COMPUTER INTEGRATED MANUFACTURING notes1.doc

8/21/2019 COMPUTER INTEGRATED MANUFACTURING notes1.doc

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ME1403 – COMPUTER INTEGRATED MANUFACTURINGIV 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 ided !esign (C!)

Computer ided Manufacturing (CM)

"le#ible Manufacturing $ystems ("M$)

Computer ided %rocess %lanning (C%%)

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

*


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deelopment of part programs to drie 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 deeloping 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 lie that. Taen by themseles they are the

application of computer technology to the process of manufacturing. *ut taen by

themseles they only crate the islands of automation.+

+ eo -oth lein, Manufacturing Control systems, Inc.

De&ini"i#n #& CIM!

It describes integrated applications of computers in manufacturing. number of

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 diss are robots machine tools and other

processing e"uipment. It is a little noisier and a little messier but its basically a

computer system.

+ 0oel 1oldhar, !ean, Illinois Institute of 2echnology

+

CIM is a management philosophy not a turney computer product. It is a philosophy

crucial to the surial of most manufacturers because it proides the leels of product

design and production control and shop fle/ibility to compete in future domestic and

international marets. & !an ppleton,

%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 een

informational systems. Its an understanding of the new way to manage.

+ Charles $avage, president, $avage ssociates

+

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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.”

+ 1hrenser 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

:


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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


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• !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

Phy(ical $i("ri2%"i#n

• %hysical distribution planning

• %hysical distribution operations

• =arranties, servicing and spares

%(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 PROCE88P6ANNING

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.

@

http://en.wikipedia.org/wiki/Cellular_manufacturinghttp://en.wikipedia.org/wiki/Cellular_manufacturing


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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( ,PFA-

9arious steps of %"

*. !ata collection

4. %art sorting and routing

:. %" chart

'. nalysis

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

B


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During the past ten years the people behind QDC Business Engineering haveperformed several Production Flow Analyses (PFA in manufacturing industries!"n short# PFA provides well$established# efficient and analytical engineeringmethod for planning the change from %process organisation& to %productorganisation&! 'his means that traditional production layouts are transformed into

production groups# which each mae a particular set of parts and is e)uippedwith a particular set of machines and e)uipment enabling them to complete theassigned parts! 'he following figure illustrates the conventional process layoutand its corresponding product based layout after PFA has been applied!

Traditional Process Layout

The resulting overall material flow between functional cells.

Product Layout

The resulting smooth material

flow between dedicated product groups.

Comple* material flow systems resulting from process based production layoutshave long throughput times# high inventories and wor in progress# whichincrease cost and reduce profitability! From the organisation+s point of view#delegation and control are difficult to implement# which leads to bureaucratic andcentralised management structures# thus increasing overhead! Applying PFA

produces a plan to change the layout and organisation in such a way thatproduction throughput times can be reduced radically# while at the same timeinventories go down and delivery punctuality and )uality improve to a completelynew level! QDC has applied the method successfully in several manufacturingindustries# especially in ,ob$shops and electronics industries# but good resultshave also been obtained in service industries! -nce the layout has beenchanged to a product based one# new and simple production scheduling routineshave been implemented to ensure e*cellent delivery performance!


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An"ici+a"e$ re(%l"(

Companies that have gone through PFA and the resulting change to productbased 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 deliveryperformance/

• in general management. maes it possible to delegate the responsibility for

component )uality# cost and completion by due$date to the group level# whichin turn reduced overhead/

• in worer+s motivation. clearer responsibilities and decision maing on the

spot increase ,ob satisfaction/

• in the point of information technology. simplified material flow speeds up theimplementation of factory automation and simplifies software applicationsused 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 flowstaing place in the factory# and using this information and the alternative routingsto form manufacturing groups that are able to finish a set parts with the resourcesdedicated to it! Depending on the scale of the pro,ect this logic is applied oncompany# factory# group# line and tooling level respectively! 0hichever the case#

the wor breas 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 asimplified 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!

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1ost production units and their layouts are the result of organic growth# duringwhich the products have e*perienced many changes affecting the arsenal of thee)uipment in the worshop! 'his continuously evolving change process leads inconventional factories into comple* material flow systems! PFA reveals thenatural grouping of production resources lie 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* reorganisedinto natural groups that finish parts!

1ost of our previous cases have focused on the forming of groups in ,ob$shops#which are part of a larger production facility! 'hese test cases have been used aseye$openers for the rest of the organisation! -ur recommendation# however# is tocontinue with PFA on higher level! Product and component allocation in thewhole supply chain combined with product and customer segmentation is an

area where not only vast savings in operating costs can be achieved# but alsocompetitive advantage can be created!

1anufacturing science nows numerous cases where complete product$orientedre$organisation of the company has produced staggering results in productivity#throughput times and competitive advantage! PFA is one of the few systematicengineering methods for achieving these results!

Production Flow Analysis was developed by Professor 2ohn 3! Burbidge of theCranfield "nstitute of 'echnology!

Facili"y $e(ign %(ing GT

*. ine layout

4. 1roup layout, machines grouped by part family

:. "unctional layout, machines grouped by process

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ene&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.

. !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(( Planning-

UNIT – 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

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%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 issome 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 abilityto 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

*:

http://en.wikipedia.org/wiki/Flexibility_(engineering)http://en.wikipedia.org/wiki/Machinehttp://en.wikipedia.org/wiki/Machinehttp://en.wikipedia.org/wiki/Flexibility_(engineering)http://en.wikipedia.org/wiki/Machine


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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 manufacturingresources 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!?CM 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 cellor 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 differentcombination of manufacturing nodes. 2he movement of parts from one node to another isdone 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.

*'

http://en.wikipedia.org/wiki/Mass_productionhttp://en.wikipedia.org/wiki/Mass_productionhttp://en.wikipedia.org/wiki/Mass_productionhttp://en.wikipedia.org/w/index.php?title=SCORBOT-ER_4u&action=edit&redlink=1http://en.wikipedia.org/wiki/Robothttp://en.wikipedia.org/wiki/Robothttp://en.wikipedia.org/wiki/CNChttp://en.wikipedia.org/wiki/Instrumentationhttp://en.wikipedia.org/wiki/Instrumentationhttp://en.wikipedia.org/wiki/File:FMS1_small.JPGhttp://en.wikipedia.org/wiki/File:FMS1_small.JPGhttp://en.wikipedia.org/wiki/Mass_productionhttp://en.wikipedia.org/wiki/Mass_productionhttp://en.wikipedia.org/w/index.php?title=SCORBOT-ER_4u&action=edit&redlink=1http://en.wikipedia.org/wiki/Robothttp://en.wikipedia.org/wiki/CNChttp://en.wikipedia.org/wiki/Instrumentation


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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 severalhundreds 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 reportingis 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 unboundedas 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 lowmessage 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 messagesare 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 forlong messages.

*>

http://en.wikipedia.org/wiki/CSMA/CDhttp://en.wikipedia.org/wiki/Token_Bushttp://en.wikipedia.org/wiki/Token_Ringhttp://en.wikipedia.org/wiki/File:Small_CNC_Turning_Center.jpghttp://en.wikipedia.org/wiki/File:Small_CNC_Turning_Center.jpghttp://en.wikipedia.org/wiki/CSMA/CDhttp://en.wikipedia.org/wiki/Token_Bushttp://en.wikipedia.org/wiki/Token_Ring


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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.


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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 software 3r is it the integration of the e#isting departmental

functions and activities as suggested by the CIM wheel

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 company’s 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,CIMO8A-

CIM3$ 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 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


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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 Communications Kthe communication and distribution of data.

L Data management Kthe definition, storage and use of data

L $resentation Kthe 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

ser interface

Installation

UNIT – V ! OPEN 878TEM AND DATAA8E 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

4*


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a(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 anumber 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(

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2he terms illustrated are relation, tuple, attribute, domain, primary 5ey and

foreign 5ey.

Da"a2a(e #+era"#r(

nion

Intersection

!ifference

%roduct

%ro&ect

$elect

0oin

!ivide

COMPUTER INTEGRATED MANUFACTURING notes1.doc

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