Computer Aided Manufacturing

Manufacturing –Types, Manufacturing

Systems

IV Year VII Sem

Department of Mechanical Engineering

SRM UNIVERSITY
 What is Manufacturing
• It is the process of converting the raw material
into product.
• It encompasses
– Design of the product
– The selection of raw material
– The sequence of processes through which the
product will be manufactured.
 Manufacturing can be defined as the
application of physical and chemical processes
to alter the geometry, properties, and/or
appearance of a given starting material to
make part or products
 Machinery

Tools
Power
Labor

Completed part
Starting material
(Raw material) (Product)
Manufacturing
Process
Scrap
Changes in manufacturing
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 changes
– Production changes
– Process change
– Equipment change
– Change of personnel
 TYPES OF MANUFACTURING
• Continuous process
• Mass production
• Batch production
 Continuous Process
• In this type of industry, the production process
generally follows a specific sequence.
• These industries can be easily automated and
computers are widely used for process
monitoring, control and optimization.
• Oil refineries, chemical plants, food processing
industries, etc are examples of continuous
process industries.
 Mass production
• Industries manufacturing fasteners (nuts, bolts
etc.), integrated chips, automobiles,
entertainment electronic products, bicycles,
bearings etc.
• which are all mass produced can be classified as
mass production industries.
• Production lines are specially designed and
optimized to ensure automatic and cost effective
operation.
• Automation can be either fixed type or flexible.
 Batch Production
• The largest percentage of manufacturing
industries can be classified as batch production
industries.
• The distinguishing features of this type of
manufacture are the small to medium size of the
batch, and varieties of such products to be taken
up in a single shop.
• Due to the variety of components handled, work
centers should have broader specifications.
• Another important fact is that small batch size
involves loss of production time associated with
product changeover.
Volume
 Manufacturing systems

• Agile manufacturing
• Flexible manufacturing
• Just-in-time manufacturing
• Lean manufacturing
• Mass production
• Ownership
• Prefabrication
• Rapid manufacturing
CIM WHEEL
 Current trends in manufacturing
• Group Technology
• Design for manufacturing
• Computer Aided Process Planning (CAPP)
• Total Quality Approach
• Concurrent engineering
• Rapid prototyping
• Computer Integrated manufacturing (CIM)
• Digital Manufacturing
• Green Manufacturing
• Lean Manufacturing
• Agile manufacturing
Digital
Manufacturing
 Automation in Manufacturing
• Automation are now perform operation
such as processing, assembly, inspection,
material handling, in some cases
accomplishing more than one of these
operations.
 Classification of Automated
Manufacturing System

• Fixed Automation
• Programmable Automation
• Flexible Automation
 Fixed Automation
• Fixed automation is a system in
which sequence of processing
operation is fixed by the equipment
configuration.
 Features of fixed automation
• High initial investments
• High production rates
• Relatively inflexible in accommodating
product variety
 Examples of fixed automation
• Machining transfer lines
• Automation assembly machines.
 Programmable Automation
• In Programmable Automation systems the
production equipments is designed with the
capability to change the sequence of
operation to accommodate different product
configuration.
Features of Programmable Automation

• High investment in general purpose

equipment
• Flower production rate than fixed automation
• Flexible to deal with variations and changes in
product configuration.
• More suitable for batch production
Examples of Programmable Automation
• Numerical controlled machine tool
• Industrial robots
• Programmable logic controllers
 Flexible Automation
• Flexible automation is capable of producing a
variety of parts with virtually no time lost for
changeover from one part style to the next.
 Features of Flexible Automation
• Continuous production of various mixtures of
products
• Medium production rate
• Flexibility to deal with product design
variations
Product variety

Programmable
Automation
Flexible
Automation
Manual Fixed
Production Automation
100 10,000 1,000,000
Production quantity
Levels of Automation
 Group Technology
• Group technology is a manufacturing
philosophy is which similar parts are identified
and grouped together to take advantage of
the similarities in design and production.

• Similar parts are arranged into part families.

Process Type Layout
 Cellular Manufacturing
• Grouping the production equipments into
machine cells, where each cell specialized in
the production of part family, is called as
cellular manufacturing.
• For each part-family a dedicated Cluster of
machines (called machine cell) are identified.
• Generally, all the processing requirements of
a particular part-family are completed in its
corresponding machine ceil
Product A

Product B

Product C

Product D
Process Type
Layout

GT
Layout
 Part Family
A part family is collation of parts that are
similar either because of geometrical shape
and size or because of similar processing steps
are required in their manufacturing.
Part A –
1) 10,00,000 pc/yr 2) Tolerance = ±0.010in 3) Material = 1015 CR Steel

Part B –
1) 100 pc/yr 2) Tolerance = ±0.001 in 3) Material = 18- 8 Stainless steel
Three Method of Part Classification
• Visual inspection
• Part classification and coding
• Product flow analysis
 Types of Coding Structure
• Attribute code structure
• Hierarchical structure
• Hybrid Type
• Special Symbol codes
 Attribute Code Structure
Another name of this type of symbol is poly-code.
 Hierarchical structure
• In this type of code structure, each code
number is qualified by the preceding digits
(characters).
• Thus if the first digits define the type of
material used, such as steel, the second digits
will define a feature related to steel (like
carbon constraint), and the next digit will
define a feature related to the feature defined
in the second digit and so on.
Hierarchical structure
Hybrid Structure
 Special Symbol codes
• This is a type of code that used picture or
symbols of an object other than numbers or
alphabets to represent an activity, event,
words, etc.
Three Method of Part Classification
• Visual inspection
• Part classification and coding
• Product flow analysis
 Part Classification and Coding
• Similarities among the parts are identified and
these similarities are related in the coding
systems.

• Two categories of part similarities are

– Design Attribute
– Manufacturing Attribute
– Both design and manufacturing attributes
• Design Attribute
– Similarities in geometry, size , material

• Manufacturing Attribute
– The sequence of processing steps required to
make a part.
• Part design Attribute
– Basic external shape
– Basic internal shape
– Rotational or
Rectangular shape
– Length to diameter ratio
– Aspect ratio
– Material type
– Part function
– Major dimensions
– Miner dimensions
– Tolerances
– Surface finish
• Part Manufacturing
attributes
– Major processes
– Minor operations
– Operation sequence
– Major dimension
– Surface finish
– Machine tool
– Production cycle time
– Batch size
– Annual production
– Fixtures required
– Cutting tools
Three Method of Part Classification
• Visual inspection
• Part classification and coding
– Opitz Classification System
– Multiclass
• Product flow analysis
Opitz Classification System
 12345 6789 ABCD
• The first five digits are called the form code
and indicate the design or the general
appearance of the part and hence assist in
design retrieval.
• Later, 4 more digits were added to the coding
scheme, in order to increase the
manufacturing information of the specific
work part.
• The extra four digits, A, B, C and D, called the
secondary code, are used by the specific
organization to include those characters that
are specific to the organization.
 Part Classification and Coding
• Opitz Classification System
• Multiclass
 For the part shown determine the
form code in the Opitz parts classification and
coding system..

Solution:

With reference to chart, the five-digit code is developed as follows:

• Length-to-diameter ratio, L/D = 1.5 Digit 1 = 1

• External shape: stepped on both ends with
screw thread on one end Digit 2 = 5
• Internal shape: part contains a through-hole Digit 3 = 1
• Plane surface machining: none Digit 4 = O
 Multiclass
0 Code system prefix
1 Main shape category
2,3 External and internal configuration
4 Machined secondary configuration
5,6 Functional description
7-12 Dimensional data (length, Diameters, etc)
13 Tolerances
14,15 Material chemistry
16 Raw material shape
17 Production quantity
18 Machined element orientation
 Product flow analysis
• Data Collections
• Sorting of process routing
• PFA Chart
• Cluster analysis
Rankin Order Clustering (ROC)
Component
Number Sequence
1 1–2–3–4–2–5–6–3–4–8
2 13 – 7 – 1 4 – 1 5 – 1 4 – 15
3 8 - 12 - 8 - 11

4 3–6–5–4–8

5 14 – 15 – 14
6 9- 10 – 8 – 11 – 12
7 7 – 14 – 15
8 1–3–6–2–5–4–8–4
9 7 – 13 – 14
10 9 – 8 – 10
 Solution
• There are 10 different types of components
with and it needs 15 machines to manufacture
the components
Step - 1
• Form machine - Components matrix as shown
below
Component
Number
Sequence
1 1–2–3–4–2–5–6–3–4–8
2 13 – 7 – 1 4 – 1 5 – 1 4 – 15
3 8 - 12 - 8 - 11 Components
Machines
4 3 – 6 – 5 –1 4 – 8 2 3 4 5 6 7 8 9 10
1 1
5 14 – 15 – 14
2 1 Already we have allotted machine 2 so we can skip
6 3 9- 10 – 8 –111 – 12Similarly for 3 and 4
7 4 7 – 14 – 151
8 5 1 – 3 – 6 –12 – 5 – 4Similarly
–8–4 fill for the remaining components
9 6 7 – 13 – 141
7 1
10 9 – 8 – 10
8 1
9
10
11
12
13 1
14 1
15 1
 Components
Machines
1 2 3 4 5 6 7 8 9 10
1 1 1
2 1 1
3 1 1 1
4 1 1 1
5 1 1 1
6 1 1 1
7 1 1 1
8 1 1 1 1 1
9 1 1
10 1 1
11 1
12 1
13 1 1
14 1 1 1 1
15 1 1 1
 Components
Machines
1 2 3 4 5 6 7 8 9 10
1 1 1
2 1 1
3 1 1 1
4 1 1 1
5 1 1 1
6 1 1 1
7 1 Give binary value for each components
1 1
8 1 1 1 1 1
9 Start the binary from the1 lower right corner 1
10 20 , 21 , 22 , 23 , 24 …… 1 1
11 1
12 1
13 1 1
14 1 1 1 1
15 1 1 1
Binary Values 29 28 27 26 25 24 23 22 21 20
 = (1 X 29) +(1 X 22) = 516
Components Binary
Machines
1 2 3 4 5 6 7 8 9 10 Equivalent
1 1 1 ?
2 1 1
3 1 1 1
4 1 1 1
5 1 1 1
6 1 1 1
7 1 1 1
8 1 1 1 1 1
9 1 1
10 1 1
11 1
12 1
13 1 1
14 1 1 1 1
15 1 1 1
Binary
29 28 27 26 25 24 23 22 21 20
Values
 = (1 X 29) +(1 X 22) = 516
Components Binary
Machines
1 2 3 4 5 6 7 8 9 10 Equivalent
1 1 1 516
2 1 1 ?
3 1 1 1
4 1 1 1
5 1 1 1
6 1 1 1
7 1 1 1
8 1 1 1 1 1
9 1 1
10 1 1
11 1
12 1
13 1 1
14 1 1 1 1
15 1 1 1
Binary
29 28 27 26 25 24 23 22 21 20
Values
 = (1 X 29)+ (1 X 26) +(1 X 22) = 580
Components Binary
Machines
1 2 3 4 5 6 7 8 9 10 Equivalent
1 1 1 516
2 1 1 516
3 1 1 1 ?
4 1 1 1
5 1 1 1
6 1 1 1
7 1 1 1
8 1 1 1 1 1
9 1 1
10 1 1
11 1
12 1
13 1 1
14 1 1 1 1
15 1 1 1
Binary
29 28 27 26 25 24 23 22 21 20
Values
 Similarly complete the remaining
Components Binary
Machines
1 2 3 4 5 6 7 8 9 10 Equivalent
1 1 1 516
2 1 1 516
3 1 1 1 580
4 1 1 1 580
5 1 1 1 580
6 1 1 1 580
7 1 1 1 266
8 1 1 1 1 1 725
9 1 1 17
10 1 1 17
11 1 144
12 1 144
13 1 1 258
14 1 1 1 1 298
15 1 1 1 296
Binary
29 28 27 26 25 24 23 22 21 20
Values
 Give Ranking for the Binary Equivalent values
Components Binary
Machines Rank no
1 2 3 4 5 6 7 8 9 10 Equivalent
1 1 1 516 6
2 1 1 516 7
3 1 1 1 580 2
4 1 1 1 580 3
5 1 1 1 580 4
6 1 1 1 580 5
7 1 1 1 266 10
8 1 1 1 1 1 725 1
9 1 1 17 14
10 1 1 17 15
11 1 144 12
12 1 144 13
13 1 1 258 11
14 1 1 1 1 298 8
15 1 1 1 296 9
Binary
29 28 27 26 25 24 23 22 21 20
Values
 Now rearrange the rows according the rank
i.e Rank 1 in the first row, rank 2 in second row and so on
Components Binary
Machines Rank no
1 2 3 4 5 6 7 8 9 10 Equivalent
Shift Row 8 to Row 1
1 1 1 516 6
2 1 1 516 7
3 1 1 1 580 2
4 1 1 1 580 3
5 1 1 1 580 4
6 1 1 1 580 5
7 1 1 1 266 10
8 1 1 1 1 1 725 1
9 1 1 17 14
10 1 1 17 15
11 1 144 12
12 1 144 13
13 1 1 258 11
14 1 1 1 1 298 8
15 1 1 1 296 9
Binary
29 28 27 26 25 24 23 22 21 20
Values
 Now rearrange the rows according the rank
i.e Rank 1 in the first row
Components Binary
Machines Rank no
1 2 3 4 5 6 7 8 9 10 Equivalent
8 1 1 1 1 1 1 725 1
 Now rearrange the rows according the rank
i.e Rank 2 in second row and so on
Components Binary
Machines Rank no
1 2 3 4 5 6 7 8 9 10 Equivalent
8 1 1 1 1 1 1 725 1
3 1 1 1 580 2
 i.e Rank It2 is
innot
second
necessary
row and
to so
writhe
on this two column in this step
Components Binary
Machines Rank no
1 2 3 4 5 6 7 8 9 10 Equivalent
8 1 1 1 1 1 1 725 1
3 1 1 1 580 2
4 1 1 1 580 3
5 1 1 1 580 4
6 1 1 1 580 5
1 1 1 516 6
2 1 1 516 7
14 1 1 1 1 298 8
15 1 1 1 296 9
7 1 1 1 266 10
13 1 1 258 11
11 1 1 144 12
12 1 1 144 13
9 1 1 17 14
10 1 1 17 15
 Give binary value for each Machine
Start the binary from the lower left corner
20 , 21 , 22 , 23 , 24 ……
Components Binary
Machines
1 2 3 4 5 6 7 8 9 10 Values
8 1 1 1 1 1 1 214
3 1 1 1 213
4 1 1 1 212
5 1 1 1 211
6 1 1 1 210
1 1 1 29
2 1 1 28
14 1 1 1 1 27
15 1 1 1 26
7 1 1 1 25
13 1 1 24
11 1 1 23
12 1 1 22
9 1 1 21
10 1 1 20
 Components Binary
Machines
1 2 3 4 5 6 7 8 9 10 Values
8 1 1 1 1 1 1 214
3 1 1 1 213
4 1 1 1 212
5 1 1 1 211
6 1 1 1 210
1 1 1 29
2 1 1 28
14 1 1 1 1 27
15 1 1 1 26
7 1 1 1 25
13 1 1 24
11 1 1 23
12 1 1 22
9 1 1 21
10 1 1 20
Binary
Equivalent
? ? ?
= (1 X 214) +(1 X 213) +(1 X 212) +(1 X 211) +(1 X 210) +(1 X 29) +(1 X 28)
 Components Binary
Machines
1 2 3 4 5 6 7 8 9 10 Values
8 1 1 1 1 1 1 214
3 1 1 1 213
4 1 1 1 212
5 1 1 1 211
6 1 1 1 210
1 1 1 29
2 1 1 28
14 1 1 1 1 27
15 1 1 1 26
7 1 1 1 25
13 1 1 24
11 1 1 23
12 1 1 22
9 1 1 21
10 Give Ranking for the Binary
1 Equivalent values1 20
Binary
Equivalent
Rank 1 2
 Components Binary
Machines
1 2 3 4 5 6 7 8 9 10 Values
8 1 1 1 1 1 1 214
3 1 1 1 213
4 1 1 1 212
5 1 1 1 211
6 1 1 1 210
1 1 1 29
2 1 1 28
14 1 1 1 1 27
15 1 1 1 26
7 1 1 1 25
13 1 1 24
11 1 1 23
12 1 1 22
9 1 1 21
10 Give Ranking for the Binary
1 Equivalent values1 20
Binary
Equivalent
Rank 1 7 5 3 9 4 8 2 10 6
 Components
Machines 2 4 6 1 3 5
M1 1 1 1

M2 1 1 1

M3 1 1 1

M4 1 1 1

83
Arranging of Machine in GT Cell
 Arranging of Machine in GT Cell
• GT Machine sequence can be bone by
– Hollier Method 1
– Hollier Method 2
 To 1 2 3 4
1 0 5 0 25

From 2 30 0 0 15
3 10 40 0 0
4 10 0 0 0

Hollier Method 1
Hollier Method 2
 Flexible Manufacturing System
• A highly automated GT machine cell,
consisting of a group of processing stations
(usually CNC machine tools), interconnected
by an automated material handling and
storage system, and controlled by an
integrated computer system
 Types of FMS
• Single Manufacturing cell (SMC)
• Flexible manufacturing cell (FMC)
• Flexible manufacturing system (FMS)
Single Manufacturing cell
Single Manufacturing cell
Flexible Manufacturing cell
Flexible manufacturing
cell
Flexible manufacturing system
Flexible manufacturing system
 Five Types of FMS Layouts
1.In-line
2.Loop
3.Ladder
4.Open field
5.Robot-centered cell
 In-line layout
Starting work parts One direction flow
Completed parts

Part transportation system

Load Unld
Man Man
Work Flow

Mach Mach Mach Mach

Auto. Auto. Auto. Auto.
 In-line layout

Load
Unld Shuttle cart Work flow
man Primary line

Auto. Auto. Auto. Auto.

Secondary handling system

Loop FMS Layouts
Ladder FMS Layouts
Open field FMS Layouts
Robot-Centered Cell FMS Layouts
 FMS Example
One Design + One Assembly Process = Multiple Models

When different models are designed to be assembled in the same sequence they can be
built in the same plant.
This maximizes efficiency and allows the company to respond quickly to changing customer
 FMS Example
Through the use of reprogrammable tooling in the body shop, standardized equipment in the
paint shop and common build sequence in final assembly, Ford can build multiple models on
one or more platforms in one plant.

Body Shop Paint Shop Final Assembly

In the body shop, where
the sheet metal comes
together to form the
vehicle’s body, flexibility
means more than 80
percent of the tooling is
not specific to one model.
It can be reprogrammed
to weld a car or a truck or
a crossover of similar size.
In the paint shop, flexibility
means robotic applicators
are programmed to cover
various body styles – as
they move through the
paint booth – with equal
precision. This results in
minimizing waste and
environmental impact
while maximizing quality.
In the final assembly
area, flexibility means
the build sequence is the
same among multiple
models on one or more
platforms allowing for
efficient utilization of
people and equipment.
 FMS Example

Virtual Verification
Virtual manufacturing technology allows Ford to quickly add various models into an
existing facility – or to reconfigure an existing facility to produce a new model. In the
virtual world, manufacturing engineers and plant operators evaluate tooling and
product interfaces before costly installations are made on the plant floor. This method
of collaboration improves launch quality and enables speed of execution.
 Classification of CNC
• Feedback control
• Motion control
• Power drive
• Circuit technology
• Positioning system
• Axis identification
Feedback Control
 Motion Control
• Positional (Point to Point)
• Paraxial (Straight line)
• Continuous path
• Combined motion
 Power drive
• Hydraulic
• Electrical
• Pneumatic
 Circuit technology
• Analog control system
• Digital control system
 Positioning system
• Absolute positioning
• Incremental positioning
 Absolute positioning

(1 ,2)
(-3 ,1)

(3 ,-2)
(-3 ,-4)
Incremental positioning

(1 ,2)
(-6 ,3)

(2 ,-3)
 Axis identification
• 2-axis
• 3-axis
• 4-axis
• 5-axis
 Features of CNC
• Storage of more then one part program
• Various forms of program input
• Program editing at the machine tool
• Fixed cycle and programming subroutines
• Interpolation
• Positioning features for setup
• Cutting length and size compensation
• Acceleration and deceleration calaulation
 Features of CNC
• Communication interface
• Malfunction and analysis
• Tool life monitoring
• Preventive maintenance notices
• Diagnostics
• Control start-up diagnostics
• Programming diagnostics
Classification of Machining Centers
• Vertical machining centre (VMC)
• Horizontal machining centre (HMC)
• Universal machining centre (UMC)
Vertical machining centre (VMC)
Horizontal Machining Centre (HMC)
Universal Machining Centre (UMC)
Universal Machining Centre (UMC)
 DNC
(Direct Numerical Control)
A type of manufacturing system in which
several NC or CNC machines are controlled
remotely from a main frame computer.
• DNC handles scheduling of work and bypasses
the need of a machine control unit.
• The system operates in a real time and time
sharing mode.
• In DNC system the processing and post
processing and post processing of part
program is performed in a centralized
computer.
 Types of DNC
• Direct machine control unit
• Behind-tape reader (BTR)
Slide and slide ways
 Slide and slide ways
Types of slide ways
• Hydrostatic type slide way
• Anti friction type slide way
• Wear resistance slide way
 Hydrostatic type slide way
• Oil Lubricated Slide ways
• Air bearing Slide ways
Oil Lubricated Slide ways
Air bearing Slide ways
 Anti friction type slide way
• Ball bearing Guide-ways
• Roller bearing guide ways
Ball bearing Guide-ways
Reticulating linear ball bearing guide
ways
 Wear resistance slide ways
• Flame Hardening
• Induction hardening
• Fastening hardened surfaces
• Surface coating
Recirculating Ball Screw and Nut
Assembly
 Steel ball recirculation
Explanation
method
Steel balls are recirculated by the end caps mounted
（1） End cap method on each end and ball recirculation tunnels within the
nut's inner wall. Good with high speed operations.

Deflectors are embedded on the nut outer tube to

Flop over method
（2） return the balls over the screw shaft land per each
(Deflector method)
lead. Suitable for compact designs.

Return tubes formed to recirculate the balls are

mounted on the outer perimeter of the nut. Easy to
（3） Return tube method
assemble design is suitable for mass production, but
the physical size tend to be large.

It uses guide plates or deflectors instead of the return

（4） Guide plate method
tubes, and is good for making the design compact.
 Design

Business Factory Mfg.

Functions Operation
Planning

Mfg.
Control
srmuniv.2012.mech.b@gmail.com