BOE 302_ UNIT - IV Introduction to Automation

Fundamentals of Computer Integrated Manufacturing

Computer Integrated Manufacturing (CIM) is a comprehensive approach to manufacturing that integrates various
technologies to control the entire production process.

Computer Integrated Manufacturing (CIM) is a method of manufacturing in which the entire production process is
controlled by compute

Computer-integrated manufacturing (CIM) refers to the use of computer-controlled machineries and

automation systems in manufacturing products.
CIM Combines various technologies like computer-aided design (CAD) and computer-aided manufacturing
(CAM) to provide an error-free manufacturing process that reduces manual labor and automates repetitive
tasks.
The CIM Approach increases the speed of the manufacturing process and uses real-time sensors and closed-
loop control processes to automate the manufacturing process. It is widely used in the automotive, aviation,
space and ship-building industries.

The objective of computer-integrated manufacturing is to streamline production processes, delivering the

following benefits:
 Reduced costs – i.e. the cost of direct and indirect labour
 Improved scheduling flexibility
 Reduced downtime
 Maintaining correct inventory levels

Benefits of computer integrated manufacturing

Time-efficiency: a fully automated system can operate much faster and work 24/7 if required;

Accuracy: adoption of a computer integrated manufacturing (CIM) system allows to achieve a higher accuracy level.
Implementing technology into your manufacturing process allows you to achieve near-perfect precision levels in
production as well as quality control;

Repeatability: automated computer integrated manufacturing systems are highly efficient when it comes to
monotonous tasks. Such a system speeds up production time and cuts down the production cost on many levels. For
instance, there is no need to train or retrain staff;

Reduced costs: with the help of computer integrated manufacturing technology, you can reduce labor costs and lower
the amount of waste (as there is less of a chance for mistake or deviation from the standard, so the overall quality of the
product gets better);

Post-pandemic value: social distancing is here to stay, so reducing the number of staff members will help you maintain
sanitation norms and your employees stay healthy.

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BOE 302_ UNIT - IV Introduction to Automation

Components of CIM

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BOE 302_ UNIT - IV Introduction to Automation

Major Elements of a CIM system:

There are 9 major elements of Computer Integrated Manufacturing system

1. 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.

2. 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
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.

3. 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.

4. 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.

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BOE 302_ UNIT - IV Introduction to Automation

5. 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.

6. 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.

7. 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.

8. 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.

9. 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.

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BOE 302_ UNIT - IV Introduction to Automation

CIM Wheel

Group Technology
Group technology is a manufacturing philosophy in
which similar parts are identified and grouped
together to take advantage of their similarities in
manufacturing and design.

Similar parts are arranged into part families, where

each part family possesses similar design and/or
manufacturing characteristics.

Grouping the production equipment into machine

cells, where each cell specializes in the production of
a part family, is called cellular manufacturing

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BOE 302_ UNIT - IV Introduction to Automation

Uses of Group Technology:

Group technology technique can be conveniently followed using a classification system. In any assembly, a
variety of parts exist. These varieties of parts can be-segregated in three broad areas, viz.
 Standard and proprietary parts (like nuts, bolts, screws, keys, washers, etc.)

 Similar parts (like shafts, gears, bearings, levers, etc.)

 Product specific parts (like gear box, bed, saddle, etc.)

How to Implement Group Technology (GT)?

1. Identify Objectives
 Define Goals: Clarify what you aim to achieve with GT, such as reducing setup times, improving workflow, or
enhancing product quality.
 Scope: Determine the scope of implementation—whether it will be across the entire organization or within
specific departments.

2. Data Collection and Analysis

 Gather Data: Collect detailed information on parts and products, including design specifications, manufacturing
processes, and usage patterns.
 Classify Parts: Use classification systems such as coding systems (e.g., Opitz, MICLASS) to categorize parts based
on attributes like shape, size, material, and manufacturing processes.

3. Form Part Families

 Cluster Analysis: Apply cluster analysis techniques to group similar parts into families. This can be done
manually or using software tools.
 Coding and Classification: Assign codes to each part based on its attributes to facilitate easy identification and
grouping.

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BOE 302_ UNIT - IV Introduction to Automation

4. Design Manufacturing Cells

 Cell Layout: Design manufacturing cells by grouping machines and equipment required to produce each part
family. Each cell should be capable of performing all the operations needed for its part family.
 Workflow Optimization: Arrange the layout to minimize movement and handling, ensuring smooth workflow
and efficient use of resources.

5. Implement Pilot Project

 Select a Pilot Area: Choose a specific area or product line to implement GT as a pilot project.
 Monitor and Adjust: Observe the performance, identify any issues, and make necessary adjustments. Use this
pilot phase to refine your approach before full-scale implementation.

6. Train Employees
 Education and Training: Train employees on the principles of GT, the new processes, and the operation of
manufacturing cells.
 Cross-Training: Ensure that employees are skilled in multiple tasks within their cell to enhance flexibility and
adaptability.

7. Integrate with Existing Systems

 ERP/MES Integration: Integrate GT with existing Enterprise Resource Planning (ERP) and Manufacturing
Execution Systems (MES) for seamless data flow and process management.
 Automation and IT: Utilize automation and IT solutions to streamline data collection, monitoring, and control
processes within manufacturing cells.

8. Continuous Improvement
 Monitor Performance: Continuously monitor the performance of manufacturing cells and part families. Use Key
Performance Indicators (KPIs) to measure efficiency, productivity, and quality.
 Feedback Loop: Establish a feedback loop to gather insights from employees and continuously improve
processes. Implement Lean and Six Sigma methodologies to identify and eliminate waste.

9. Full-Scale Implementation
 Scale Up: Once the pilot project proves successful, gradually scale up the implementation of GT across the
organization.
 Standardize Processes: Develop standard operating procedures (SOPs) for GT processes to ensure consistency
and repeatability.

10. Evaluate and Adapt

 Regular Audits: Conduct regular audits to assess the effectiveness of GT implementation and make necessary
adjustments.
 Adapt to Changes: Stay agile and adapt to changes in product design, market demands, and technological
advancements.

Benefits of Group Technology

1. Reduced Setup Time: Grouping similar parts reduces the frequency of setup changes.
2. Increased Productivity: Streamlined processes and reduced handling lead to higher output.
3. Improved Quality: Consistency in manufacturing processes enhances product quality.
4. Lower Inventory: Efficient production planning reduces the need for large inventories.
5. Enhanced Flexibility: Manufacturing cells can quickly adapt to changes in production requirements.
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BOE 302_ UNIT - IV Introduction to Automation

Disadvantages of Group Technology:

(i) Additional cost of implementation of this system.
(ii) Rate of change in product range and mix.
(iii) Difficulties with out-of-cell operations.
(iv) Coexistence with non-cellular systems.

Flexible Manufacturing System

 A Flexible Manufacturing System [FMS] is a highly automated Group Technology [GT] machine cell,
consisting of a group of processing workstations, interconnected by an automated material handling and
storage system, and controlled by a distributed computer system.

 “FMS consists of a group of processing work stations interconnected by means of an automated material
handling and storage system and controlled by integrated computer control system.”

 FMS is called flexible due to the reason that it is capable of processing a variety of different part styles
simultaneously at the workstation and quantities of production can be adjusted in response to changing
demand patterns.

There are three levels of manufacturing flexibility.

(a) Basic flexibilities
 Machine flexibility: The ease with which a machine can process various operations
 Material handling flexibility: A measure of the ease with which different part types can be transported
and properly positioned at the various machine tools in a system
 Operation flexibility: A measure of the ease with which alternative operation sequences can be used
for processing a part type
(b) System flexibilities
 Volume flexibility: A measure of a system’s capability to be operated profitably at different volumes of
the existing part types
 Expansion flexibility: The ability to build a system and expand it incrementally
 Routing flexibility: A measure of the alternative paths that a part can effectively follow through a system
for a given process plan
 Process flexibility: A measure of the volume of the set of part types that a system can produce without
incurring any setup
 Product flexibility: The volume of the set of part types that can be manufactured in a system with minor
setup

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BOE 302_ UNIT - IV Introduction to Automation

(c) Aggregate flexibilities

 Program flexibility: The ability of a system to run for reasonably long periods without external
intervention
 Production flexibility: The volume of the set of part types that a system can produce without major
investment in capital equipment
 Market flexibility: The ability of a system to efficiently adapt to changing market conditions

Components of a Flexible Manufacturing System

The basic components of FMS are:
1. Workstations
2. Automated Material Handling and Storage system.
3. Computer Control System

1. Workstations: In present day application these workstations are typically computer numerical control (CNC) machine
tools that perform machining operation on families of parts. Flexible manufacturing systems are being designed with other
type of processing equipments including inspection stations, assembly works and sheet metal presses. The various
workstations are

(i) Machining centers (iv) Inspection stations

(ii) Load and unload stations (v) Forging stations
(iii) Assembly work stations (vi) Sheet metal processing, etc
2. Automated Material Handling and Storage system: The various automated material handling systems are used to
transport work parts and subassembly parts between the processing stations, sometimes incorporating storage into
function. The various functions of automated material handling and storage system are
(i) Random and independent movement of work parts between workstations
(ii) Handling of a variety of work part configurations
(iii) Temporary storage
(iv) Convenient access for loading and unloading of work parts
(v) Compatible with computer control

3. Computer Control System: It is used to coordinate the activities of the processing stations and the material handling
system in the FMS. The various functions of computer control system are:
(i) Control of each work station
(ii) Distribution of control instruction to work station
(iii) Production control
(vi) Traffic control
(v) Shuttle control
(vi) Work handling system and monitoring
(vii) System performance monitoring and reporting

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BOE 302_ UNIT - IV Introduction to Automation

TYPES OF FMS
The different types of FMS are
 Sequential FMS  Engineered FMS
 Random FMS  Modular FMS
 Dedicated FMS

Sequential FMS: It manufactures one-piece part batch type and then planning and preparation is carried out for the next
piece part batch type to be manufactured. It operates like a small batch flexible transfer line.

Random FMS: It manufactures any random mix of piece part types at any one time.

Dedicated FMS: It continually manufactures, for extended periods, the same but limited mix of piece part batch types.

Engineered FMS: It manufactures the same mix of part types throughout its lifetime.

Modular FMS: A modular FMS, with a sophisticated FMS host, enables and FMS user to expand their FMS capabilities in a
stepwise fashion into any of the previous four types of FMS.

Types of FMS Layout:

The different types of FMS layouts are:

1. Progressive or Line Type

2. Loop Type

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BOE 302_ UNIT - IV Introduction to Automation

3. Ladder Type
4. Open field type
5. Robot centered type

1.Progressive or Line type: The machines and handling system are arranged in a line in this type of system. It is most
appropriate for a system in which the part progress from one workstation to the next in a well-defined sequence with no
back flow. The operation of this type of system is very similar to transfer type. Work always flows in unidirectional path
as shown in the figure below

2.Loop Type: The basic loop configuration is as shown in figure below. The parts usually move in one direction around
the loop, with the capability to stop and be transferred to any station. The loading and unloading station are typically
located at one end of the loop as shown in the figure below.

3.Ladder Type: The configuration is as shown in the figure below. The loading and unloading station is typically located at
the same end. The sequence to the operation/transfer of parts from one machine tool to another is in the form of ladder
steps as shown in the figure below.

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BOE 302_ UNIT - IV Introduction to Automation

4. Open Field Type: The configuration of the open field is as shown in the figure. The loading and unloading station is
typically located at the same end. The parts will go through all the substations, such as CNC machines, coordinate
measuring machines and wash station by the help of AGV’s from one substation to another.

6.Robot Centered Type: Robot centered cell is a relatively new form of flexible system in which one or more robots are
used as the material handling systems as shown in the figure below. Industrial robots can be equipped with grippers that
make them well suited for handling of rotational parts.

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BOE 302_ UNIT - IV Introduction to Automation

Advantages of Flexible Manufacturing Systems

 Enhanced Flexibility: Ability to handle different products and adapt to changes in production volumes.
 Improved Efficiency: Reduced setup times and optimized material handling increase overall productivity.
 Better Quality Control: Continuous monitoring and automated inspection ensure high product quality.
 Reduced Inventory: Just-in-time production reduces the need for large inventories.
 Cost Savings: Automation and optimized processes lead to lower labor and operational costs.

Challenges of Implementing FMS

 High Initial Cost: Significant investment required for setup and integration.
 Complexity: Requires advanced planning and coordination.
 Training Needs: Operators and staff need to be trained to handle new systems and technologies.
 Maintenance: Regular maintenance is crucial to ensure smooth operation and minimize downtime.

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