Computer-Integrated Manufacturing Overview
Computer-Integrated Manufacturing Overview
Man,1fa~·t_uJj_ng
marketplace . The enterprise must chnng·P . Chnn gf' to improvl' I lwir p 11rform1111c11 011 llw 1-1 ,s.
worldwide standards
Six Worldwide Standards
o Design & l\[Link] lea d. t ime by product
o Inventory turns by product
o Setup times on production equipment.
o Output/productivity by product per e mployee
o Total quality and level of rework
o Number of suggestions by product for improvenwnt.s pN dn y p<w Pmpl<>yc,u
Customer demand is always for :
o A quality product
o Wide product selection
o Frequent product improvements
o New models on a regular basis.
Satisfying the six enterprise standards is necessnry to mee t. the~l' cfomn nd~ of' cu:-.t.011H11·:-- .
Definition of CIM by the Computer and [Link] Sy~[Link]::- /\::-~oci11t io11 uf [Link] Suci l1 t.y 111'
manufacturing Engineers (CASA/Sl\tfE) :
"CIM is the integration of the total man11fact11ring e11.t_erprisc through Ill.I' 11s,· o/ i 11 tl'g rnt.<'<I
systems and data cornm11n1:cafrons coupled with nrw 111<111agcrial µl,i/nsophics tho! i:,,,,,,. 0 ., 1,
common datab ase for all procluct information wil h l'V <'l'Y dq1ilrl.11H 11l pnrl [Link] g,
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Integrate all production and support processes usmg computer n e tworks , cross -functional
business software, and other information technologies
Elements of CIM
o Information technology: Computer, Communication, Control
o 'Manufacturing technology: Manufacturing, :rvlarket, Management
o 3Cs support 3Ms
o 3Cs support 3Ms
Elements of 3Cs
o Computer: IT, OS, programming language, database , artifici a l intellige nce
o Communication: communication technology, MAP, TOP, LAN, VAN
o Control: control technology, algorithm , S/W for control
Targ·ets of CIM
o Developing high quality products with low cost
o Integration and control of product design and manufacturing processes
o Easy financial management
o Increasing volume of sales
Function of CIM
1) Order information and automatic scheduling through computer
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Resource Execution Systems
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Shop Floor
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~ PrOduetion Robotics Cont~
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Computer-Integrated Manufacturing ]
CIM Systems
o Comp uter-aided manufacturing (CAM) - automate the production process
0
Machin e Control - controls the actions of machines
The opera tion of a CL\! ~ys te m gi \·es the use r s ubsta nti a l bene fit s :
0 Opportunities for Robotic applications are present but limited by the high variation in
parts and products.
Repetitive:
0 Orde rs for repeat business is 100%
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CIMS Benefits:
1
CIM refers to a production system that consists of:
Why CIMS?
In Production Systems
Production ,,
Volumn
(part/yr)
Transfer
Lines
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CIM System
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Stand Alone
15 - NC Machine
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Part Variety (# of different parts)
In Manufacturing Systems:
Production
Volumn Special
(part/yr) System
15,000
Flexible
Manufacturing
System
Manfuacturing
15 Cell
2 100 800
Part Variety (# of different parts)
I. Spec ial Mfg. System: the least fl ex ible CIM system. It is designed to produce a
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very limited number of different parts (2 - 8).
2: M fg. Cell : the most flexible but generally has the lowest number of different parts
manufactured in the cell would be between 40 - 80. Annual production rates rough
from 200 - 500.
3. Flexible Mfg. System : A typical FMS will be used to process several part families
with 4 to 100 different part numbers being the usual case.
General FMS
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2 . Line or flow layout - the arrangement of machines in the part processing order or
sequence required. A transfer line is an example of a line layout. Parts progressively
move from one machine to another in a line or flow layout by means of a roller
conveyor or through manual material handling. Typically, one or very few different
parts are produced on a line or flow type of layout, as all parts processed require the
same processing sequence of operations. All machining is performed in one
department, thereby minimizing interdepartmental material handling.
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3. Cell - It combines the efficiencies of both layouts into a single multi-functional unit.
It referred to as a group technology cell, each individual cell or department is
comprised of different machines that may not be identical or even similar. Each cell
is essentially a factory within a factory, and parts are grouped or arranged into
families requiring the same type of processes, regardless of processing order.
Cellular layouts are highly advantageous over both function and line machine
layouts because they can eliminate complex material flow patterns and consolidate
material movement from machine to machine within the cell.
Milling
machine I I
Grinder
Drilling
machine
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station to another.
A. The primary work handling system - used to move parts between machine tools
in the C fMS . It should meet the following requirements.
B. The secondary work handling system - used to present parts to the individual
machine tools in the CIMS.
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Ill. Computer Control Syslcm - Co111rol functi ons ofa flrn1 and lhc supporting
comp11li11g cq11ip111c11I
Mfg , t-=..ource5
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Mfg p/annm9 olgonlhm,
Factory r esources
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IV. Functions of the computer in a manufacturing organization
Market (CustoJOer)
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l. Sales (Marketing I Management 12. Shipping
Product development Personnel dept . Shipping documents
Planning Achainistraition Customer b i ll i ng
Statistics Control of the
• . shiooed o r d e r
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2. Sub■ is sion ot
[Link] 11 . Cost Account 1ng
Product pricing Account i ng for
Coopecat.1on with p r oduction
cost accounting - by unit factory
ClMUTER SYSTEM cost
l - proportioning and
allocation of
ove r head
J . Production plan- - by cost centers
ning and control Mfg . information - total product
Long- and short · ., system cost
range planning Data base Close cooperation
Del ivery date P'inanc ial with quotation ac-
Order scheduling Personnel tivities
Purchasing Recognition of dif -
i Catalogue
Material
ficulties when cost
deviates from cost
4. Order processing Manufacturing standards
(Servicing) Sales/Marketing Payroll calculation
Organizational "' Inventory in conjunction
processing of with personnel
o rder
. '
5. Design 10. Assembly
Coepu te r- aided Computer-aided MTM
design (also data studies
for machine se- i.
Time calculation
quencing and part Assembly sequence-
progra111s ) ing
Classification of Release fo r pur-
vorkpieces and
subassemblies . chased parts
Creation of bill
of [Link]
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Manufacturing
Adaptive cont ro 1
. NC control
Reporting of com-
pleted work orders
Payroll calcula-
. . rinn
.
6 . Manutacturing pro- 7. Manufacturing B. Material requirement
cess planning control planning
Raw m~terial speci- Detailed sche- Inventory planning
fication duling of shop control
P~ocess sequencing orders Order point and lead
C lculation of pro- Material sche- time- contro.l
cessing times du ling Economical order
Ma~erial require- Machine allo - quantities
aent [Link]
Cla ssification of
part families by
. cation Cmathe-
matical model- ~
i ng)
Vendor per!ormance
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2. Direct Numerical Control (DNC) - A manufacturing system in which a number of
m/c are controlled by a computer through direct connection & in real time.
• Central computer
• Bulk memory (NC program storage)
• Telecommunication line
• Machine tools (up to I 00)
Satellit
Bulk
Minicomputer I memory
3. Production Control - This function includes decision on various parts onto the
system.
Decision arc based on:
• red production rate/day for the various parts
• Number of raw work parts available
• Number ofavl!ilable pallets
4. Traffic & Shuttle Control - Refers to the regulations of the primary & secondary
transportation systems which moves parts between workstation.
5. Work Handling System Monitoring - The computer must monitor the status of
each cart & /or pallet in the primary & secondary handling system.
6. Tool Control
• Keeping track of the tool at each station
• Monitoring of tool life
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Production Strategy
The production strategy used by manufacturers is based on several factors; the two
most critical are customer lead time and manufacturing lead time.
Customer lead time identifies the maximum length oftime that a typical customer is
willing to wait for the delivery ofa product afier an order is placed
Manufacturing lead time identifies the maximum length oftime between the receipt of
an order and the delivery ofa finished product.
Manufacturing lead time and customer lead time must be matched. For example,
when a new car with specific options is ordered from a dealer, the customer is willing
to wait only a few weeks for delivery of the vehicle. As a result, automotive
manufacturers must adopt a production strategy that permits the manufacturing
lead-time to match the customer's needs. ··
The production strategies used to match the customer and manufacturer lead times are
grouped into four categories:
I . Engineer to order (ETO)
2. Make to order (MTO)
3. Assemble to order (ATO)
4. Make to stock (MTS)
Engineer to Order
A manufacturer producing in this category has a product that is either in the first stage
of the life-cycle curve or a complex product with a unique design produced in
single-digit quantities. Examples of ETO include construction industry products
(bridges, chemical plants, automotive production lines) and large products with
special options that are stationary during production (commercial passenger aircraft,
ships, high-voltage switchgear, steam turbines). Due to the nature of the product, the
customer is willing to accept a long manufacturing lead time because the engineering
design is part of the process.
Make to Order
The MTO technique assumes that all the engineering and design are complete and the
production process is proven . Manufacturers use this strategy when the demand is
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unpredictable and when the customer lc:-id-time permits the production process to s1ar1
on receipt of an order. New residential homes me t:xamples of this product ion strategy.
Some outline computer companies make personal computer to customer specitications.
so they followed MTO specifications.
Assemble to Order
The primary reason that manufacturers adopt the ATO strategy is tlrnt customer lead
time is less than manufacturing lcud time . An example from the automotive industry
was used in the preceding section to dcscrihe this situation for line manufacturing
systems. This strategy is used when the option mix for the rroduct s c:-in be forcc asl
statistically: for c.xa111pk. the percentage of four-door versus two-door aulomobilcs
asscmblcd per week . In addition . the subusscmhlies and par1 s for the li11lll producl arc
carried in a finished co111ponenls inventory. so the final llSSL·mbly schedule is
determined by the customer order. John Deere and General Motors arc exampl es o f
companies using this production strategy.
Make to Stock
MTS. is used for two rcusons: (I) the customer lead time is less than the
manufacturing lead time, (2) the product hus a sci configuration and few options so
that the demand can be fort:cast accurately. If positive i1ivcntory levels (the store shelf
is never empty) for a product is an order-winning criterion, this strategy is used. When
this order-winning criterion is severe, the products arc often stocked in distribution
warehouses located in major population centers. This option is often the last phase of
a product's life cycle and usually occurs at maximum production volume.
Soles Producl
and Production
design engineertng
promotion
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release
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Distribution 1 - - - - l Receiving a.
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Plant floor (J)
Shipping
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Interlace to all
functions Support
organizations
Sales and Promotion
• The fundamental mission of sales and promotion (SP) is to create customers.
To achieve this goal, nine internal functions are found in many companies: sales,
customer service, advertising, product research and development, pricing,
packaging, public relations, product distribution, and forecasting.
sales and promotion interfaces with several other areas in the business:
• The customer services interface supports three major customer functions :
order entry, order changes. and order shipping and billing. The order change
interface usually involves changes in product specifications, change in
product quantity (ordered or available for shipment), and shipment dates and
requirements.
• Sales and marketing provide strategic and production planning information to
the finance and management group, product specification and customer
feedback information to product design, and information for master
production scheduling to the manufacturing planning and control group.
Product/Process Definition Engineering
• The unit includes product design, production engineering. and engineering
release.
• The product design provides three primary functions : (I) product design and
conceptualization, (2) material selection, and (3) design documentation .
• The production engineering area establishes three sets of standards: work,
process, and quality.
• The engineering release area manages engineering change on every
production part in the enterprise. Engineering release has the responsibility of
securing approvals from departments across the enterprise for changes made
in the product or production process.
Manufacturing Planning and Control (MPC)
• The manufacturing planning and control unit has a formal data and
information interface with several other units and departments in the
enterprise.
• The MPC unit has responsibility for:
I. Setting the direction for the enterprise by translating the management
plan into manufacturing terms. The translation is smooth if
order-winning criteria were used to develop the management plan.
2. Providing detailed planning for material flow and capacity to support
the overall plan .
3. Executing these plans through detailed shop scheduling and purchasing
action .
MPC Model for Information Flow
r r
Demand Production
planning planning
!
Master
' production
schedule (MPS)
i
Detailed Material
capacity requirements
planning planning (MAP)
!
' Material and
capacity plans
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Produclion
!
Financial
activity
control
control
systems
systems
Shop Floor
• Shop floor activity often includes job planning and reporting, material
movement, manufacturing process, plant floor control. and quality control.
• Interfaces with the shop floor unit are illustrated.
Manufacturing
planning
and control
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Gi Distribution Receiving a.
a.
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B Plant floor en
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:,
(.) Shipping
Quality
Interface to all
functions
S11pp11rl ()rg1111iz11lio11
• Thu supporl orgu11izalio11s , indicnlcd vary signifi ca ntly from firm to firm .
• The t'1111c1ion.i 111ost oflen included arc security, pcrso nn<.:I , maintenance,
h11111 t111 resource development . and computer services .
• ll11sic11lly. lhc s11ppur1 organizulion is re sponsible for all of the func1ions not
provided by the o ther llloJel elements.
Prod11ctio11 Sequence :011c poss ibility for the flow requi red to bring a product to a
CIIStOIIHlr
I. Un•lon 2. Engineering 3. Production dellnitlon 4. Eng,noering
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CAO Engineering
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An FMS is characterized by its ability to handle multiple part families and variations in product configurations, primarily using automation for random movements and palletized parts . Unlike traditional systems which rely on fixed paths and structure, FMS offers flexibility in scheduling, reduced lead times, and lower work-in-process inventory by facilitating independent and random part movement, thus allowing greater product variety .
Advanced communication technologies such as MAP (Manufacturing Automation Protocol) and TOP (Technical Office Protocol) facilitate real-time data exchange and integration across different manufacturing units. This enables synchronization of production schedules and operations, improving operational responsiveness and reducing bottlenecks . Communication technologies also support centralized control over distributed processes, ensuring consistent quality and efficient resource utilization .
In an MPC system, production planning and control are interconnected to manage the flow of materials and information efficiently. MPC translates management plans into manufacturing terms, ensuring resources are allocated efficiently to meet production goals . It involves demand forecasting, master production scheduling (MPS), detailed planning (Material Requirements Planning, Capacity Requirements Planning), and executes these plans through job planning and control on the shop floor . This integrated approach ensures that production activities are aligned with business objectives, enhancing overall operational agility and efficiency .
In CIM systems, material handling is crucial as it provides the necessary connectivity between various machine tools, ensuring smooth and efficient operations. It involves compatible computer controls that allow random, independent movement of palletized work parts, which helps in reducing wait times and increasing machine utilization . Efficient material handling minimizes interdepartmental transportation, consolidates steps within cells, and ultimately aids in executing just-in-time (JIT) strategies, thus enhancing overall system efficiency .
Machine cell layout, such as cellular manufacturing, groups machines of different types into cells to handle specific part families, combining both line and functional layout advantages . This enables efficient production by minimizing material handling and reducing setup times, allowing for quick changes between product types. The flexible nature of machine cells supports customized production and rapid response to market demands, leading to enhanced manufacturing efficiency and scalability . By adopting cellular layouts, companies can streamline processes and achieve more consistent production workflows, thereby enhancing overall productivity .
Integrating robots into CIM systems enhances efficiency by automating repetitive tasks, reducing human error, and enabling precision in production processes . This leads to increased machine utilization and faster cycle times. However, challenges include the high initial cost of integration, the need for complex programming and control systems, and potential disruptions during transitions . Despite these challenges, the long-term benefits of increased production flexibility and reduced labor costs can outweigh the initial difficulties .
CIM facilitates automated inspection through technologies like Computer Numerical Control (CNC) and Direct Numerical Control (DNC) which automate and monitor the precision of manufacturing processes . Additionally, computer process control and industrial robots are used for maintaining consistent quality standards . Automated inspection methods integrate these components to ensure that product specifications are met, reducing human error and increasing reliability in inspection processes .
CIM integrates JIT principles by implementing real-time inventory tracking systems such as barcodes and RFID, which minimize raw material and work-in-progress (WIP) inventories . Automated ordering and scheduling systems ensure that materials are delivered exactly when needed, reducing storage costs and preventing overproduction. This approach allows for streamlined resource allocation and improved response times, directly supporting lean manufacturing goals .
CIM systems improve competitiveness by enhancing customer service, reducing time to market for new products, and improving scheduling performance. These capabilities lead to shorter lead times, increased manufacturing productivity, and decreased inventory levels, all of which help companies respond quickly to market demands and changes, thus gaining a competitive edge .
CIM involves integrating various technologies like IT, manufacturing technology, control technology, etc., to achieve improved product quality and lower costs. The 3Cs (Computer, Communication, Control) support the 3Ms (Manufacturing, Market, Management) by enabling more efficient order processing, inventory control, and production scheduling . Moreover, elements like statistical quality control and monitoring systems help maintain high-quality standards, leading to better customer satisfaction and competitive advantages .