ManufProc2_7CIM

8/9/2019 ManufProc2_7CIM

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COMPUTER-

INTEGRATEDMANUFACTURING

Chapter 7


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Assignment No. 3

• Select a comple enginee!ing component " p!o#leo$ %o&! c'oice an( (e)elop t'e t&!ning o! millingp!og!am $o! its mac'ining. T'e p!og!am m&stincl&(e ci!c&la! inte!polations*

a+sol&te"inc!emental mo(es an( spee(* $ee(* an(coolant $&nctions.

•

• Assignments s'o&l( +e 'an(-!itten onl%.

•

• M&t&all% copie( assignments ill +e cancelle(.

•

• S&+mission (ea(line /0-DEC-01/2


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Challenges in Manufacturing

Challenges in Manufacturing


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CIM Denition• Computer-integrated manufacturing (CIM) is themanufacturing approach of using computers tocontrol the entire production process

• This integration allows individual processes toexchange info with each other and initiateactions

• Through the computers integration,manufacturing can e faster and less error!prone, although the main advantage is theailit" to create automated manufacturingprocesses

• T"picall" CIM relies on closed!loop controlprocesses, ased on real!time input from sensors

• It is also #nown as exible design andmanufacturing


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CIM ! Introduction

• CIM encompasses the entire range of product

development and manufacturing activities with allthe functions eing carried out with the help ofdedicated software ($%) pac#ages

• The data re&uired for various functions are passedfrom one application $% to another in a seamless

manner• 'or example, the product data is created during

design• This data has to e transferred from the modeling

$% to manufacturing $% without an" loss of data•

CIM use a common D wherever feasile andcommon!tech to integrate design, manufacturingand associated usiness

• CIM reduces the human component ofmanufacturing and there" relieves the process of

its slow, expensive and error!prone component


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Manufacturing SystemsIntegration Program


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rigin

•

The term *CIM* is oth a method ofmanufacturing and the name of a computer!automated s"stem in which individualengineering, production, mar#eting, and

support functions of a manufacturingenterprise are organi+ed

• In a CIM s"stem functional areas such asdesign, anal"sis, planning, purchasing, costaccounting, inventor" control, anddistriution are lin#ed through the computerwith factor" -oor functions such as materialshandling and management, providing directcontrol and monitoring of all the operations


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rigin

•

CIM also encompasses the whole lot ofenaling technologies including total &ualit"management, usiness processreengineering, concurrent engineering,wor#-ow automation, enterprise resource

planning and -exile manufacturing• . distinct feature of manufacturing toda" ismass customization

• This implies that though the products are

manufactured in large &uantities, productsmust incorporate customer!specic changesto satisf" the diverse re&uirements of thecustomers

• This re&uires extremel" high -exiilit" in the

manufacturing s"stem


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P!o(&ction s%stems can +e (i)i(e( into to le)els

/. FacilitiesThe facilities of the production system consists of

• t'e $acto!%

• t'e e&ipment in t'e $acto!%* an(

• t'e a% t'e e&ipment is o!gani4e(.

0. Man&$act&!ing s&ppo!t s%stems

Set of procedures used by the company to:• manage p!o(&ction• sol)e t'e tec'nical an( logistics p!o+lems enco&nte!e( in

• ordering material• moving work through the factory • ensuring that products meet quality standards.

/roduction $"stems


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In mo(e!n man&$act&!ing ope!ations* po!tions o$ t'e p!o(&ction

s%stem a!e a&tomate( an("o! comp&te!i4e(.

/roduction $"stems


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I- P!o(&ction S%stem Facilities

Facilities in the production system are:

• T'e $acto!%• P!o(&ction mac'ines an( tooling• Mate!ial 'an(ling e&ipment• Comp&te! s%stems t'at cont!ol t'e man&$act&!ing ope!ations

Facilities also incl&(e t'e plant la%o&t* 'ic' is t'e a% t'ee&ipment is p'%sicall% a!!ange( in t'e $acto!%.

T'e e&ipment is &s&all% o!gani4e( into logical g!o&pings* an(

e !e$e! to t'ese e&ipment a!!angements an( t'e o!5e!s

'o ope!ate t'em as t'e manufacturing systems in t'e $acto!%


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II- Man&$act&!ing S&ppo!t S%stems

To operate the production facilities eciently, a company

must organie itself to

• Design t'e p!ocesses an( e&ipment

• Plan an( cont!ol t'e p!o(&ction o!(e!s6 an(

• Satis$% p!o(&ct &alit% !e&i!ements

complis'e( +% man&$act&!ing s&ppo!t s%stems 7people an( p!oce(&!es

Most o$ man&$act&!ing s&ppo!t s%stems (o not (i!ectl%

contact t'e p!o(&ct* +&t t'e% plan an( cont!ol itsp!og!ess t'!o&g' t'e $acto!%.


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II- Man&$act&!ing S&ppo!t S%stems

anufacturing support involves a cycle of information"processing activities


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A&tomation in P!o(&ction S%stems

A&tomation can +e (e#ne( as a tec'nolog% conce!ne( it' t'e

application o$ mec'anical* elect!onic an( comp&te!-+ase( s%stems

to ope!ate an( cont!ol p!o(&ction T'e a&tomate( elements o$ t'e p!o(&ction s%stem can +e sepa!ate( into to

catego!ies

• A&tomation o$ t'e man&$act&!ing s%stems in t'e $acto!%

• Comp&te!i4ation o$ t'e man&$act&!ing s&ppo!t s%stems


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A&tomate( Man&$act&!ing S%stems

#$amples of automated manufacturing system included:

• A&tomate( mac'ine tools t'at p!ocess pa!ts• T!ans$e! lines t'at pe!$o!m a se!ies o$ mac'ining ope!ations

• A&tomate( assem+l% s%stems

• In(&st!ial !o+ots to pe!$o!m p!ocessing o! assem+l%

• A&tomatic mate!ial 'an(ling an( sto!age s%stems

• A&tomatic inspection s%stems $o! &alit% cont!ol

ated manufacturing systems can be classi&ed into three basic types:

( a&tomation

!amma+le a&tomation

i+le a&tomation


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/- Fie( A&tomation

Fie( a&tomation is a s%stem in 'ic' t'e se&ence o$

p!ocessing 7o! assem+l%8 ope!ations is #e( +% t'e

e&ipment con#g&!ation. Eac' o$ t'e ope!ations in t'e

se&ence is &s&all% simple.

Eamples

•

mac'ining t!ans$e! lines• a&tomate( assem+l% mac'ines


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0- P!og!amma+le A&tomation

In p!og!amma+le a&tomation* t'e p!o(&ction e&ipment is

(esigne( it' t'e capa+ilit% to c'ange t'e se&ence o$

ope!ations to accommo(ate (i9e!ent p!o(&ct con#g&!ations.

T'e ope!ation se&ence is cont!olle( +% a p!og!am

#$amples:

•

N&me!icall% cont!olle( mac'ines 7NC8• In(&st!ial !o+ots


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T' t $ t ti l ti t ( ti


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T'!ee t%pes o$ a&tomation !elati)e to p!o(&ction&antit% an( p!o(&ct )a!iet%


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Three DistinguishedComponents of CIM

• .s a method of manufacturing,three components distinguish CIM from other manufacturing

methodologies0• Means for data storage,retrieval, manipulation andpresentation

• Mechanisms for sensing stateand modif"ing processes

• .lgorithms for uniting the dataprocessing component with the


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CIM ! Implementation

• CIM is an example of the implementation of infoand common technologies in manufacturing

• CIM implies that there are at least two computersexchanging info, eg the controller of an armroot and a micro!controller of a Computerumerical Control(CC) machine

• $ome factors involved when considering a CIM implementation are the production volume, theexperience of the compan" or personnel to ma#e

the integration, the level of the integration intothe product itself and the integration of theproduction processes

• CIM is most useful where a high level of ICT isused in the compan" or facilit", such as C.D1C.M

s"stems


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enet from CIM

Integration of technologies rings followingbenets0

8 Creation of a trul" interacti!e system thatenales manufacturing functions to

communicate easil" with other relevantfunctional units9 .ccurate data transferailit" amongmanufacturing plants or sucontractingfacilities at in!plant or diverse locations

: 'aster responses to data!changes formanufacturing -exiilit"

; Increased -exiilit" towards introduction ofnew products

< Improved accurac" and &ualit" in the

manufacturing process (continued"


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enet from CIM

= Improved &ualit" of the products7 Control of data!-ow among various units

and maintenance of user!lirar" fors"stem!wide data

> 3eduction of lead times which generatesa competitive advantage

? $treamlined manufacturing -ow fromorder to deliver"

8@ 6asier training and re!training facilities


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Integrated

Manufacturing• CIM is considered a natural evolution of the technolog" of

C.D1C.M which " itself evolved " the integration of C.Dand C.M

• Massachusetts Institute of Technolog" (MIT, A$.) iscredited with pioneering the development in oth C.D andC.M

• The need to meet the design and manufacturingre&uirements of aerospace industries after the $econd%orld %ar necessitated the development thesetechnologies

• The manufacturing technolog" availale during late ;@Bsand earl"


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Digital Manufacturing

The idea of *digital manufacturing*was prominent the 8?>@s, whencomputer!integrated

manufacturing was developedand promoted " machine toolmanufacturers and the Computerand .utomated $"stems

.ssociation and $ociet" ofManufacturing 6ngineers (C.$.1$M6)

*CIM is the integration of total

manufacturing enterprise "


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e" challenges ! three ma#orchallenges• Integration of components from diEerent

suppliers0 when diEerent machines, such asCC, conve"ors and roots, are using diEerentcommunications protocols

• Data integrit"0 The higher the degree of

automation, the more critical is the integrit" ofthe data used to control the machine• %hile the CIM s"stem saves on laor of operating

the machines, it re&uires extra human laor inensuring that there are proper safeguards for thecontrol data signals

• /rocess control0 Computers ma" e used toassist the human operators of manufacturingfacilit", ut there must alwa"s e a competentengineer to handle circumstances which couldnot e foreseen " software designers


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CIM 5 production controls"stem


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$us"stems in computer!integrated manufacturing

• CIM ma#es full use of the capailities of the digitalcomputer to improve manufacturing Two of themare0

i Fariale and /rogrammale automation

ii 3eal time optimi+ation

• . computer!integrated manufacturing s"stem is notthe same as a *lights!out* factor",

• which would run completel" independent of humanintervention, although it is a big step in thatdirection

•

/art of the s"stem involves -exile manufacturing,where the factor" can e &uic#l" modied to producediEerent products, or where the volume of productscan e changed &uic#l" with the aid of computers

• $ome or all of the following sus"stems ma" efound in a CIM operation G see next slide

C t I t t ( M $ t i A ti iti


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Comp&te! Integ!ate( Man&$act&!ing Acti)ities

CIM A i i i


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CIM Acti)itiesCAD 7Comp&te! Ai(e( Design8 T'e acti)it% comp!ises comp&te! s&ppo!t (esign* (!a$ting* an( enginee!ing

calc&lations

CAPP 7Comp&te! Ai(e( P!ocess Planning8 T'is acti)it% is conce!ne( it' t'e comp&te! ai(e( gene!ation o$ atec'nological plan to ma5e t'e p!o(&ct. T'e p!ocess plan (esc!i+es t'eman&$act&!ing p!ocesses an( se&ences to ma5e a pa!t.

CAM 7Comp&te! Ai(e( Man&$act&!ing8 T'is acti)it% (e#nes t'e $&nctions o$ a comp&te! to cont!ol t'e acti)ities ont'e man&$act&!ing :oo!* incl&(ing (i!ect cont!ol o$ p!o(&ction e&ipment

7Comp&te! Ai(e( ;&alit% Cont!ol8i)it% com+ines all ongoing &alit% cont!ol o!5 o$ a man&$act&!ing s%stem.

PP


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CIM Mo(el

CIM Mo(el


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CIM Mo(el


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• Computer!aided techni&ues0• C.D (computer!aided design)

• C.6 (computer!aided engineering)

•

C.M (computer!aided manufacturing)• C.// (computer!aided processplanning)

• C.H (computer!aided &ualit"

assurance)• //C (production planning andcontrol)

• 63/ (enterprise resource planning)

• . usiness s"stem integrated " a


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• Computer-aided design $C%D" also 5non ascomputer!aided design and drafting 7C.DD8 is the use of computer technolog"for the process of design and design!

documentation• C%D descries the process of drafting witha computer providing the user with input!tools for the purpose of streamliningdesign processes drafting, documentation

• C%D output is often in the form ofelectronic les for print or machiningoperations

• C%D!ased software is in direct correlation

with the processes


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• Computer!aided engineering (C.6) is theroad usage of computer software to aid inengineering tas#s

• It includes computer!aided design (C.D),

computer!aided anal"sis (C..), computer!integrated manufacturing (CIM), computer!aided manufacturing (C.M), materialre&uirements planning (M3/), andcomputer!aided planning (C./)

•Computer!aided process planning (C.//) isthe use of computer technolog" to aid inthe process planning of a part or product,in manufacturing

• C.// is the lin# etween C.D and C.M in

that it provides for the planning of the


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• Computer-aided manufacturing $C%M" is theuse of computer software to controlmachine tools and related machiner" in themanufacturing of wor# pieces

•

C.M ma" also refer to the use of acomputer to assist in all operations of amanufacturing plant, including planning,management, transportation and storage

• /rimar" purpose is to create a faster

production process and components andtooling selection with more precisedimensions and material consistenc", whichin some cases, uses onl" the re&uiredamount of raw material while

simultaneousl" reducing energ"


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CIM + d d


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CIM +ard(are andSoft(are• CIM software comprises computerprogrames to carr" out the followingfunctions0• Management Information $"stem• $ales 5 Mar#eting 5 'inance• Dataase Management• Modeling and Design• .nal"sis

• $imulation• Communications• Monitoring• /roduction Control•

Manufacturing .rea Control


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Ma2or 6lements of a CIM $"stem


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Farious .ctivities in CIM

u s"s ems n


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u s"s ems ncomputer!integrated

manufacturing• Devices and e&uipment re&uired0• CC, Computer numerical controlledmachine tools

• DC, Direct numerical control

machine tools• /4Cs, /rogrammale logic controllers• 3ootics• Computers• $oftware

• Controllers• etwor#s• Interfacing•

Monitoring e&uipment


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$us"stems in computer!integrated manufacturing• Technologies0

• 'M$, (-exile manufacturing s"stem)• .$3$, automated storage and retrieval s"stem• .JF, automated guided vehicle• 3ootics• .utomated conve"ance s"stems

• thers0• 4ean manufacturing


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Development of CIM

ManufProc2_7CIM

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