Computer

Integrated
Manufacturing
(CIM)
 What is CIM?
 C+I+M
 C = Computer
i. Enabling tool
ii. Information flow
iii.
 What is CIM?
 I = Integrated
i. Integration vs. interfacing
ii. Shared information
iii. Shared functionality
 M = Manufacturing
i. Production control
ii. Production scheduling
iii. Process design
iv.
v.
 What is CIM?
CIM is the integration of all enterprise
operations and activities around a common
corporate data repository.
It is the use of integrated systems and data
communications coupled with new
managerial philosophies.
CIM is not a product that can be purchased
and installed.
Defining CIM
• Technology, tool or method used to improve entirely the design
and manufacturing process and increase productivity

• Using computers to help people and machines to communicate

• Architecture for integration of multiple technologies through

computers, linking each individual island of automation to a
closed loop business system

• integration of computer aided design, automatic material

handling, robotics, process technologies, manufacturing
planning & control, computer aided quality control, computer
aided manufacturing

• focuses on the computer as the center of control of the entire

factory, starting from the
 Definition
 Computer-integrated manufacturing (CIM) is
the manufacturing approach of using
computers to control the entire production
process
 This integration allows individual processes to
exchange info with each other and initiate
actions
 Through the computers integration,
manufacturing can be faster and less error-
prone, although the main advantage is the
ability to create automated manufacturing
processes
 Typically CIM relies on closed-loop control
processes, based on real-time input from
sensors
 .
 Definition
 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 use a common database wherever feasible and
commun-tech to integrate design, manufacturing and
associated business
 CIM
 Origin

 The term "CIM" is both a method of

manufacturing and the name of a
computer-automated system in which
individual engineering, production,
marketing, and support functions of a
manufacturing enterprise are organized
 In a CIM system functional areas such as
design, analysis, planning, purchasing,
cost accounting, inventory control, and
distribution are linked through the
computer with factory floor functions such
as materials handling and management,
providing
 Origin
 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
 A distinct feature of manufacturing today
is mass customization
 This implies that though the products are
manufactured in large quantities, products
must incorporate customer-specific
changes to satisfy the diverse
requirements of the customers
 .
Challenges in Manufacturing

Challenges in Manufacturing
 Three Distinguished Components

 As a method of manufacturing, three

components distinguish CIM from
other manufacturing methodologies:
• Means for data storage, retrieval,
manipulation and presentation
• Mechanisms for sensing state and
modifying processes
• .
 Definition
 CIM is an example of the implementation of
info and common technologies in
manufacturing
 CIM implies that there are at least two
computers exchanging info, e.g. the controller
of an arm robot and a micro-controller of a
Computer Numerical Control(CNC) machine
 Some factors involved when considering a CIM
implementation are the production volume,
the experience of the company or personnel to
make the integration, the level of the
integration into the product itself and the
integration of the production processes
 CIM
 Definition
 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 & Production changes
 Process & Equipment change
 .
 Benefit from CIM
Integration of technologies brings following
benefits:
1. Creation of a truly interactive system that
enables manufacturing functions to
communicate easily with other relevant
functional units
2. Accurate data transferability among
manufacturing plant or subcontracting
facilities at implant or diverse locations
3. Faster responses to data-changes for
manufacturing flexibility
4. Increased flexibility towards introduction of
new products
5
 Benefit from CIM

6. Improved quality of the products.

7. Control of data-flow among
various units and maintenance of
user-library for system-wide data.
8. Reduction of lead times which
generates a competitive
advantage.
9. Streamlined manufacturing flow
from order to delivery.
10.
 Evolution of 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
 Digital Manufacturing
The idea of "digital manufacturing" was
prominent the 1980s, when computer-
integrated manufacturing was developed
and promoted by machine tool
manufacturers and the Computer and
Automated Systems Association and
Society of Manufacturing Engineers
(CASA/SME).
"CIM is the integration of total
manufacturing
 Key challenges - three major
challenges
 Integration of components from different
suppliers: when different machines, such
as CNC, conveyors and robots, are using
different communications protocols
 Data integrity: The higher the degree of
automation, the more critical is the
integrity of the data used to control the
machine
• While the CIM system saves on labor of
operating the machines, it requires extra
human labor in ensuring that there are
proper safeguards for the control data
signals
 Process control: Computers may be used
to assist the human operators of
manufacturing facility, but there must
always be a competent engineer to handle
circumstances which could not
CIM & production control system
 Subsystems in computer-integrated
manufacturing
 CIM makes full use of the capabilities of the
digital computer to improve manufacturing.
Two of them are:
i. Variable and Programmable automation
ii. Real time optimization
 A computer-integrated manufacturing system
is not the same as a "lights-out" factory,
• which would run completely independent of
human intervention, although it is a big step
in that direction
 Part of the system involves flexible
manufacturing, where the factory can be
quickly modified to produce different
products, or where the volume of products can
be changed quickly with the aid of computers
 Some or
 Subsystems in computer-integrated
manufacturing
 Computer-aided techniques:
• CAD (computer-aided design)
• CAE (computer-aided engineering)
• CAM (computer-aided manufacturing)
• CAPP (computer-aided process
planning)
• CAQ (computer-aided quality
assurance)
• PPC (production planning and control)
• ERP (enterprise resource planning)
• .
Computer Integrated Manufacturing Activities
 Subsystems in computer-integrated
manufacturing
 Computer-aided design (CAD) also known as
computer-aided design and drafting (CADD) is the
use of computer technology for the process of
design and design-documentation
 CAD describes the process of drafting with a
computer providing the user with input-tools for the
purpose of streamlining design processes; drafting,
documentation
 CAD output is often in the form of electronic files
for print or machining operations
 CAD-based
 Subsystems in computer-integrated
manufacturing
 Computer-aided engineering (CAE) is the broad
usage of computer software to aid in
engineering tasks
 It includes computer-aided design (CAD),
computer-aided analysis (CAA), computer-
integrated manufacturing (CIM), computer-
aided manufacturing (CAM), material
requirements planning (MRP), and computer-
aided planning (CAP)
 Computer-aided process planning (CAPP) is the
use of computer technology to aid in the process
planning of a part or product, in manufacturing
 CAPP is
 Subsystems in computer-integrated
manufacturing
 Computer-aided manufacturing (CAM) is the use of
computer software to control machine tools and
related machinery in the manufacturing of work
pieces
 CAM may also refer to the use of a computer to assist
in all operations of a manufacturing plant, including
planning, management, transportation and storage
 Primary purpose is to create a faster production
process and components and tooling with more
precise dimensions and material consistency, which
 Subsystems in computer-integrated
manufacturing
 Computer-aided quality assurance (CAQ) is the
engineering application of computers and
computer controlled machines for the definition
and inspection of the quality of products

 Computer aided Process Planning (CAPP) Generative

process planning is an advanced generation of
CAD/CAM. This uses a more powerful software
program to develop a process plan based on the part
geometry,
 Subsystems in computer-integrated
manufacturing
 Production Planning & Control is the organization and
planning of the manufacturing process.
 It co-ordinates supply and movement of materials and
labor, ensures economic and balanced utilization of
machines and equipment as well as other activities
related with production to achieve the desired
manufacturing results in terms of quantity, quality,
time and place.
 Enterprise resource planning (ERP) integrates internal
and external management info across an entire
organization, embracing finance/accounting,
manufacturing, sales and service, customer relationship
management
• It automates this activity with an integrated
software application
 .
 Production Planning & Control
There are three stages in PPC
Planning : The choice from several
alternatives of the best utilizing the available
resources to achieve the desired objective .
Operations: Performance in accordance with
details set out in production plan.
Control: The monitoring of performance
through a feed back by. .
 Objective of PPC
 To deliver goods in required quantities to
customers in required delivery schedule.ion
 To ensure maximum utilization of all
resources
 To ensure production quality products
 To minimize the product throughput time
 To maintain optimum level inventory
 To maintain flexibility in manufacturing
operations
 Coordinate
 Functions of PPC
 Routing
 Estimating
 Scheduling
 Loading
 Dispatching
 Expediting
 .
 .
 Levels of PPC
 Strategic Planning(Long range): It is process of
thinking though the organizations current mission
and environment and setting a guide for future
decisions and results. e.g. Technology forecasting
and choice of appropriate technology for the long
range time horizon.
 Tactical Planning(Intermediate Range): It is
done over an intermediate term or medium range
time horizon by middle level management. These
plans focus on aggregate products rather than
individual products.
 Operational Planning(Short Range ): It is done
over a
 Benefits of PPC
 PPC coordinates all the phases of
production / Operating system
 An efficient plan results in higher
quality ,better utilization of
resources, reduced inventories,
better customer services.
 An
 Limitations of PPC
 PPC function is based on certain
assumptions or forecasts of customer’s
demand, Plant capacity, availability of
materials etc
 Employee may resist change in production
levels set as per production plans.
 This process is time consuming when we
need to carry out routing and scheduling
function for large products.
 This
 CIM Hardware and Software
 CIM software comprises computer
programms to carry out the following
functions:
• Management Information System
• Sales & Marketing & Finance
• Database Management
• Modeling and Design
• Analysis
• Simulation
• Communications
• Monitoring
• .
• .
 Nature and Role of the
Elements of CIM System
 Nine major elements of a CIM system are
in next slide:
• Marketing
• Product Design
• Planning & Purchase
• Manufacturing Engineering
• Factory Automation Hardware
• Warehousing
• Logistics and Supply Chain Management
• .
• .
Subsystems in computer-integrated
manufacturing

Major Elements of a CIM System

Subsystems in computer-integrated
manufacturing

Various Activities in CIM

 Subsystems in computer-
integrated manufacturing
 Devices and equipment required:
• CNC, Computer numerical controlled
machine tools
• DNC, Direct numerical control
machine tools
• PLCs, Programmable logic controllers
• Robotics
• Computers
• Software
• Controllers
• Networks
• .
• .
 Subsystems in computer-integrated
manufacturing
 Technologies:
• FMS, (flexible manufacturing
system)
• ASRS, automated storage and
retrieval system
• AGV, automated guided vehicle
• Robotics
• Automated conveyance systems
 Others:
• .
 CIMOSA
 CIMOSA -Computer Integrated
Manufacturing Open System Architecture is
the enterprise modeling framework, which
aims to support the enterprise integration of
machines, computers and people
 Its framework is based on the system life
cycle concept, and offers a modeling
language, methodology and supporting
technology to support these goals
• is a 1990s European proposal for an open
system architecture for CIM developed by
the AMICE Consortium as a series of
ESPRIT projects
 The goal”
 CIMOSA
 CIMOSA provides a solution for business
integration with four types of products:
• The CIMOSA Enterprise Modeling
Framework providing a reference
architecture for enterprise architecture
• CIMOSA IIS,
 a standard for physical and application
integration.
• CIMOSA Systems Life Cycle,
 is a life cycle model for CIM development
and deployment.
• Inputs to
 CIMOSA Architecture
 The main focus of CIMOSA has
been to construct:
• a framework for enterprise
modelling, a reference architecture
• an enterprise modeling language
• an integrating infrastructure for
model enactment supported by
•a
 CIMOSA Architecture
 CIMOSA aims at integrating enterprise
operations by means of efficient information
exchange within the enterprise
 CIMOSA models enterprises using four
perspectives:
• the function view describes the functional
structure required to satisfy the objectives of an
enterprise and related control structures;
• the information view describes the information
required by each function;
• the resource view describes the resources and
their relations to functional and control
structures; and
• the
 Development of CIM
 CIM is an integration process
leading to the integration of the
manufacturing enterprise
 .
 Development of CIM
 Flexible manufacturing cells, automatic storage
and retrieval systems, CAD/CAM based design
etc. are the examples of islands of automation
i.e. a sort of computer based automation
achieved completely in a limited sphere of
activity of an enterprise
 This involves data exchange among computers,
NC machines, robots, gantry systems etc.
• Therefore the integration process has started
bottom up
• The
Development of CIM
Production Systems
Production system is the collection of people, Equipment, and procedures
organized to accomplish the manufacturing operations of a company.
Production Systems
Production systems can be divided into two levels:

1. Facilities
The facilities of the production system consists of
• the factory
• the equipment in the factory, and
• the way the equipment is organized.

2. Manufacturing support systems

Set of procedures used by the company to:
• manage production

• solve the technical and logistics problems encountered in

• ordering material
• moving work through the factory
• .
Production Systems

In modern manufacturing operations, portions of the production

system are automated and/or computerized.
I- Production System Facilities
Facilities in the production system are:
• The factory
• Production machines and tooling
• Material handling equipment
• Computer systems that control the manufacturing operations

Facilities also include the plant layout, which is the way the
equipment is physically arranged in the factory.

The equipment is usually

Various Types of Plant Layouts
1- Fixed – position layout
Workers and processing equipment are
Various Types of Plant Layouts
2- Process layout
In which the equipment is arranged according to function or type.
The lathes are in one
Various Types of Plant Layouts
3- Cellular layout
Each cell is designed to produce a limited variety of part
configurations;
Various Types of Plant Layouts
4- Product layout
Multiple workstations arranged in sequence, and the parts or
assemblies are moved through the sequence to complete the
product.
Production quantity and product variety

Production quantity: refers to the number of units of a given part

or product produced annually by the plant.
Production quantity can be classified into three ranges

1- Low Production (Job Shop)

Quantities in the range of 1 to 100 units per year

2- Medium Production (Batch Production)

Quantities in the range of 100 to 10000 units per year

3- High Production (Mass Production)

Quantities are 10000 to millions of units per year
Product Variety: refers to the different product designs or types
that are produced in a plant.
Relationship between product variety and production quantity in
discrete product manufacturing

When product variety is high, production

quantity tends to be low; and vice versa.
Types of facilities and layouts used for different levels
of production quantities and product variety
II- Manufacturing Support Systems
To operate the production facilities efficiently, a
company must organize itself to

• Design the processes and equipment

• Plan and control the production orders; and
• Satisfy product quality requirements

This accomplished by manufacturing

support systems (people and procedures)
II- Manufacturing Support Systems
Manufacturing support involves a cycle of information-processing activities
II- Manufacturing Support Systems

1- Business Functions

Included in business functions are

• Sales and marketing

• Sales forecasting
• Order entry
• .
• .
II- Manufacturing Support Systems

2- Product Design

Included are

• Research and development

• Design engineering
• .
II- Manufacturing Support Systems

3- Manufacturing Planning

The information-processing activities

included in manufacturing planning are:

• Process planning
• Scheduling
• .
II- Manufacturing Support Systems

4- Manufacturing Control

Information included in manufacturing control

function are

• Shop control
• Inventory control
• .
Automation in Production Systems

Automation can be defined as a technology concerned with the

application of mechanical, electronic and computer-based systems
to operate and control production
The automated elements of the production
system can be separated into two categories:
• Automation of the manufacturing systems in the factory
• Computerization of the manufacturing support systems
Automated Manufacturing Systems
Examples of automated manufacturing system included:

• Automated machine tools that process parts

• Transfer lines that perform a series of machining operations
• Automated assembly systems
• Industrial robots to perform processing or assembly
• Automatic material handling and storage systems
• Automatic inspection systems for quality control

Automated manufacturing systems can be classified into three basic

• Fixed automation
• .
• .
Automated Manufacturing Systems

1- Fixed Automation

Fixed automation is a system in which the sequence of

processing (or assembly) operations is fixed by the
equipment configuration. Each of the operations in the
sequence is usually simple.

Examples:
• machining transfer lines
• .
Automated Manufacturing Systems

2- Programmable Automation

In programmable automation, the production equipment is

designed with the capability to change the sequence of
operations to accommodate different product configurations.
The operation sequence is controlled by a program

Examples:
• Numerically controlled machines (NC)
• .
Automated Manufacturing Systems

3- Flexible Automation

Flexible automation is an extension of programmable

automation. A flexible automated system is capable of
producing a variety of parts with virtually no time lost
for changeovers from one part style to the next.

Example
• .
Three types of automation relative to production quantity
and product variety
Computerized manufacturing support systems

Automation of the manufacturing support systems is aimed at

reducing the amount of manual effort in;

• product design
• manufacturing planning
• manufacturing control; and
• business functions

All modern manufacturing support systems are implemented using

computer systems
Computerized manufacturing support systems
Computer Integrated Manufacturing (CIM) is the use of
computer systems to design the products, plan the production,
control the operations, and perform the various business-related
functions needed in a manufacturing firm
Reasons for Automating

• To increase labor productivity

• To reduce labor cost

• To reduce or eliminate routine manual tasks

• To improve worker safety

• To improve product quality

• To reduce manufacturing lead time

• To accomplish processes that can not be done manually

• .
Automation Migration Strategy
Manufacturing Systems
A manufacturing system is a collection of integrated equipment and human
resources, whose function is to perform one or more processing and/or
assembly operations on a starting raw material, part, or set of parts.

The integrated equipment includes production machines and tools,

material handling and work positioning devices, and computer systems
Components of a Manufacturing System

A manufacturing system consists of several

components usually include:
• Production machines plus tools, fixtures and other
related hardware

• Material handling system

• Computer systems to coordinate and/or control the

above components

• .
Production Machines
Manually operated machines are directed or supervised
by a human worker.
Example : conventional machine tools

Semi-automated machines perform a portion of the

work style under some form of program control and a
human worker tends to the machine for the remainder
of the cycle.
Example: CNC machines

Fully automated machines operate for extended periods

of time with ni human attention
Example: .
Material Handling System
1- Loading, positioning and unloading
These material handling functions occur at each workstation

Loading involves moving work units into the production

machine or processing equipment from a source inside the
station

Positioning provides for the part to be in a known location and

orientation relative to workhead or tooling that performs the
operation

Unloading
Material Handling System
2- Work Transport between Stations
• Work transport means moving parts between
workstations in a multi-station system.
• The transport function can be accomplished manually
or by the most appropriate transport equipment

Variable Routing, work units are Fixed Routing, the work units
transported through a variety of always flow through the
different station sequences. same sequence of stations
Computer Control System

A computer is required to control the automated and semi-

automated equipment and to participate in the overall
coordination and management of the manufacturing systems
Typical computer system functions include:

• Communicate instructions to workers

• Download part programs to CNC machines

• Control material handling systems

• Schedule production

• Quality control

• .
Human Resources
Direct labor
The directly add to the value of the work unit
by performing manual work on it or by
controlling the machines that perform the work

Indirect labor
Classification of Manufacturing Systems
Factors that define and distinguish the different types of
manufacturing systems are:
1. Types of operations performed
2. Number of workstations and system layout
3. Level of automation
4. Part or product variety
Classification of Manufacturing Systems
Classification of Manufacturing Systems
Classification of Manufacturing Systems

M=The manning level of a workstation is defined as the

portion of time a worker is in attendance at the station
Classification of Manufacturing Systems
Classification of Manufacturing Systems
Classification of Manufacturing Systems
Classification of Manufacturing Systems
Classification of Manufacturing Systems
Classification of Manufacturing Systems
 POTENTIAL BENEFITS OF CIM
 Improved customer service
 Improved quality
 Shorter time to market with new products
 Shorter flow time
 Shorter vendor lead time
 Reduced inventory levels
 Improved schedule performance
 Greater flexibility and responsiveness
 Improved competitiveness
 Lower total cost
 .
 .
 .