Computer integrated manufacturing (CIM) incorporates all manufacturing processes including CAD/CAM, business functions, and engineering functions. CIM aims to achieve lower costs, higher quality, and better responsiveness through techniques like group technology, flexible manufacturing systems, and shop floor control using concepts like CONWIP. Group technology groups similar parts into families to improve productivity. Flexible manufacturing systems are reprogrammable systems that can produce different product types automatically using components like machine tools and automated material handling.

1. ME6703 COMPUTER INTEGRATED MANUFACTURING
By,
S. Muthu Natarajan M.E., (Ph.D.),
Asssistant Professor,
Departyment of Mechanical Engineering,
Kamaraj College of Engineering and Technology,
Virudhunagar

2. UNIT 1
INTRODUCTION

3. Meaning and origin of CIM
Computer integrated manufacturing includes all if the
engineering functions of CAD/CAM ,and also includes
firm’s business functions that are related
manufacturing

4. ASRSASRS
CAD/CAMCAD/CAM
AGVAGV
Order EntryOrder Entry
AutomatedAutomated
AssemblyAssembly
NCNC
MachiningMachining
Computer Integrated
Manufacturing (CIM)
Incorporates all manufacturing processes

6. Introduction to Manufacturing systemManufacturing system divides into five groups
Project
Job type
Repetitive
Line
Contionus

7. Changes in manufacturing
The changes of manufacturing in to modernization
activities is required to overcome global competition,
consumer demand for better product and quality and
judicious application of newer technologies

8. Computer control of manufacturing

10. CIM software
The CIM software is an integrated package containing
as many individual programs functionally
amalgamated into one as possible. The CIM requires
the application programs that can be integrated

11. Programming languages used in CIM
Apt
C
FORTRAN
MODULA-2
PROLONG
BASIC
COBAL
LISP
PASCAL
VAL

12. Plant operation
Various operations
processing
Assembly
Material handling and storage
Inspection
Control

13. Task modeling of CIM

14. CIM manager’s Task

15. Production planning
The production planning is the function of setting the
overall level of manufacturing output and other
activities to satisfy the current planned levels of sales

16. Production planning functions

17. Manufacturing organization model

18. CIM is synonymous with world-class measures
such as:
􀂃 lower manufacturing costs
􀂃 higher product quality
􀂃 better production control
􀂃 better customers responsiveness
􀂃 reduced inventories
􀂃 greater flexibility
􀂃 smaller lot-size production

19. Components Of CIM
CIM
Product
design
Manufacture
Process
planning
Systems
management
RoboticsFMS
NC/CNC/
DNC
Cells
and centers
Automated
inspection
AGV,
ASRS
JIT/
kanban
DSS/ES/
AI
LAN, TOP,
satellites
TQM
Bar codes,
EDI
MRP
GTCAECAD
IGES,
PDES,
DMIS
DFM
Cellular
manufacturing
MAP,
STEP
CAD/CAM
CAPP

20. Why Use CIM?
Responsiveness to Rapid Changes in Market Demand
and Product Modification.
Better Use of Materials, Machinery, Personnel,
Reduction in Inventory.
Better Control of Production and Management of the
Total Manufacturing Operation.
The Manufacture of High-Quality Products at Low
Cost.

21. Integrated systems
Architecture

22. GROUP TECHNOLOGY AND COMPUTER
AIDED PROCESS PLANNING

23. Introduction
Group technology was introduced by Frederick Taylor
in 1919 as a way to improve productivity.
One of long term benefits of group technology is it
helps implement a manufacturing strategy aimed at
greater automation.

24. What is group technology?
Group technology (GT) is a manufacturing philosophy
that seeks to improve productivity by grouping parts
and products with similar characteristics into families
and forming production cells with a group of
dissimilar machines and processes.

25. Background
The introduction of GT techniques in:
General Electric
Lockheed Missiles and Space Co.
Boeing
GT viewed as:
An essential step in the move toward factory automation.
A necessary step in maintaining a high quality level and
profitable production.

26. Group Technology
Group technology implementation can be broken
down into 3 different phases:
 Actions on the manufacturing process
 Changes to the production process
 Results for the organization
Examples of the impacts group technology has had on
the production process.

27. Part families
A part family is a collection of parts which are similar
either because of geometry and size or because of
similar processing steps are required in their
manufacture

28. Parts classification and coding
Part classification and coding system can be grouped
into three types
1.Design attribute group
2.Manufacturing attribute group
3.Combined attribute group

29. Various coding systems
The widely used coding systems are
 DCLASS
 MICLASS
 OPITZ
 RNC
 CODE

30. OPTIZ CLASSIFICATION SYSTEM

31. Implementation Phases
Group technology has the
following actions on the
manufacturing process:
Part Simplification
Process Standardization
Production Control

32. Implementation Phases
The changes group technologies can have on the
production process.
 Tighter Parts Control
 Close physical layout of machine groups
 Orderings tied to production

33. Implementation Phases
The results that group technologies have at the
organizational level.
 Systematic design and redesign
 High-quality level
 Less process planning time and setup time

34. Impacts of Group Technology
Different impacts group technology has on the
production process:
 Reduced purchasing cost
 Less redundant purchases.
 Accurate cost estimation
 A more efficient process
 Quicker design changes
 Standardized Parts
 Improved customer service
 Classification builds customer relationships

35. PROCESS PLANNING
Introduction
Process planning consists of preparing a set of
instructions that describe how to fabricate a part or
build an assembly which will satisfy engineering
design specifications. The resulting set of instructions
may include any or all of the following:

36. PROCESS PLANNING STEPS
 Study the overall shape of the part. Use this information to classify the
part and determine the type of workstation needed.
• Thoroughly study the drawing. Try to identify every manufacturing
features and notes.
 If raw stock is not given, determine the best raw material shape to use.
 Identify datum surfaces. Use information on datum surfaces to determine
the setups.
• Select machines for each setup.
 For each setup determine the rough sequence of operations necessary to
create all the features.

37. PROCESS PLANNING STEPS
(continue)
Sequence the operations determined in the previous
step.
Select tools for each operation. Try to use the same
tool for several operations if it is possible. Keep in
mind the trade off on tool change time and estimated
machining time.
Select or design fixtures for each setup.
Evaluate the plan generate thus far and make
necessary modifications.
Select cutting parameters for each operation.
Prepare the final process plan document.

38. Process Planning Automation
There are three approaches to
computeraided
process planning (CAPP):
• Manual Approach
Not Computer-Aided.
• Variant Approach
Computers store/match existing process
plans.
• Generative Approach
Computers generate a process plan from
scratch.

39. Manual Approach
The process plan is developed by a skilled
planner
who is familiar with the company’s
manufacturing
capabilities.
The steps involved are:
1. Study the overall shape of the part.
2. Determine what stock material to use.
3. Identify datum surfaces for setups
4. Identify part features.

40. Manual Approach
Steps, cont’d:
5. Group features into setups.
6. Sequence the operations in the setup
7. Select tools for each operation
8. Determine fixtures for each setup
9. Final Check
10. Elaborate Plan (e.g. feeds and speeds)
11. Prepare process plan document

41. COMPUTER-AIDED
PROCESS
PLANNINGADVANTAGES
1. It can reduce the skill required of a planner.
2. It can reduce the process planning time.
3. It can reduce both process planning and
manufacturing cost.
4. It can create more consistent plans.
5. It can produce more accurate plans.
6. It can increase productivity.

42. WHY AUTOMATED
PROCESS
PLANNING
• Shortening the lead-time
• Manufacturability feedback
• Lowering the production cost
• Consistent process plans

43. PROCESS
PLANNING
Machining featuresDesign
Workpiece Selection
Process Selection
Tool Selection
Feed, Speed Selection
Operation Sequencing
Setup Planning
Fixturing Planning
Part Programming

44. VARIANT PROCESS
PLANNING Standard
process
plans &
individual
process
plans
process
plan
editing
part
coding
part
family
formation
standard
plan
preparation
part
coding
part
family
search
process
plan
retrieval
finished
process
plan
GROUP TECHNOLOGY BASED RETRIEVAL SYSTEM

45. PROBLEMS ASSOCIATED
WITH
THE VARIANT APPROACH
1. The components to be planned are limited to
similar components previously planned.
2. Experienced process planners are still required to
modify the standard plan for the specific
component.
3. Details of the plan cannot be generated.
4. Variant planning cannot be used in an entirely
automated manufacturing system, without
additional process planning.

46. ADVANTAGES OF
THE
VARIANT APPROACH1. Once a standard plan has been written, a variety of
components can be planned.
2. Comparatively simple programming and
installation (compared with generative systems) is
required to implement a planning system.
3. The system is understandable, and the planner
has control of the final plan.
4. It is easy to learn, and easy to use.

47. GENERATIVE
APPROACH
(i) part description
(ii) manufacturing databases
(iii) decision making logic and
algorithms
A system which automatically synthesizes a
process plan for a new component.
MAJOR COMPONENTS:

48. ADVANTAGES OF THE
GENERATIVE
APPROACH1. Generate consistent process plans rapidly;
2. New components can be planned as easily as
existing components;
3. It has potential for integrating with an
automated manufacturing facility to provide
detailed control information.

49. Some typical benefits include
1. 50% increase in process planner productivity
2. 40% increase in capacity of existing equipment
3. 25% reduction in setup costs
4. 12% reduction in tooling
5. 10% reduction in scrap and rework
6. 10% reduction in shop labor
7. 6% reduction in work in process

50. UNIT III
SHOP FLOOR CONTROL AND INTRODUCTION
OF FMS

51. What is Shop Floor Control?
Definition: Shop Floor Control (SFC) is the
process by which decisions directly affecting
the flow of material through the factory are
made.

52. Functions
WIP
Tracking
Throughput
Tracking
Status
Monitoring
Work
Forecasting
Capacity
Feedback
Quality
Control
Material Flow
Control

53. Planning for SFC
 Gross Capacity Control: Match line to demand via:
Varying staffing (no. shifts or no. workers/shift)
Varying length of work week (or work day)
Using outside vendors to augment capacity
 Bottleneck Planning:
Bottlenecks can be designed
Cost of capacity is key
Stable bottlenecks are easier to manage
 Span of Control:
Physically or logically decompose system
Span of labor management (10 subordinates)
Span of process management (related technology?)

54. Basic CONWIPRationale:
Simple starting point
Can be effective
Requirements:
Constant routings
Similar processing times (stable bottleneck)
No significant setups
No assemblies
Design Issues:
Work backlog – how to maintain and display
Line discipline – FIFO, limited passing
Card counts – WIP = CT × rP initially, then conservative
adjustments
Card deficits – violate WIP-cap in special circumstances
Work ahead – how far ahead relative to due date?
. . .

55. CONWIP Line Using Cards
Production Line
Inbound
Stock
Outbound
Stock
CONWIP Cards

56. Card Deficits
B
Bottleneck Process
Jobs with CardsJobs without Cards
Failed Machine

57. Tandem CONWIP Lines
Links to Kanban: when “loops” become single process centers
Bottleneck Treatment:
Nonbottleneck loops coupled to buffer inventories (cards are
released on departure from buffer)
Bottleneck loops uncoupled from buffer inventories (cards are
released on entry into buffer)
Shared Resources:
Sequencing policy is needed
Upstream buffer facilitates sequencing (and batching if necessary)

58. Tandem CONWIP LoopsBasic CONWIP
Kanban
Multi-Loop CONWIP
Workstation Buffer Card Flow

59. Coupled and Uncoupled CONWIP
Loops
Bottleneck
Buffer
Card FlowMaterial FlowCONWIP Card
JobCONWIP Loop

60. Splitting Loops at Shared Resource
Routing A Routing A
Routing B Routing B
Buffer
Card Flow
Material Flow
CONWIP Loop

61. Modifications of Basic CONWIP
Multiple Product Families:
Capacity-adjusted WIP
CONWIP Controller
Assembly Systems:
CONWIP achieves synchronization naturally (unless
passing is allowed)
WIP levels must be sensitive to “length” of fabrication
lines

62. CONWIP Controller
PC
R G
PC
PN Quant–— ––––––— ––––––— ––––––— ––––––— ––––––— ––––––— ––––––— ––––––— ––––––— ––––––— ––––––— ––––––— –––––Indicator Lights
Work Backlog
LAN
. . .
Workstations

63. CONWIP Assembly
Processing Times
for Line B
Processing Times
for Line A
Assembly
1
3233
2 4
1
Material FlowCard FlowBuffer

64. Data Collection Devices
special purpose data collection terminals
card or badge reader
CRT or LED display
a fairly robust keypad
MICR, OCR and punched cards
bar-code readers

65. Bar Codes
The bar-codes used internally in factories are usually
either item numbers, which identify materials, or
order numbers, which allow the shop floor control
system to track the progress of an order through
production. Employee badges, machines, and
production processes can also be bar-coded.

66. Bar Code Readers
essentially two types
hand-held scanners and
mounted scanners

68. Flexible Manufacturing Systems
(FMS)
 An FMS is a “reprogrammable” manufacturing system capable of
producing a variety of products automatically. Conventional
manufacturing systems have been marked by one of two distinct features:
The capability of producing a variety of different product types,
but at a high cost (e.g., job shops).
The capability of producing large volumes of a product at a lower
cost, but very inflexible in terms of the product types which can be
produced (e.g., transfer lines).
 An FMS is designed to provide both of these features.

69. FMS Components
Numerical Control (NC) machine tools
Automated material handling system (AMHS)
Automated guided vehicles (AGV)
Conveyors
Automated storage and retrieval systems (AS/RS)
Industrial Robots
Control Software

70. Flexible Manufacturing System
Parts
Finished
goods
Load Unload
Computer
control
room
Terminal
Machine Machine
Tools
Conveyor
Pallet

71. Classification of FMS-related
Problems Strategic analysis and economic justification, which provides long-range,
strategic business plans.
 Facility design, in which strategic business plans are integrated into a
specific facility design to accomplish long-term managerial objectives.
 Intermediate-range planning, which encompasses decisions related to
master production scheduling and deals with a planning horizon from
several days to several months in duration.
 Dynamic operations planning, which is concerned with the dynamic,
minute-to-minute operations of FMS.

72. FMS Problems
 Part type selection (Askin) - selecting parts that will be produced in the FMS
over some relatively long planning horizon.
 Part selection (Stecke) - from the set of parts that have current production
requirements and have been selected for processing in the FMS, select a subset for
immediate and simultaneous processing.
 Machine grouping (Stecke) - partition machines into groups where each machine
in a group can perform the same set of operations.
 Loading (Stecke) - allocate the operations and required tools of the selected part
types among the machine groups.
 Control - provide instructions for, and monitor the equipment in the FMS so that
the production goals identified by the above problems are met.

73. FMS Layouts
Progressive Layout:
Best for producing a variety of parts
Closed Loop Layout:
Parts can skip stations for flexibility
Used for large part sizes
Best for long process times

74. FMS Layouts Continued
• Ladder Layout:
― Parts can be sent to any machine in any sequence
― Parts not limited to particular part families
• Open Field Layout:
― Most complex FMS layout
― Includes several support stations

75. Automated Material Handling
Automated Guided Vehicle
(AGV)
Automated Storage and
Retrieval System (ASRS)
Conveyors

76. Components of Flexible Manufacturing
Systems
NC
CNC
DNC
Robotics
AGV
ASRS
Automated Inspection
Cells and Centers

77. Flexible Automation
Ability to adapt to
engineering changes in parts
Increase in number of similar
parts produced on the
system
Ability to accommodate
routing changes
Ability to rapidly change
production set up

78. Applications and benefits of FMS
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

79. CIM IMPLEMENTATION AND DATA
COMMUNICATION

81. The Local Area Network (LAN)
The LAN has many variations:
Wired (or fiber) or Wireless
Operate at speeds from 1 Mbps to 1 Gbps (+++)
Support Desktops, Laptops, Personal Devices
Allow access to many resources
 Print
 File Server
 Internet
 Mainframe
 Collaborative Planning
 Etc….

82. LAN Characteristics
Typically serves a limited area
Typically serves a single organization
Varies from serving a few users to thousands
Provides access to shared services
Through a Network Operating System (NOS)
 Examples: Windows NT, Novell, HP Unix
Uses some form of access control
High speed network connection

83. LAN Topologies
LAN Topology describes how the network is
constructed and gives insight into its strengths and
limitations
Bus
Star
Branching Tree
Ring

85. Bus/Tree Topology
• The original topology
 Workstation has a network interface card
(NIC) that attaches to the bus (a coaxial
cable) via a tap
• Data can be transferred using either
baseband digital signals or broadband
analog signals

91. Access Control
Like a noisy classroom--difficult to
communicate if every terminal is going at
the same time
Two forms we’ll discuss
Non-Contention Access:
Token
Contention Access:
Carrier Sense Multiple Access with Collision
Detection (CSMA/CD)

92. Token
Used in Bus and Ring topologies
Token Ring for instance
A token is placed on the network and passed to each
member of the network
When someone has something to say, they “grab” the
token and then transmit their information
The message is sent to all other members of the
network
The member the message is addressed to “hears” the
message and all others ignore the message
Once the message is delivered, the token is freed for
someone else to use

93. Token Issues
The system has very good control, but is complex in
implementation
If token is lost or mutilated, a member of the network
must replace the token
Usually automatic after some specified wait time
System is deterministic
That means that if a station has higher priority traffic to
send, the system can deal with that, either by
preemption or allocation

94. OPEN SYSTEM AND DATABASE FOR CIM

95. Open system
Generally Computer network architectures are based
on the layering principle following a standard namely
the reference model of OSI (open system inter
connection). It is defied by ISO (International
standard organization)

96. OSI model’s seven layer
Level No Layer Type
7 Application
6 presentation
5 Session
4 Transport
3 Network
2 Data link
1 Physical

97. Information flow through the layer

98. CIM system database structure

99. What is MAP
The MAP is a hardware cum software implementable
set of rules that facilitate information transfer among
network computers and computer equipment

100. What is TOP
A related protocol standard is being adopted for office
network is the technical and office protocol

101. What is DBMS?
Need for information management
A very large, integrated collection of data.
Models real-world enterprise.
 Entities (e.g., students, courses)
 Relationships (e.g., John is taking CS662)
A Database Management System (DBMS) is a
software package designed to store and manage
databases.

105. Why Use a DBMS?
Data independence and efficient access.
Data integrity and security.
Uniform data administration.
Concurrent access, recovery from crashes.
Replication control
Reduced application development time.

106. Why Study Databases??
Shift from computation to information
at the “low end”: access to physical world
at the “high end”: scientific applications
Datasets increasing in diversity and volume.
Digital libraries, interactive video, Human Genome
project, e-commerce, sensor networks
... need for DBMS/data services exploding
DBMS encompasses several areas of CS
OS, languages, theory, AI, multimedia, logic
?

107. Data ModelsA data model is a collection of concepts for
describing data.
A schema is a description of a particular collection
of data, using the a given data model.
The relational model of data is the most widely
used model today.
Main concept: relation, basically a table with rows
and columns.
Every relation has a schema, which describes the
columns, or fields.

108. Levels of Abstraction
Many views, single
conceptual (logical)
schema and physical
schema.
 Views describe how users
see the data.
 Conceptual schema defines
logical structure
 Physical schema describes
the files and indexes used.Schemas are defined using DDL; data is modified/queried using DML.
Physical Schema
Conceptual Schema
View 1 View 2 View 3

109. Structure of a DBMS
A typical DBMS has a
layered architecture.
The figure does not
show the concurrency
control and recovery
components.
This is one of several
possible architectures;
each system has its own
variations.
Query Optimization
and Execution
Relational Operators
Files and Access Methods
Buffer Management
Disk Space Management
DB
These layers
must consider
concurrency
control and
recovery

110. Commercial query languages
SQL-STRUCTURED QUERY LANGUAGE
QUEL-QUERY LANGUAGE
QBE-QUERY BY EXAMPLE

111. SQL (STRUCTURED QUERY LANGUAGE)
A query language is one with which a user requests
information from the data base
SQL is widely used in all organisations.
Convient for the user
The sql is embedded in a procedural languages such
as C,COBAl,or PL/I

112. SQL languages
Oracle
Informix
SQL BASE XDB
Sybase
Progress