UNIT 1

COMPUTER INTEGRATED
MANUFACTURING - INTRODUCTION

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CIM

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 COMPUTER INTEGRATED
MANUFACTURING
• Computer Integrated Manufacturing (CIM) includes all of 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 order receipt, through
design and production, to product shipment.

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SCOPE OF
CIM

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CIM WHEEL

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CIM HARDWARE
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.
II. 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.,

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CIM SOFTWARE
SOFTWARE ELEMENTS OF CIM
Management Information System Job Tracking
Sales Inventory Control
Marketing Shop Floor Data Collection
Finance Order Entry
Database Management Materials Handling
Modeling and Design Device Drivers
Analysis Process Planning
Simulation Manufacturing Facilities Planning
Communications Work Flow Automation
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 ELEMENTS OF CIM
The major elements of a CIM system are in Figure MARKETING PRODUCT
DESIGN
they are, INFORMATION

1. Marketing
2. Product Design LOGISTICS

3. Planning PLANNING
4. Purchase
5. Manufacturing Engineering CIM
6. Factory Automation Hardware FINANCE
7. Warehousing
8. Logistics and Supply Chain Management PURCHASE

9. Finance WARE
10. Information Management HOUSING

AUTOMATED
WORK MANUFACTURE
CENTRES

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 ELEMENTS OF CIM
1. Marketing
The need for a product is identified by the marketing division. The specifications of the product, the
projection of manufacturing quantities and the strategy for marketing the product are also decided by the
marketing department. Marketing also works out the manufacturing costs to assess the economic viability
of the product.

2. Product Design
The design department of the company establishes the initial database for production of a proposed product.
In a CIM system this is accomplished through activities such as geometric modeling and computer aided
design while considering the product requirements and concepts generated by the creativity of the design
engineer.
Configuration management is an important activity in many designs. 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.

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 ELEMENTS OF CIM
3. Planning:
The planning department takes the database established by the design department and enriches it with production data
and information to produce a plan for the production of the product. Planning involves several subsystems dealing with
materials, facility, process, tools, manpower, capacity, scheduling, outsourcing, assembly, inspection, logistics etc. In a
CIM system, this planning process should be constrained by the production costs and by the production equipment and
process capability, in order to generate an optimized plan.

4. Purchase:
The purchase departments is responsible for placing the purchase orders and follow up, ensure quality in the production
process of the vendor, receive the items, arrange for inspection and supply the items to the stores or arrange timely
delivery depending on the production schedule for eventual supply to manufacture and assembly.

5. Manufacturing Engineering:
Manufacturing Engineering is the activity of carrying out the production of the product, involving further enrichment of
the database with performance data and information about the production equipment and processes. In CIM, this
requires activities like CNC programming, simulation and computer aided scheduling of the production activity. This
should include online dynamic scheduling and control based on the real time performance of the equipment and
processes to assure continuous production activity. Often, the need to meet fluctuating market demand requires the
manufacturing system flexible and agile.

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 ELEMENTS OF CIM
6. Factory Automation Hardware:
Factory automation equipment further enriches the database with equipment and process data, resident either in the
operator or the equipment 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, computer controlled assembly systems, flexibly automated inspection systems and so on.

7. 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.

8. Logistics and Supply Chain Management

Involved in shipping or transporting the finished goods to the customers and keep live tracking of the shipped goods.

9. Finance:
Finance deals with the resources pertaining to money. Planning of investment, working capital, and cash flow control,
realization of receipts, accounting and allocation of funds are the major tasks of the finance departments.

10. Information Management:

Information Management is perhaps one of the crucial tasks in CIM. This involves master production scheduling,
database management, communication, manufacturing systems integration and management information systems.
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COMPUTERISED
ELEMENTS OF
CIM

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CONCEPT OF CIM
The CIM concept is that all of the firm's operations related to production are
incorporated in an integrated computer system to assist, augment and
automate the operations.
In CIM the output of one activity serves as the input to the next activity.
Customer orders are initially entered by the company's sales force or directly
by the customer into a computerized order entry system.
The orders contain the specifications describing the product.
The specifications serve as the input to the product design department.
New products are designed on a CAD system.
The components that comprise the product are designed, the bill of materials
is compiled, and assembly drawings are prepared.

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CONCEPT OF CIM
The 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. Process planning is
performed using CAPP.
 Many of these manufacturing engineering activities are supported by the
CIM system.
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.
Full implementation of CIM results in the automation of the information
flow through every aspect of the company's organization.

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BENEFITS OF CIM
CIM helps to achieve the following world class standards such as
• Decrease in manufacturing cost
• Increase in product quality
• Increase in productivity
• Increase in customer responsiveness
• Decrease in inventory cost
• Increased flexibility
• Increased production control

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BASIC ELEMENTS OF AN AUTOMATED SYSTEM

An automated system consists of three basic elements:

• power to accomplish the process and operate the system.
• a program of instructions to direct the process
• a control system to actuate the instructions.
The relationship amongst these elements is illustrated
in the following Figure. All systems that qualify as being
automated include these three basic elements in one form or
another.

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BASIC ELEMENTS OF AN AUTOMATED SYSTEM

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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
The principal source of power in automated systems is electricity.
Electric power has many advantages in automated as well as non
automated processes.
1. Electrical power is widely available at moderate cost. It is an
important part of our industrial infrastructure.
2. Electrical power can be readily converted into 10 alternative
energy forms such as mechanical, thermal, light, acoustic,
hydraulic, pneumatic, etc,.
3. Electrical power at low levels can be used to accomplish functions
such as signal transmission, information processing, and data
storage and communication.
4. Electrical energy can be stored in long life batteries for use in
locations where an external source of electrical power is not
conveniently available.(remote areas). 19
BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Alternative power sources include fossil fuels, solar energy,
water, and wind. However, their exclusive use is rare in automated
systems. In many cases when alternative power sources are used to
drive the process, electrical power is used for the controls that
automate the operation.

Example:

For example, in casting or heat treatment, the furnace may be

heated by fossil fuels, but the control system to regulate temperature
and time cycle is electrical.
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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Program of Instructions :
The actions performed in an automated process are defined by a
program of instructions that, whether the manufacturing operation
involves low, medium, or high production.

These processing steps are performed during a work cycle.

A new part is completed during each work cycle (in some

manufacturing operations, more than one part is produced during
the work cycle, e.g., a plastic injection molding operation may
produce multiple parts each cycle using a multiple cavity mold).21
BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Program of Instructions :
The particular processing steps for the work cycle are specified in
a work cycle program.

Work cycle programs are called part programs in numerical control.

Other process control applications use different names for this type
of program.

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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Work Cycle Programs:
In the simplest automated processes, the work cycle consists of
essentially one step, which is to maintain a single process parameter
at a defined level.

For example, maintain the temperature of a furnace at a designated

value for the duration of a heat treatment cycle.

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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Work Cycle Programs:
In this case, programming simply involves monitoring the
temperature dial on the furnace, to change the program, the
operator simply changes the temperature setting.

An extension of this simple case is when the single step process is
defined by more than one process parameter, for example, in case of
a VMC.

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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Work Cycle Programs: (three steps being repeated)
A typical work cycle program involves the following sequence of steps:
1. Load the part into the production machine
2. Perform the process
3. Unload the part
During each step, there are one or more activities that
involve changes in one or more process parameters.
Examples:
Temperature setting of a furnace
Axis position in a positioning system
Motor on or off
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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Work Cycle Programs
An Automated Turning Operation is a good example of work cycle
program which has the following sequence of steps:
1. Load the workpiece in the chuck
2. Position the cutting tool prior to turning
3. Turn (machining operation)
4. Reposition the tool to a safe location at the end of the turning
5. Unload the finished workpiece
6. Identify the activities and process parameters in each set of
operations

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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Decision making in a programmed cycle
The two features of the work cycle are

1. the number and sequence of processing steps

2. the process parameter changes in each step.

Each work cycle consists of the same steps and associated process
parameter changes with no variation from one cycle to the next. The
program of ‘instructions is repeated in each work cycle without
deviation.
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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Decision making in a programmed cycle
In fact, many automated manufacturing operations require decisions to
be made during the programmed work cycle to cope with variations in the
cycle.

In many cases, the variations are routine elements of the cycle, and the
corresponding instructions for dealing with them are incorporated into
the regular part program. These include the following cases:
1. Operator interaction. (manual entry in a existing NC code)
2. Different parts or products styles processed by the system (car
assembly using robot arms) 28
BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Control system: (CLOSED LOOP)
The controls in an automated system can be either closed loop
or open loop.

A closed loop control system, also known as a feedback control

system is one in which the output variable is compared with an
input parameter (set point or desired value), and any difference
between the two is used to drive the output into agreement with
the input.
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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Control system: (CLOSED LOOP)

A closed loop control system consists of six basic elements:

(1) input parameter, (2) process, (3) output variable, (4) feedback
sensor. (5) controller and (6) actuator.

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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Control system: (CLOSED LOOP)

The process of interest is usually a manufacturing operation, and the

output variable is some process variable, perhaps a critical performance
measure in the process, such as temperature or force or flow rate.

A sensor is used to measure the output variable and close the loop
between input and output.

Sensors perform the feedback function in a closed loop control system.

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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Control system: (CLOSED LOOP)

The controller compares the output with the input and makes the
required adjustment in the process to reduce the difference between
them.

The adjustment is accomplished using one or more actuators, which

are the hardware devices that physically carry out the control
actions, such as an electric motor or a flow valve.

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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Control system: (OPEN LOOP)
In contrast to the closed loop control system, an open loop control
system operates without the feedback loop.
In this case, the controls operate without measuring the output
[Link] no comparison is made between the actual value of the
output and the desired input parameter.
The controller relies on an accurate model of the effect of its
actuator.

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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Control system: (OPEN LOOP)

With an open loop system, there is always the risk that the actuator
will not have the intended effect on the process, and that is the dis
advantage of an open loop system.

It’s advantage is that it is generally simpler and less expensive than

a closed loop system.

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BASIC ELEMENTS OF AN AUTOMATED SYSTEM
Control system: (OPEN LOOP)

Appropriate conditions:

1. The actions performed by the control system are simple

2. the actuating function is very reliable

3. any reaction forces opposing the actuation are small enough to

have no effect on the actuation

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OPEN LOOP VS CLOSED LOOP
Positioning system using feedback control

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LEVELS OF AUTOMATION

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LEAN PRODUCTION

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 LEAN PRODUCTION

Lean Production also known as Lean Manufacturing, are a set of tools and methodologies
that aims for the continuous elimination of all wastes in the production process.
Lean production is also called as the Toyota Production System (TPS), because the
concept was originated at Toyota Motors in Japan after WW2.
Lean Production is defined as an adaption of mass production in which workers and work
cells are made more flexible and efficient by adapting methods that reduce waste in all
forms.

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 LEAN PRODUCTION

Key Principles of Lean Manufacturing:

1. Recognition of need:
 The first step is to recognize what/which does not create value from the customer’s
perspective.
 Any material, process or feature which is not required for creating value from the
customers perspective is waste and it should be eliminated.
2. Standard process:
 Lean requires the implementation of every detailed production guidelines, called
standard work procedure which clearly states the content, sequence, timing and
outcome of all actions by workers.
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 LEAN PRODUCTION

Key Principles of Lean Manufacturing:

3. Continuous flow:
 Lean usually aims for the implementation of a continuous production flow free of
bottlenecks, interruption, defects, backflow.
 Buy this the production cycle time can be reduced by as much as 90%.
4. Pull production:
 Also called JIT (JUST – IN – TIME) production, aims to produce only what is needed
and when it is need.
 Production is pulled by the downstream workstation so that each workstation should
only produce what is requested by the next workstation.
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 LEAN PRODUCTION

Key Principles of Lean Manufacturing:

5. Quality of the source:
 Lean aims for defects to be eliminated at the source and for quality inspection to be
done by the workers as part of the in-line production process.
6. Continuous improvement:
 Lean requires driving for perfection by continually removing layers of waste as they are
uncovered.
 This in turn requires a high level of worker improvement in the continuous
improvement process.
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JUST IN TIME (JIT)

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 JUST IN TIME (JIT)

Just In Time is a manufacturing philosophy that strives to eliminate sources of manufacturing waste by
producing the right part, in the right place at the right time.
JIT is also referred as stockless production.
It improves profits and return on investment by :
Reducing inventory levels
Reducing variability
Improving product quality
Reducing production and delivery lead times
Reducing other costs such as machine setup cost and equipment breakdown cost
The basic elements of JIT were developed by Toyoto in the 1950’s and hence JIT is also known as Toyota
Production System (TPS)

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 JUST IN TIME (JIT)

The ideal JIT production system produces and delivers only the required items, at the required time and in the

required quantities.

Each item is delivered “just-in-time”.

This delivery discipline minimizes work-in-process and manufacturing lead time.

In single line, JIT means producing what is needed, when it s needed and no more.

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JUST IN TIME (JIT)-OBJECTIVES

The following are the main objectives of a JIT system

Zero defects
Zero setup time
Zero inventories
Zero handling
Zero breakdowns
Zero lead time
Lot size of one

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JUST IN TIME (JIT)-ELEMENTS
Reduce or eliminate setup times:
In JIT, one has to aim for single digit setup times or one touch setup. This can be done by
better planning, process design and product design.
Reduce manufacturing and purchasing lot sizes:
Reducing setup times allows economical production of smaller lots. Close cooperation
with suppliers is necessary to achieve reduction in lot sizes for purchased items.
Reduce production and delivery lead times:
Production lead times can be reduced by moving the workstations closer together,
applying group technology concepts, reducing queue length and improving coordination and
communication between the processes. Delivery lead times can be reduced through close
communication with the suppliers.

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JUST IN TIME (JIT)-ELEMENTS
Preventive maintenance:
Machine and worker idle time can be used to maintain equipment and prevent
breakdowns.
Stabilize and level the production schedule with uniform plant loading:
For JIT, one has to create a uniform load on all work centers through constant daily
production and mixed model assembly.
Flexible workforce:
Workers should be trained to operate several machines, to perform maintenance
tasks, and to perform quality inspections. In general, JIT requires teams of competent,
empowered employees who have more responsibility for their own work.
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JUST IN TIME (JIT)-ELEMENTS
Require supplier quality assurance and implement a zero defect quality program:
Error leading to defective items must be eliminated, since there are no buffers of
excess parts. A quality at source program must be implemented to give workers the
personal responsibility for the quality of their work.
Small unit conveyance:
A control system such as Kanban system is used to convey parts between
workstations in small quantities.

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KANBAN SYSTEMS
 Kanban means “sign” or “instruction card” in Japanese.
 A kanban is a card system that is attached to a storage and transport container.
 It identifies the part number and container capacity along with other information.
Types of Kanban system:
 Production Kanban system:
It is often referred as P-Kanban
It delivers the signal to produce more number of parts.
 Transportation or Conveyance Kanban system (T-Kanban)
It signals the need to deliver more parts to the next work center. T-Kanban is also
called as Transportation Kanban.
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KANBAN SYSTEMS-TWO CARD KANBAN SYSTEM
The machine center makes two parts, A and B.
These two parts are stored in containers that are located next to assembly line and next
to the machine center.
Each container next to the machine center has a production kanban and each container
next to the assembly line has a withdrawal kanban.
This is commonly called as a two card kanban system.

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KANBAN SYSTEMS-TWO CARD KANBAN SYSTEM
When the assembly line takes the first part A from a full container, a worker takes the
transportation kanban from the container and takes the card to the machine center storage
area.
In the machine centre area, the worker finds a container of part A removes the production
Knaban and replaces it with the transportation kanban. Placement of this card on the
container authorizes the movement of the container in the assembly line.

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 KANBAN SYSTEMS-TWO CARD KANBAN SYSTEM
In the machine centre area, the worker finds a container of part A, removes the production
Kanban and replaces it with the transportation kanban. Placement of this card on the
container authorizes the movement of the container in the assembly line.
The freed Production kanban is placed on a rack by the machine center, which authorizes
the production of another lot of material.
Thus the cards on the rack become the dispatch list to the machine center.
PRODUCTION KANBAN TRANSPORTAION KANBAN

A
MACHINING CENTER ASSEMBLY LINE
B 53
TYPES OF PRODUCTION PROCESS

The following are the four major types of production processes:

Unit or Job type of production

Batch type of Production

Mass Production or Flow production

Continuous production or Process production

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TYPES OF PRODUCTION PROCESS
Unit or Job type of production
This type of production is most commonly observed when you produce one
single unit of a product.
A typical example of the same will be tailored outfits which are made just for
you or a cake which is made just like you want it.

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TYPES OF PRODUCTION PROCESS
Unit or Job type of production
Example of Unit type of production
It is one of the most common types used because it is generally used by small businesses like
restaurants, individual products providers or individual services providers.
It is also a type of production used by very premium companies like Harley Davidson, or Dell. Harley Davidson actually
has a lot of accessories which can be customized, and which suit the individual. Same ways, you can design your own
DELL laptop on their website with the given specifications.

Features of Unit production or Job Production

Depends a lot on skill
Dependency is more on manual work than mechanical work
Customer service and customer management plays and important role

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TYPES OF PRODUCTION PROCESS
Batch type production:
It is one of the types of production most commonly used in consumer durables, FMCG or other such industries where
there are large variety of products with variable demands. Batch production takes place in batches. The manufacturer
already knows the number of units he needs to a manufacturer and they are manufactured in one batch.

So, if a manufacturer has the shortage of Product X and 100 units of this product is consumed in one month, then the
manufacturer can give orders for batch production of 100 units of Product X.

Features of Batch production

Production is done in batches
The total number of units required is decided before the batch production starts
Once a batch production starts, stopping it midway may cost a huge amount to the company.
Demand plays a major role in a batch production. Example – seasonality of products.

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TYPES OF PRODUCTION PROCESS
Batch type production:
LG has many different types of home appliance products in its portfolio. It has to manufacture all these different variants
of the same type of product. There would be 10-20 types of mixer grinders alone in the product portfolio of LG home
appliances. Thus, a company like LG manufactures these variants via Batch production.

First, one type of mixer will be manufactured completely and then the second type will be manufactured. They are
manufactured on the basis of demand. Depending on demand, the batch production can produce the number of units
required in one batch.

The batches may be as small as 10 units or they may be as large as 1 lakh units of the same products. However, as long
as there is a defined quantity of product which has to be manufactured before moving on to the next item in the list, it is
known as batch production. Examples of batch production include FMCG like Biscuits, confectionaries, packaged food
items etc. It is used in Medicines, Hardware, Consumer durables and many such industries.

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TYPES OF PRODUCTION PROCESS
Batch type production:
LG has many different types of home appliance products in its portfolio. It has to manufacture all these different variants
of the same type of product. There would be 10-20 types of mixer grinders alone in the product portfolio of LG home
appliances. Thus, a company like LG manufactures these variants via Batch production.

First, one type of mixer will be manufactured completely and then the second type will be manufactured. They are
manufactured on the basis of demand. Depending on demand, the batch production can produce the number of units
required in one batch.

The batches may be as small as 10 units or they may be as large as 1 lakh units of the same products. However, as long
as there is a defined quantity of product which has to be manufactured before moving on to the next item in the list, it is
known as batch production. Examples of batch production include FMCG like Biscuits, confectionaries, packaged food
items etc. It is used in Medicines, Hardware, Consumer durables and many such industries.

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TYPES OF PRODUCTION PROCESS
Mass production or Flow Production:
One of the best examples of mass production is the manufacturing process adopted by Ford. Mass production is also
known as flow production or assembly line production. It is one of the most common types of products used in
the automobile industry and is also used in industries where continuous production is required.

An Assembly line or mass production plant typically focus on specialization. There are multiple workstations installed
and the assembly line goes through all the workstations turn by turn. The work is done in a specialized manner and each
workstation is responsible for one single type of work. As a result, these workstations are very efficient and production
due to which the whole assembly line becomes productive and efficient.
Products which are manufactured using mass production are very standardized products. High sophistication is used in
the manufacturing of these products. If 1000 products are manufactured using mass production, each one of them should
be exactly the same. There should be no deviation in the product manufactured.

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TYPES OF PRODUCTION PROCESS
Mass production or Flow Production:
Features of Mass Production
Mass production is generally used to dole out huge volumes of the product
It is used only if the product is standardized
Demand does not play a major role in a Mass production. However, production capacity determines the success of a
mass production.
Mass production requires huge initial investment and the working capital demand is huge too.

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TYPES OF PRODUCTION PROCESS
Continuous production or Process Production:
There is a lot of confusion between mass production and continuous production. It can be differentiated by a single
element. The amount of mechanical work involved.
In Mass production, both machines and humans work in simultaneously. However, in continuous production, most of the
work is done by machines rather than humans. In continuous production, the production is continuous,24×7 hours, all days
in a year.
Example:
A good example of the Continuous production is brewing. In brewing, the production goes on 24 hours a day and 365 days
a year. This is because brewing takes a lot of time and production is important. As a result, there is a continuous input of
raw materials such as malt or water, and there is continuous output in the form of beer or other alcoholic drink. The key
factor in this is that the brewing and fermentation process itself is time-consuming, and the maximum time is spent in the
fermentation which is a continuous process.

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