COMPUTER INTEGRATED MANUFACTURING

(MF 40601) Dr. Sankha Deb Department of Mechanical Engineering Email: sankha.deb@mech.iitkgp.ernet.in Phone: 282912

Computer Integrated Manufacturing (MF 40601)

Course coverage: Introduction, Definition and Evolution of CIM, Computer Numerical Control, Robotics, PLCs, Automated Material Handling / transport, Automated Storage / Retrieval, Introduction to Manufacturing Systems and their classifications, Automated Assembly Systems, Cellular Manufacturing, Flexible Manufacturing Systems, Computer-Aided Process Planning, Production Planning and Control Systems, Lean Manufacturing, Agile Manufacturing. Suggested References: Groover, M. P., Automation production systems, and computer-integrated manufacturing, third edition, Prentice-Hall of India, New Delhi. ISBN:978-81-2033418-2 Deb, S.R. and Deb, S., Robotics Technology and Flexible Automation, second edition, Tata McGraw Hill, New Delhi. ISBN:9780070077911 Lecture material available on Course Homepage http://www.facweb.iitkgp.ernet.in/~sankhadeb/MF40601.html

Introduction to CIM
In conventional manufacturing, Taylorism-Fordism (division of labour) is the most effective means of mass production. Automation technology for mass production is known as hard automation and uses conventional production and assembly machines with traditional mechanical handling equipment. Over the years, the product and process complexity as well as product variety have increased manyfolds. By virtue of their programmability, computers are used extensively in manufacturing. Customers have direct access through internet. With the advent of semiconductor technology, product life cycle has been shortened. Zero defect products are produced due to increased quality control. Innovative design and production at competitive cost became available due to the utilization of better design techniques, improved technology and scientific management .

Introduction to CIM (continued)

Due to various factors viz.
open market-driven competition, globalization of markets, customer satisfaction for well designed, timely produced products, improved supply chain management, increasing usage of information processing due to common data base management, better labour-management relations, and advanced automation in manufacturing technology and management,

a new approach known as Computer Integrated Manufacturing (CIM) has emerged, wherein integration of off-line and on-line manufacturing functions, business and office functions have been made possible. CIM is a management philosophy at the higher level and at the same time a technology for the design and manufacture of new products and processes at the middle and lower levels of hierarchy. CIM bridges the business goals and the manufacturing strategies of a business enterprise.

Introduction to CIM (continued)

In todays manufacturing scenario, there is lot of social pressure. Customer satisfaction is one of the major objectives of the enterprise. The other factors are:
1. Waste minimization 2. Perfect quality (defect free) of products 3. Continuous improvement (Kaizen).

In order to cope with the above, instead of mass production, a novel philosophy in manufacturing has emerged. This is Lean Manufacturing and later modified to Agile Manufacturing. This is a sort of mass production, but is more flexible and efficient system avoiding wastes in all forms.

Agile Manufacturing on the other hand emphasizes on production of new products into rapidly changing markets with the strength of organizational ability in the competitive market, undergoing unforeseen changes and it satisfies customers expectations.

In fact, it produces customized products and adds more values to the customers. CIM, infact, attempts to solve the manufacturing problems to the greatest satisfaction of the customers.

Definition of CIM
CIM is the integration of the total manufacturing enterprise through the use of computer and data communications coupled with new managerial philosophies that improve organizational and personnel efficiency. It aims to integrate all of the operational and information processing functions in manufacturing from order receipt, through design and manufacturing, to product shipment. The CASA / SME has suggested a framework, the CIM wheel to illustrate the integration called for in the definition of CIM, and shows the interrelationship among all the parts of an enterprise.

Definition of CIM (continued)

Evolution of CIM
Development of numerical control played an important role in the development of CIM. In 1947, Parsons Corp. took the challenge of developing a new method of moving the tool, using numbers and thus numerical control was born. Parsons worked with MIT to produce the first NC milling machine in 1954. Since then, NC has developed, along with microelectronics and computers, into a sophisticated technology that drives modern machining centres, FMSs, etc. While NC was evolving on its own, computers were being developed independently. They provided an effective tool for carrying out repetitive tasks, storing large amounts of data and handle various types of mathematical analyses. Initially computers were introduced in manufacturing to support payroll and accounting. Next computers were extended to inventory control.

Evolution of CIM (continued)

Further inroads to manufacturing had to wait until computer graphics matured. Today, with enhanced capabilities and lower cost, computers represent an attractive technology. Computer-Aided Design (CAD) also played an important role. Design involves both creative and repetitive tasks. The repetitive tasks within design are very appropriate for computerization. In the early 1970s, using computers for generating drawings and documentation proved cost-effective. Since then, computer use in design has exploded. The computers help in designing and drafting is commonly expressed by the term Computer-Aided Design (CAD).

Evolution of CIM (continued)

By this time, NC technology had matured to become cost-effective for applications in machining. In the case of components with complex geometries, part programmers had to carry out lengthy calculations, for which it was logical to use computers. This gave rise to MCUs with built-in microprocessors. The use of computers in extending the applications of NC technology to part programming was earlier termed computer-aided machining (CAM). Later CAM became the acronym for computer-aided manufacturing. As the use of computers in design and machining broadened under CAD and CAM, it became evident that certain tasks are common to both. Part geometries created during CAD can readily be saved in a database for later use. Why reenter such information again at the MCU?

Evolution of CIM (continued)

In the beginning CAD and CAM developed independently of each other. Later, when the drawbacks of CAD and CAM compartmentalization were realized, the logical move from CAD and CAM was to CAD/CAM. In the 1970s, another concept flexible automation came into being to distinguish this type of automation from Detroit-type of automation, which is inflexible. To denote the flexibly automated independent units of processes or workstations, a new terminology island of automation came into popular use. But soon it was realized that the islands were not enough by themselves without a big picture of the entire manufacturing operations. Somehow we need a larger view of the enterprise and how it best functions as a whole. We began to think of integration as a way to make automation really work. So the emphasis changed from automation to integration.

Evolution of CIM (continued)

An integrated approach to computer-based automation was the next logical step, giving rise to the concept of computer-integrated manufacturing (CIM). CIM developed primarily in response to the demands of the marketplace for more product variety, better quality, and lower prices. In the 1960s and 1970s, manufacturers coped with the latter requirement by concentrating only on direct labor cost. In the 1990s, the emphasis has shifted to other cost elements, since in most cases direct labor represents today only a small portion (10-15%) of the total manufacturing cost. The push for CIM in the 1980s came from the challenges manufacturers were facing in an ever changing global market. The various challenges involve complex interrelated issues that can be grouped as technological, social and political. The major issues are product quality, global competition, government regulations, high wages, and product liability. CIM brings home the point that integration of all the resources capital, human, technology, and equipment is vital to success in manufacturing.

Evolution of CIM (continued)

Implicitly CIM discourages any haphazard application of computers, and other technologies. Integration is achieved through timely and effective communication, which CIM relies heavily on. Although computers and communication had been with us since the 1950s, CIM began to draw attention only in the 1980s. Why this late? For two reasons. First, until recently computers had been too expensive to be cost-effective in manufacturing. The second reason is the sheer complexity of integration. CIM is an umbrella term under which all functions of manufacturing and associated acronyms such as CAD, CAD/CAM, FMS, CAPP find a place. Discrete manufacturing has always presented a challenge because of the large number of factors involved and their interaction. CIM is being projected as a panacea for this type of industry, which produces 40% of all goods.

Important Components of CIM

Figure in next slide indicates a simplified CIM structure showing the major components of CIM. It starts with the product design. Product design has undergone many a changes in the present scenario and is not the same as the traditional way of designing the products by only design department. New products are designed by a team of a) production engineering, b) design engineering, c) quality control personnel, d) purchasing and e) marketing and even f) supplier. Product development now-a-days is altogether different. The traditional design process starts from the conceptualization, then synthesis, analysis, and evaluation and if accepted by the management, the necessary documentations are done or sometimes depending on the feedback, the design modifications are made.

Important Components of CIM (continued)

HR Management

Design

Finance Production Manufacturing, Planning and Control (MPC)

Purchasing

Marketing and Sales

Important Components of CIM (continued)

But the present design process of new product design involves similar steps as followed in the traditional approach, but concurrent engineering, production engineering have greater roles in the enterprise . Thus computer-aided design (CAD) with design softwares and running on engineering workstations and PCs are extensively used in connection with the computer-aided manufacturing (CAM) leading to CAD/CAM system. The other important component is manufacturing planning and control (MPC) which includes the process planning, production scheduling, inventory management, materials requirement planning (MRP), just-in-time (JIT) production, enterprise resource planning (ERP), and capacity requirement planning (CRP).

Important Components of CIM (continued)

Another important component is production and processes. However, unlike traditional machines, computer controlled machines such as Flexible manufacturing system (FMS), Flexible manufacturing cell (FMC), and Flexible assembly cells are employed. An automation strategy is adopted in this case so that CAD data is translated into CAM data. Robots, Automated systems of conveying, and AGVs, etc. are now used as supports/aids to manufacturing. Computer numerical control (CNCs) or Direct numerical control (DNCs) are extensively used in place of traditional machines or older generations of NC machines.

Important Components of CIM (continued)

These three basic modules of manufacturing viz. design, manufacturing planning and control are encircled by finance, marketing and sales, purchasing, strategic planning and human resources (HR) management. All these components were discretely used by the early production units. There was no integration. Later on, CAD is used in conjunction with CAM leading to CAD/CAM systems using a common database. But in the present scene, management and planning functions are added along with finance and marketing leading to CAD/CAM/CIM.

Important Components of CIM (continued)

Computer integrated manufacturing (CIM) with databases is illustrated in Figure, which depicts CAD-CAM, planning, management and control to be integrated taking inputs from different modules.
CAD/CAM Workstation

Planning, Management and Control CAD/CAM

Concurrent Engineering CE

Product Design
Computer-Aided Design (CAD)

Production Engineering Strategic Planning

Computer-Aided Manufacturing (CAM)

Conceptualization Synthesis Analysis 2D Design and Drafting

NC/CNC/DNC Robots / AGV Computer-Aided Engineering (CAE)

Computer-Aided Process Planning (CAPP)

Group Technology and Part Coding Master Production Scheduling (MPS) Materials Requirement Planning (MRP) Manufacturing Resource Planning (MRP II) Capacity Resource Planning (CRP) Scheduling Control

Finance Marketing / Sales

Evaluation 3D Drawing Documentation Solid Modeling

Processors, PLC / P FMC FMS

Computer-Aided Quality Control (CAQ)

Computer Integrated Manufacturing (CIM)

Benefits of CIM
Tangible benefits
Higher profits Less direct labor Increased machine use Reduced scrap and rework Increased factory capacity Reduced inventory Shortened new product development time Fewer missed delivery dates Decreased warranty costs

Intangible benefits
Higher employee morale Safer working environment Improved customer image Greater scheduling flexibility Greater ease in recruiting new employees Increased job security More opportunities for upgrading skills