COMPUTER INTEGRATED MANUFACTURING (CIM) - PowerPoint Presentation

Slide1

COMPUTER INTEGRATED MANUFACTURING (CIM)

CAD/CAM/CAESlide2

The Society of Manufacturing Engineers (SME) defined CIM as ‘CIM is the

integration

of the total manufacturing enterprise through the use of integrated systems and data communications coupled with new managerial philosophies which results in the improvement of personnel or organizational efficiencies.

DEFINATIONSlide3

Manufacturing can be considered in three broad areas:

(i) continuous process production,

(ii) mass production, and (iii) job-shop production. Among these three, mass production and job-shop production can be categorized as discrete- item production. INTRODUCTIONSlide4

Continuous

Process Production

Such type of product flows continuously in the manufacturing system, e.g. petroleum, cement, steel rolling, petrochemical and paper production etc. Equipment used here are only applicable for small group of similar products. INTRODUCTIONSlide5

Mass

Production

It includes the production of discrete unit at very high rate of speed. Discrete item production is used for goods such as automobiles, refrigerators, televisions, electronic component and so on. INTRODUCTIONSlide6

Job

Shop Production

A manufacturing facility that produces a large number of different discrete items and requires different sequences among the production equipments is called job shop. Scheduling and routine problems are the essential features of job shop. So automation is been restricted to individual component of job shop. INTRODUCTIONSlide7

Continuous

flow

process cannot be automated fully as it only consists of a small percentage of manufacturing system. Mass production of discrete items is included in this category, where segments of production line are largely automated but not the entire line. Job shop facilities have used automated machines, but transfer of work among these machines is a difficult task.

INTRODUCTIONSlide8

Major

component of the automated information that needs to be made available to the manufacturing operation must come from product design.

This allows a plant to be automated and integrated. However, manufacturing is more concerned with process design rather than product design. INTRODUCTIONSlide9

The characteristic of present world market include

higher competition

short product life cyclegreater product diversityfragmented marketVariety

Complexity

smaller

batch

sizes

to satisfy a variety of customer profile.

INTRODUCTIONSlide10
Slide11

Furthermore

,

non price factors such as quality of product design, innovation and delivery services are the preliminary determinant for the success of product. In today‟s global arena, to achieve these requirements manufacturing company needs to be flexible, adaptable and responsive to changes and be able to produce a variety of products in

short time and at lower cost

.

These

issues attract manufacturing industries to search for some advanced technology, which can overcome these difficulties.

Computer

integrated manufacturing (CIM), which emerged in 1970, was the outcome of this

search

.

INTRODUCTIONSlide12

CIM involves a fundamental strategy of

integrating

manufacturing facilities and systems in an enterprise through the computer and its peripheral. CIM can be defined in different ways depending upon its application. CIM involves integration of advanced technologies in various functional units of an enterprise, in an effective manner to achieve the success

of the manufacturing industries.

A

deep knowledge and understanding of all the technology is required for an effective integration.

INTRODUCTIONSlide13

At first

integration

of advanced manufacturing technology (AMT) is required to get success in the application of CIM. Computers act as a subordinate to the technologies. Computers help, organize, and restore information in order to achieve high accuracy and speed. Their basic aim is to achieve the goals of the objectives within limited available capital. Traditionally

, all the efforts were focused on achieving

single

goal to improve the effectiveness and competitiveness of the organization.

INTRODUCTIONSlide14

But

they

failed because they didn‟t satisfy the overall objectives of the manufacturing companies. So, a multiple goal selection was proposed to make the CIM an effective tool to improve the economy of the company. This new approach should improve the existing multi-criteria optimization mechanism, so that CIM can be realized globally. In

addition, global integration approach should be applied to make globally distributed company as a single entity.

INTRODUCTIONSlide15

This concept is applied to make virtual CIM more effective and hence helps in meeting the present global economic circumstances using intelligent manufacturing.

Therefore

, manufacturing technology should be blended with intelligence. This will help manufacturing enterprise to produce better quality. It will also facilitate the manufacturing equipment to solve problems posed during normal course of the operations. INTRODUCTIONSlide16

CIM

basically involves the integration of advanced technologies such as

CAD, CAM, CNC, robots, AMHS.Today CIM has moved a step ahead by including and integrating the business improvement activities such as customer satisfaction, total quality and continuous improvement. These activities are now managed by computers. Business

and marketing teams continuously

give

the customer feedback to the design and production teams by using the networking systems.

INTRODUCTIONSlide17

Based

on the customer requirements, design and manufacturing teams can immediately improve the existing product design or can develop an entirely new product.

Thus, the use of computers and automation technologies made the manufacturing industry capable to provide rapid response to the changing needs of customers.INTRODUCTIONSlide18

CIM

encompasses

the entire range of product development and manufacturing activities.And all the functions are 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.

INTRODUCTIONSlide19

For

example, the

product data created during design is transferred from the modeling software to manufacturing software without any loss of data. CIM uses a common database and communication technologies to integrate design, manufacturing and associated business functions that combine the automated segments of a factory or a manufacturing facility.

INTRODUCTIONSlide20

CIM

reduces the

human component of manufacturing and thereby relieves the process of its slow, expensive and error-prone component. CIM stands for a holistic and methodological approach to the activities of the manufacturing enterprise in order to achieve vast improvement in its performance.INTRODUCTIONSlide21

INTRODUCTION

This methodological approach is applied to all activities from

the design of the product to customer support in an integrated way, using various methods, means and techniques in order to achieve production improvement, cost reduction, fulfillment of scheduled

delivery

dates

,

quality

improvement and total

flexibility

in the manufacturing

system.

CIM requires all those associated with a company to involve totally in the process of

product development

and manufacture. Slide22

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.

INTRODUCTIONSlide23

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. This requires extremely high flexibility in the manufacturing system.INTRODUCTIONSlide24

The challenge before the manufacturing engineers is illustrated in

Fig.

Manufacturing industries strive to reduce the cost of the product continuously to remain competitive in the face of global competition. In addition, there is the need to improve the quality and performance levels on a continuing basis. INTRODUCTIONSlide25

INTRODUCTION

Another important requirement

is on time delivery. In the context of global outsourcing and long supply chains cutting across several international borders, the task of continuously reducing delivery times is really

a difficult

task

.

CIM

has several software tools to address the above needs.Slide26

INTRODUCTION

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

CIM technology is an enabling technology to meet the above challenges to

the manufacturing

.Slide27

EVOLUTION

OF CIM

CIM is considered a natural evolution of the technology of CAD/CAM which by itself evolved by the integration of CAD and CAM.MIT (Massachusetts Institute of Technology, 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 of these

technologies

.Slide28

EVOLUTION

OF CIM

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 the US Air Force to approach MIT to develop suitable control systems, drives and programming techniques for machine tools using electronic control.Slide29

1950’s

The

first major innovation in machine control is the Numerical Control (NC), demonstrated at MIT in 1952. Early NC Systems were all basically hardwired systems, since these were built with discrete systems Early NC machines used paper tape as an input medium.

Every

NC machine

was fitted

with a

tape reader

to read paper tape and transfer the program to the memory of

the machine

tool block by block.

EVOLUTION

OF CIMSlide30

1960’s

Mainframe

computers were used to control a group of NC machines by mid 60's. It was then called as DNC as the computer bypassed the tape reader to transfer the program data to the machine controller.

By

late 60's

mini computers

were being commonly used to control NC machines.

At this stage NC became

truly soft wired

with the facilities of mass program storage, offline editing and software logic control and processing.

This development is called Computer Numerical Control (CNC

).

EVOLUTION

OF CIMSlide31

1970’s

Since

70's, NC’s are being designed around microprocessors, resulting in compact CNC systems. A further development to this technology is the distributed numerical control (also called DNC) in which processing of NC program is carried out in different computers operating at different hierarchical levels -

typically from mainframe host computers to plant computers to the machine controller.

Today CNCs are

built around

32

bit and 64 bit microprocessors.

EVOLUTION

OF CIMSlide32

Late1970’s

Manufacturing

engineers also started using computers for such tasks like inventory control, demand forecasting, PPC etc. CNC technology was adapted in the development of CMMs which automated inspection.

Robots

were introduced to automate several tasks like machine loading

, materials

handling, welding, painting and assembly.

T

hese

developments led to

the evolution

of

FMC

and

FMS

in

late 70's.

EVOLUTION

OF CIMSlide33

Evolution of

CAD

, on the other hand was to cater to the geometric modeling needs of automobile and aeronautical industries. The developments in computers, design workstations, graphic cards, display devices and graphic input and output devices

during the last ten years have been phenomenal

.

This

coupled with

the development

of operating system with graphic user interfaces and

user friendly

software packages for

modeling

, drafting, analysis and optimization

provides the

necessary tools to automate the design process

.

EVOLUTION

OF CIMSlide34

CAD in fact owes its development to the

APT language

project at MIT in early 50's. Several clones of APT were introduced in 80's to automatically develop NC codes from the geometric model of the component. Today anyone can model, draft, analyze, simulate, modify, optimize and create the NC code to manufacture a component and simulate the machining operation sitting at a computer workstation

.

EVOLUTION

OF CIMSlide35

If we review the manufacturing scenario during 80's we will find that the manufacturing is characterized by a few islands of automation.

In

the case of design, the task is well automated.In the case of manufacture, CNC machines, DNC systems, FMC, FMS etc provide tightly controlled automation systems. EVOLUTION OF CIMSlide36

Similarly

computer control has

been implemented in several areas like manufacturing resource planning, accounting, sales,marketing and purchase.Yet the full potential of computerization could not be obtained unless all the segments of manufacturing are integrated, permitting the transfer of data across various functional modules. EVOLUTION OF CIMSlide37

EVOLUTION

OF CIM

This realization led to the concept of computer integrated manufacturing. Thus the implementation of CIM required the development of whole lot of computer technologies related to hardware and software.Slide38

CIM plays a vital role in the economy of the manufacturing system or enterprise.

The benefits of CIM are indicated as follows: (i) Products quality improvement. (ii) Shorter time in launching new product in the market. (iii) Flow time minimized. (iv) Inventory level reduced. (v)

Competitivenes

s increases.

BENEFITS OF CIMSlide39

(vi) Improved

scheduling performance. (vii) Shorter vendor lead time. (viii) Improved customer service. (ix) Increase in flexibility and responsiveness. (x) Total cost minimized. (xi) Long term profitability increases.

(xii)

Customers lead time

minimized.

(xiii) Manufacturing

productivit

y increases.

(xiv)

Work in process

inventory decreases.

BENEFITS OF CIMSlide40

CIM HARDWARE AND CIM SOFTWARE

CIM Hardware comprises the following:

i. Manufacturing equipment such as CNC machines or computerized work centers, robotic

work cells,

DNC/FMS systems

,

work

handling and tool handling devices

,

storage devices

,

sensors

,

shop

floor data collection devices,

inspection

machines etc

.

Slide41

CIM HARDWARE

AND CIM SOFTWARE

CIM Hardware comprises the following: ii. Drawing equipment such as Computers, controllers,

CAD/CAM

systems,

workstations /

terminals,

data entry terminals

,

bar

code readers,

RFID tags

, printers, plotters and other

peripheral

devices

,

modems

,

cables

,

connectors

etc.,Slide42

CIM software comprises computer programmes to carry out the following functions:

Analysis

Business Process Engineering (redesign & analysis of existing work flow)CommunicationsDevice DriversDatabase ManagementFinance Inventory Control

CIM HARDWARE AND

CIM SOFTWARESlide43

Job

Tracking

Manufacturing Area Control Marketing Materials Handling Management Information System (MIS)Modeling and DesignMonitoringManufacturing Facilities Planning

CIM HARDWARE AND

CIM SOFTWARESlide44

Network

Management

Order EntryProcess PlanningProduction ControlQuality ManagementSalesShop Floor Data CollectionSimulation Work Flow Automation

CIM HARDWARE AND

CIM SOFTWARESlide45

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEM

Nine major elements of a CIM system are

shown in Figure.MarketingProduct DesignPlanningPurchaseManufacturing EngineeringFactory

Automation Hardware

Warehousing

Finance

Information

ManagementSlide46

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide47

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide48

i. Marketing

:

The need for a product is identified by the marketing division. Marketing department decidesSpecifications of the product, Projection of manufacturing quantities

Marketing

strategy for the product.

Marketing also works

out the

manufacturing costs

to assess the

economic

viability of the product

.

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide49

ii. Product

Design:

Design department of the company establishes the initial database for production of a proposed product. Product Design is accomplished through activities such as

GM and CAD

while

considering

the product

requirements and concepts

generated by the creativity of the design

engineer

.

Configuration

management

(consistency)

is an important activity in many designs.

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide50

ii. Product

Design:

Complex designs are usually carried out by several teams working simultaneously, located often in different parts of the world. The design process is constrained

by the

costs

that will

be incurred

in actual production and by the

capabilities

of the available

production equipment

and processes.

The

design process creates

the

database

required

to manufacture

the part.

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide51

iii

.

Planning: Input is : database established by the design department Process : enriches it with production data and information to produce a plan for

the production

of the product.

Constrain

: The

planning process should be constrained by the

production costs

and by the

production equipment

and

process capability

, in order to generate an optimized plan.

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide52

iii

.

Planning: Involves several subsystems: dealing with materials, facility, process,

tools

,

manpower

,

capacity

,

scheduling

,

outsourcing,

assembly

, inspection, logistics etc.

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide53

iv.

Purchase:

The purchase departments is responsible forplacing the purchase orders and follow upensure quality in the procurement process

receive

the items

arrange

for

inspection

supply

the items to the

stores

arrange

timely

delivery

of items

depending on the production schedule for eventual supply to manufacture

and assembly

.

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide54

v.

Manufacturing Engineering:

ME is the activity of carrying out the production of the product.ME further enrich the database with performance data

and

information

about the production

equipment and processes

.

CIM

requires activities like

CNC

programming,

simulation

computer aided scheduling

of the production activity.

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide55

v.

Manufacturing Engineering:

ME include online dynamic scheduling and control based on the real time performance of the equipment and processes to assure

continuous

production activity.

The

need to meet

fluctuating

market demand

requires the manufacturing

system to be

flexible and agile

.

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide56

vi.

Factory Automation Hardware:

Factory automation equipment further enriches the database with equipment and process data to carry out the production process.In

CIM system this consists

of computer

controlled process machinery such as

CNC

machine tools,

flexible manufacturing

systems (

FMS

), Computer controlled

robots

, material handling

systems (

MHS

), computer

controlled

assembly

systems,

automated

inspection

systems and so on.

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide57

vii

. Warehousing:

Warehousing is the function involving storage and retrieval of raw materials, components, finished goods as well as shipment of items. In today's complex outsourcing scenario

and the need for

just-in-time

supply

of components

and subsystems

,

logistics and supply chain management

assume great importance

.

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide58

viii

. Finance:

Finance deals with the resources pertaining to money. Major tasks of the finance department are:Planning of investment, working capital,

(

Arrangement)

cash

flow

control

,

realization

of

receipts

,

allocatio

n

of

funds

accounting

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide59

ix.

Information Management:

Information Management is the most crucial tasks in CIM. This involves: master production scheduling, database management,

c

ommunicatio

n,

manufacturing

systems

integration

management

information systems.

NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEMSlide60

CIM WHEELSlide61

CIM WHEELSlide62

The

common business administrative tasks related to CIM are located on the outer ring of the wheel. They mainly form the connection of the company to the outside world Data processing applications can be found in the most diverse areas. Most software systems applied in these areas were originally self-styled developments, which are increasingly being replaced with

commercial standard software

packages.

Currently this software is installed primarily on

mainframes

.

Overlaps of its functionality exist mainly with the software of the PPC.

THE OUTER RINGSlide63

On

the inner ring of the wheel, the functions closely related to

the operational performance of the company are situated. Data processing applications of the development and design area are computer aided design (CAD), simulations, analysis programs such as the finite element method (FEM) as well as drawing storage and management, for instance with the help of GT.THE INNER RINGSlide64

The

types of data found in this area are diverse

:drawings, technical specifications, and bills of material. In manufacturing companies, the data itself are often in considerable disorder. Frequently there are several types of part numbers, more than one group technology system, many kinds of bills of material, a number of different CAD systems each having its own sort of computer internal representation of geometric data, etc. The applied software rarely runs on the same hardware, resulting also in a large number of different hardware systems. 

THE INNER RINGSlide65

The

second group

is attributed to process planning and PPC.It comprises tasks such as routing generation, resource planning, material requirements planning, capacity planning, order distribution and supervision, but also the planning of quality assurance.As in the common business administrative area, the software packages-which at least are integrated within themselves-have a modular structure and their single components can also be bought and applied. THE INNER RINGSlide66

Therefore

a company rarely has purchased and installed all modules of such a package, which in turn frequently results in functional overlaps and data

redundancy.THE INNER RINGSlide67

Third

group on the inner ring includes the automation of the manufacturing installations

. Examples are robots, NC machines, FMS and computer aided measuring and testing methods. This area is characterized by the extreme heterogeneity of the systems involved, the diversity of which being much more pronounced than in the previously mentioned groups of functions.THE INNER RINGSlide68

At present

within these groups of applications there are serious

hindrances with regard to integration.There are few suppliers covering all three sectors. Therefore little or nothing has been done by the suppliers with regard to interfaces, not to mention the integration of the various groups of applications. Information and communication management, represented by the hub of the wheel which links everything, is intended to serve as the information management and communication control function between the single areas. It operates on a common, integrated database.

THE HUBSlide69

Many of the firms that are currently using

CIM

have reported a number of improvements including:• 15-30 % reduction in engineering design cost,• 30-60 % reduction in overall lead times,• 40-70% gain in overall production,• 200-500 % gain in quality• 30-60 % reduction in working progress.BENEFITS OF CIM Slide70

In

the

competitive business at globalization era, a company faces many challenges from business world wide also competitive from other company and its business strategies as well.

Therefore

company should come out with a

good

planning and

strategy.

Thus

, with

implementing

CIM

system at company several things

could be improved.

OBJECTIVE OF CIMSlide71

Simplify

production

processes, product design and factory organisation, as these are vital foundation to automation and integrationTo reduce lead

time,

costs

and

inventory

Automate

production

processes

A

nd

automate

business

functions

that support them with computers, machines and robots.

To

coordinate and organize

data

effectively

OBJECTIVE OF CIMSlide72

To

eliminate

paper and the costs associated with its useTo automate communication within a factory and increases

its

speed

To

facilitate

simultaneous

engineering

Integrate

all,

production and support processes using computer networks, cross-functional business software and other information technologies.

OBJECTIVE OF CIMSlide73

DATABASE REQUIREMENTS FOR CIM

Information

is needed by mfg. companyTo carry a task needs certain amount of skill.E.g. machining of casting Machining data should be knownIf not known has to consult supervisor or handbookHandbook does not provide failure dataFollowing information may be required

Serial number of faulty part

Scheduled maintenance of XY machine

Company profit of last year

Stress value of grey cast iron

How many days ABC was absent

What is

approx

cutting speed for machining of new ceramic part?Slide74

Product Design and Manufacturing

process

increasingly requires access to substantial technical information in various stages like DesignAnalysismanufacturing.It also needs

smooth

co-ordination

among the many

functions

constituting an enterprise.

Manufacturing

organizations

may

waste

a considerable portion of their

resources

due to delayed or

error prone

communication

from one segment to another.

It

would therefore be

desirable

to have

one

single central database

that would contain all information.

DATABASE REQUIREMENTS FOR CIM Slide75

The

CIM database

comprises basically following classes of data:Product Data: Data about parts to be manufactured It includes text and

geometry

data

ii

.

Manufacturing / Production

Data:

Information on

how

parts

are to be

manufactured

iii

.

Engineering

Data:

Information on use of computer in analysis, inspection, testing

iv

.

Operational Data:

Describes

the

things specific

to

production:

lot

size, schedule,

assembly sequence

etc

.

v

. Resource Data:

Describes resources involved

in

operations:

materials

,

machines

, human resources and money.

DATABASE REQUIREMENTS FOR CIM Slide76

DATABASE REQUIREMENTS FOR CIM

CIM Data BaseSlide77

DATABASE REQUIREMENTS FOR CIM

Product data:

contain the description of the products involved in the manufacturing process. The data may consist of graphic, text, and numeric information.

Production data:

describe

how the parts are to be manufactured.

Machines data:

conventional & Non-Conventional

Specification of machines

Design data:Slide78

DATABASE REQUIREMENTS FOR CIM

Design data:

Depending on product complexity, shape may be defined by any of the following methods CSGB-rep

Wireframe

modelling

Parametric

modellingSlide79

DATABASE REQUIREMENTS FOR CIM

Manufacturing Data:

Classified as :Permanent & temporary data

Static and Dynamic data

Computer compatible

Data Source :

Internal

ExternalSlide80

Production Planning & control

Shop floor control

Order entryPurchasing

Cost accounting

DATABASE REQUIREMENTS FOR CIM Slide81

Materials

Machines

Human resourcesMoney

DATABASE REQUIREMENTS FOR CIM Slide82

Computer aided design

Computer

aided analysisComputer aided programmingComputer aided tool designComputer aided process planning

Computer

aided quality control

Programmable controllers

Computer

aided inspection

Computer

aided testing

Computer

aided assembly

Computer

aided material handling

DATABASE REQUIREMENTS FOR CIM Slide83

Inspection of parts :

Incoming

FinishedInventory : Inprocess Finished goods Tools Materials

ASRS:

DATABASE REQUIREMENTS FOR CIM Slide84

Following

is the list

of varied tasks one might expect to accomplish in a CIM environment.Designing assemblies and performing tolerance analysis on those assemblies.ii. Preparing production drawings of assemblies, individual parts,

tooling

,

fixtures and

other manufacturing facilities

.

iii. Creating

analytical models

of parts for structural, kinematical and thermal

analysis (FEM).

iv.

Calculating

weights, volumes, centres of gravity and other mass properties

and costs

of manufacturing (cost estimation

).

DATABASE REQUIREMENTS FOR CIM Slide85

v

.

Classifying existing parts according to shape, function, and the process by which they are manufactured and retrieving these parts from the parts library on demand (Group technology and coding).vi. Preparing part lists and bill of materials (BOM).vii. Preparing process plans

for individual part manufacture and assembly (

Variant or

Generative

).

viii.

Programming CNC

machines for processing

parts -

CAM

DATABASE REQUIREMENTS FOR CIM Slide86

ix. Designing work cells and programming the movement of components in those cells using work handling devices like robots, conveyors, AGV’s/ RGV’s, etc. (Cellular manufacture

)x. Controlling engineering changes and maintaining associativity between design and manufacturingxi. Preparing programs to handle components or manipulate production equipment (like welding torches or robots

)

xii. Preparing

inspection

programs including programs for CNC co-ordinate

measuring machines

[CNC CMM’s

]

DATABASE REQUIREMENTS FOR CIM Slide87

DATA BASE

A data base can be

defined as a collection of data in a single location designed to be used by different programmers for a variety of applications. The term database denotes a common base of data collection designed to be used by different programmers.

More

specifically

it is

a

collection of logically related data

stored together in a set of files intended to serve

one or

more applications in an optimal fashion.

A

database

not

only stores the data but also provides

several ways

to view the data depending upon

the needs

of the user.

DATABASE REQUIREMENTS FOR CIM Slide88

OBJECTIVES

OF DATABASE

A database serves the following objectives:• Reduce or eliminate redundant data• Integrate existing data• Provide security• Share data among users• Incorporate changes quickly and effectively• Exercise effective control over data• Simplify the method of using data• Reduce the cost of storage and retrieval of data• Improve accuracy and integrity of data

DATABASE REQUIREMENTS FOR CIM Slide89

ISSUES

OF CONCERN IN

DATABASEThere are, of course, some issues to be considered while implementing a database. These include:• High investment in hardware and software• Need to use larger and faster hardware• Necessity to have highly trained manpower• Redundancy to take care of eventualities like crash of the database server.• Need to ensure integrity and reliability of dataDATABASE REQUIREMENTS FOR CIM Slide90

ROLE OF CAD/CAM IN CIM Slide91

ROLE OF CAD/CAM IN CIM Slide92

Computer-Aided Manufacturing Computer-aided manufacturing

(CAM) is defined as the

effective use of computer technology in manufacturing planning and control. CAM is most closely associated with functions in manufacturing engineering, such as process planning and numerical control (NC) part programming. CAM can be divided into two broad categories: manufacturing planning manufacturing controlROLE OF CAD/CAM IN CIM Slide93

Manufacturing Planning

CAM

applications for manufacturing planning are those in which the computer is used indirectly to support the production function, but there is no direct connection between the computer and the process. The computer is used "off-line" to provide information for the effective planning and management of production activities.

The Manufacturing planning areas include:

Computer-aided

process planning (

CAPP)

Computer-assisted NC part programming

Computerized

machinability data systems.

Development

of work standards.

Cost

estimating,

Production

and inventory planning.

Computer-aided

line balancing.

ROLE OF CAD/CAM IN CIM Slide94

b) Manufacturing Control.

The second category of CAM application is concerned with developing computer systems to implement the manufacturing control function. Manufacturing control is concerned with managing and controlling the physical operations in the factory These management and control areas include:

Process monitoring and

control

Quality control

Shop floor control

Inventory control

Just-in-time

production

systems

ROLE OF CAD/CAM IN CIM Slide95

Computer-aided

process planning (CAPP

):Process planning is concerned with the preparation of route sheets that list the sequence of operations and work centers required to produce the product and its components. CAPP systems are available today to prepare these route sheets. Computer-assisted

NC part

programming:

For

complex part

geometries, CAPP represents

a much more

efficient

method of generating the control

instructions

for the machine tool

than

manual part

programming

ROLE OF CAD/CAM IN CIM

MANUFACTURING PLANNINGSlide96

Computerized

machinability data

systems:One of the problems in operating a metal cutting machine tool is determining the speeds and feeds that should be used to machine a given work part. Computer

programs

have been written to recommend the

appropriate cutting

conditions to use for different materials.

The

calculations are

based on data

that have been obtained either in the factory or laboratory that relate tool life to

cutting

conditions

.

ROLE OF CAD/CAM IN CIM

MANUFACTURING PLANNINGSlide97

Development

of work standards

. The time study department has the responsibility for setting time standards on direct labor jobs performed in the factory. Establishing

standards

for

direct time

study

can be a tedious and time-consuming task.

There

are several

computer

packages

for setting work

standards.

These

computer programs

use

standard time data

that have been developed for basic work e

lements

that comprise any manual task.

ROLE OF CAD/CAM IN CIM

MANUFACTURING PLANNINGSlide98

Cost estimating:

The

task of estimating the cost of a new product has been simplified by computerizing several of the key steps required to prepare the estimate. The computer is programmed to apply the appropriate labor and overhead rates

to the sequence of planned operations for the components of new products.

The

program then

sums the individual

component

costs

from the engineering bill of materials to determine the overall product cost.

ROLE OF CAD/CAM IN CIM

MANUFACTURING PLANNINGSlide99

Production

and inventory

planning:The computer has found widespread use in many of the functions in production and inventory planning. These functions include: maintenance of inventory records

automatic

reordering

of stock items when inventory is

depicted

production

scheduling

maintaining

current priorities for the different

procurement orders

material

requirements

planning

MRP

capacity planning

ROLE OF CAD/CAM IN CIM

MANUFACTURING PLANNINGSlide100

Computer-aided

line

balancing:Finding the best allocation of work elements among stations on an assembly line is a large and difficult problem if the line is of significant size.

Computer

programs have been developed to

assist

in the solution of this problem

ROLE OF CAD/CAM IN CIM

MANUFACTURING PLANNINGSlide101

Process

monitoring and

control:Process monitoring and control is concerned with observing and regulating the production equipment and manufacturing processes in the plant. The applications of computer process control are common today in automated production systems.

They

include transfer

lines,

assembly

systems, NC

,

robotic,

material

handling

and flexible manufacturing

systems

Quality control:

Quality

control includes a variety of approaches to ensure the

highest possible quality levels

to the

manufactured product.

ROLE OF CAD/CAM IN CIM

MANUFACTURING CONTROLSlide102

•

Shop

floor control:Shop floor control refers to production management techniques for collection of data from factory operations and using the data to help control production and

inventory of

the factory.

•

Inventory

control

:

Inventory

control is concerned with

maintaining

the most appropriate levels of

inventory

in the

face

of two opposing

objectives

:

minimizing

the investment and storage

costs

of holding

inventory

maximizing

service

to

customers

ROLE OF CAD/CAM IN CIM

MANUFACTURING CONTROLSlide103

Just-in-time

production

systems:The term just-in-time refers to a production system that is organized to deliver exactly the right number of each component to downstream workstations in the manufacturing sequence just at the time when that component is needed. The

term applies not only to production operations but

to

supplier delivery

operations as well.

ROLE OF CAD/CAM IN CIM

MANUFACTURING CONTROLSlide104

CAD/CAM

CAD/CAM

is concerned with the engineering functions in both design and manufacturing. Product design, engineering analysis, and documentation of the design (e.g. drafting) represent engineering activities in

design

.

Process

planning, NC part programming, and other activities associated with CAM represent engineering activities in

manufacturing

.

The

CAD/CAM systems developed during the 1970s and early 1980s were designed primarily to address these types of engineering problems.

ROLE OF CAD/CAM IN CIM Slide105

CAD/CAM

In

addition, CAM has evolved to include many other functions in manufacturing, such asmaterial requirements planning (MRP)production schedulingcomputer production monitoringcomputer process control.

It

should also be noted that

CAD/CAM

denotes an

integration of design and manufacturing

activities by means of computer systems.

The

method of manufacturing a product is a

direct function

of its design.

ROLE OF CAD/CAM IN CIM Slide106

CAD/CAM

With

conventional procedures practiced for so many years in industry, engineering drawings were prepared by design draftsmen and later used by manufacturing engineers to develop the process plan. The

activities

involved in designing the product were

separated

from the activities associated with process planning.

Essentially a

two-step procedure

was employed.

This was time-consuming and involved

duplication

of effort by design and manufacturing personnel.

ROLE OF CAD/CAM IN CIM Slide107

Using

CAD/CAM technology

, it is possible to establish a direct link between product design and manufacturing engineering.In effect, CAD/CAM is one of the enabling technologies for concurrent engineering CE. It

is the

goal of CAD/CAM

to

automate

certain

phases

of

design

and

manufacturing

a

nd also

to automate the

transition

from design to manufacturing.

ROLE OF CAD/CAM IN CIM Slide108

In the ideal

CAD/CAM system

, it is possible to convert the design specification of the product it into a process plan This conversion is done automatically by the CAD/CAM system. As part of the process plan, the NC part program is generated automatically by CAD/CAM.

The CAD/CAM system

downloads the NC program

directly to the machine tool

by means of a telecommunications network.

Thus in CAD/CAM, product design, NC programming, and physical production are

all implemented by computer

.

ROLE OF CAD/CAM IN CIM Slide109

Computer Integrated Manufacturing

CIM includes all the engineering functions of CAD/CAM, and also includes the firm's business functions that are related to manufacturing. The ideal CIM system applies computer and communications technology

to

all

of the

operational functions

and

information processing functions

in manufacturing from

1

) order receipt

, through

2)

design

and

3)

production

, to product

4)

shipment

.

The

scope of

CIM

, compared with the more limited scope of CAD/CAM, is depicted in

Figure.

ROLE OF CAD/CAM IN CIM Slide110

The

scope of CAD/CAM and

ClMROLE OF CAD/CAM IN CIM Slide111

CIM concept:

All firm's operations related to production are incorporated in an integrated computer system to automate the operations. The computer system be pervasive throughout the firm, touching all activities that support manufacturing.

In

this integrated computer system, the

output

of one activity serves as the

input

to the next activity, through the

chain of

events

.

Chain

starts

with the

sales order

and

culminates

with

shipment

of the

product.

ROLE OF CAD/CAM IN CIM Slide112

Computerized

elements of a

CIM systemROLE OF CAD/CAM IN CIM The components of the integrated computer system are illustrated in figure.Slide113

Customer

orders

are initially entered by the company's sales force into a computerized order entry system. The orders contain the specifications describing the product. Specifications

serve as the input

to the

product design department.

ROLE OF CAD/CAM IN CIM Slide114

New

products

are designed on a CAD system. Components that comprise the product are designed,

the

bill of materials

BOM is

compiled

,

and

assembly

drawings are prepared

.

Output

of the

design

department serves as the

input

to

manufacturing engineering

,

where

process planning. tool design, and similar activities are accomplished to prepare for production.

ROLE OF CAD/CAM IN CIM Slide115

Process

planning

is performed using CAPP. Tool and fixture design is done on a CAD system, making use of the product model generated during product design. The output from

manufacturing engineering

provides the

input

to

production planning and

control

,

where

material requirements planning and scheduling are performed using the computer system.

ROLE OF CAD/CAM IN CIM Slide116

And

so it goes. through each step in the

manufacturing cycle. Implementation of CIM results in the automation of the information flow through every aspect of the company's organization.

ROLE OF CAD/CAM IN CIM Slide117

Cost

Time

Technical skills of support staffManagement commitmentNature of businessIntegration of components from different suppliersData IntegrityProcess Control

OBSTACLES TO

CIM