based systems are also becoming increasingly popular. Manufacturing engineers also started using computers for such tasks like inventory control, demand forecasting, production planning and control ete. CNC technology was adapted in the development of co-ordinate measuring machine's (CMMs) which automated inspection. Robots were introduced to automate several tasks like machine loading, materials handling, welding, painting and assembly. All these developments led to the evolution of flexible manufacturing cells and flexible manufacturing systems in late 70's. Evolution of Computer Aided Design (CAD), on the other hand was to cater to the geometric modeling needs of automobile and aeronautical industries. The developments in computers, design workstations, graphic cards, display devices and graphic input and output devices during the last ten years have been phenomenal. This coupled with the development of operating system with graphic user interfaces and powerful interactive (user friendly) software packages for modeling, drafting, analysis and optimization provides the necessary tools to automate the design process. CAD in fact owes its development to the APT language project at MIT in early 50's. Several clones of APT were introduced in 80's to automatically develop NC codes from the geometric model of the component. Now, one can model, draft, analyze, simulate, modify, optimize and create the NC code to manufacture a component and simulate the machining operation sitting at a computer workstation. If we review the manufacturing scenario during 80's we will find that the manufacturing is characterized by a few islands of automation. In the case of design, the task is well automated. In the case of manufacture, CNC machines, DNC systems, FMC, FMS etc provide tightly controlled automation systems. Similarly computer control has been implemented in several areas like manufacturing resource planning, accounting, sales, marketing and purchase. Yet the full potential of computerization could not be obtained Dept. Mechanical Engineering, ACE, BangaloreCOMPUTER INTEGRATED MANUFACTURING. SANDEEP TR. unless all the segments of manufacturing are integrated, permitting the transfer of data across various functional modules. This realization led to the concept of computer integrated ‘manufacturing. Thus the implementation of CIM required the development of whole lot of computer technologies related to hardware and software, 3. CIM HARDWARE AND CIM SOFTWARE CIM Hardware comprises the following: i, Manufacturing equipment such as CNC machines or computerized work centers, robotic work cells, DNC/FMS systems, work handling and tool handling devices, storage devices, sensors, shop floor data collection devices, inspection machines ete. ii, Computers, controllers, CAD/CAM systems, workstations / terminals, data entry terminals, bar code readers, RFID tags, printers, plotters and other peripheral devices, modems, cables, connectors etc, CIM software comprises computer programmes to carry out the following functions: Management Information System Sales Marketing Finance Database Management Modeling and Design Analysis Simulation Communications Monitoring Production Control Manufacturing Area Control Job Tracking Inventory Control Shop Floor Data Collection Order Entry Materials Handling Device Drivers Process Planning ‘Manufacturing Facilities Planning Work Flow Automation Business Process Engineering Network Management Quality Management Dept. Mechanical Engineering, ACE, BangaloreCOMPUTER INTEGRATED MANUFACTURING. SANDEEP TR. 4. NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEM Nine major elements of a CIM system are in Figure 2 they are, © Marketing * Product Design * Planning * Purchase © Manufacturing Engineering * Factory Automation Hardware © Warehousing © Logistics and Supply Chain Management * Finance * Information Management & Figure Nt Major elements of CIM systems 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 modeling 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 Dept. Mechanical Engineering, ACE, BangaloreCOMPUTER INTEGRATED MANUFACTURING. SANDEEP TR. 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 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, 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. . 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. Dept. Mechanical Engineering, ACE, BangaloreCOMPUTER INTEGRATED MANUFACTURING. SANDEEP TR. ix. Information Management: Information Management is pethaps one of the crucial tasks in CIM. This involves master production scheduling, database management, communication, manufacturing systems integration and management information systems Definition of CIM Joel Goldhar, Dean, Hlinois Institute of Technology gives CIM as a computer system in which the peripherals are robots, machine tools and other processing equipment. Dan Appleton, President, DACOM, Inc. defines CIM is a management philosophy, not a turkey product. Jack Conaway, CIM Marketing manager, DEC, defines CIM is nothing but a data management and networking problem. ‘The computer and automated systems association of the society of Manufacturing Engineers (CASA/SEM) defines 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. CIM is recognized as Islands of Automation, They are 1. CAD/CAMICAE/GT 2. Manufacturing Planning and Control. 3. Factory Automation 4. General Business Management CASA/SME's CIM Wheel is as shown in figure 4 Oo wae 1 (‘ar \ Figure 4 CASA/SME's CIM Wheel Dept. Mechanical Engineering, ACE, BangaloreCOMPUTER INTEGRATED MANUFACTURING. SANDEEP TR. Conceptual model of manufacturing The computer has had and continues to have a dramatic impact on the development of production automation technologies. Nearly all modem production systems are imple- mented today using computer systems. The term computer integrated manufacturing (CIM) has been coined to denote the pervasive use of computers to design the products, plan the production, control the operations, and perform the various business related functions needed in a manufacturing firm, CAD/CAM (computer-aided design and com- puter-aided manufacturing) is another term that is used almost synonymously with CIM. Let us attempt to define the relationship between automation and CIM by developing a conceptual model of manufacturing. In a manufacturing firm, the physical activities related to production that take place in the factory can be distinguished from the infor- mation-processing activities, such as product design and production planning, that usually occur in an office environment. The physical activities include all of the manufacturing processing, assembly, material handling, and inspections that are performed on the prod- ‘uct, These operations come in direct contact with the product during manufacture. They touch the product. The relationship between the physical activities and the information- processing activities in our model is depicted in Figure 5. Raw materials flow in one end of the factory and finished products flow out the other end. The physical activities (processing, handling, etc.) take place inside the factory. The information-processing functions form a ring that surrounds the factory, providing the data and knowledge required to produce the product successfully. These information-processing functions include (1) certain business activities (e.g., marketing and sales, order entry, customer billing, etc.), (2) product design, (3) manufacturing planning, and (4) manufacturing control. These four functions form a cycle of events that must accompany the physical production activities but which do not directly touch the product. Now consider the difference between automation and CIM. Automation is concemed with the physical activities in manufacturing. Automated production systems are designed to accomplish the processing, assembly, material handling, and inspecting activities with litle or no human participation. By comparison, computer integrated manufacturing is (figure 5° 7% Product > nformation- isn oe busnes \ sewing Aw po false | ea Secale ie | roots vas ae } Ya | VW} erty \~ J / Monutersitg X_// Dept. Mechanical Engineering, ACE, Bangalore