Topic 1 Chapter 1

Integrated Manufacturing Systems Topic 1.IMSs - 1.
Introduction 1
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CHAPTER 1. INTEGRATED MANUFACTURING SYSTEMS:
AN INTRODUCTION
Evolution and Nowadays Challenges
Production Systems: Support and facilities
Computer Integrated Manufacturing – Integrated Manufacturing Systems
Manual Labor
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Sistemas Integrados de Fabricación. UJAEN Máster en Ingeniería Industrial.
Integrated Manufacturing Systems Topic 1.IMSs - 1. Introduction 2
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Historical Evolution: Several Ideas

• Manufacturing Manus (hand) + Factus (make) à Until XVIII century goods made by hand
• Rapid development of manufacturing during the last 2 centuries.
Manufacturing evolution. Fuente: http://www.mr-automation.at/en-eu/competence/Industry_4_0.php
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• Main developments:
Source: http://www.bbc.co.uk
First Industrial Revolution: Human energyàSteam Energy + Mechanical control
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Second Industrial RevolutionàMass production: Interchangeability and division of labour +

Electrical energy
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Third Industrial Revolution à Looking for

Flexible Manufacturing: Electronic Control
Systems
üControl systems: mechanicalàvacuum
tube and transistorsàlimited machine
controllers
ü1947 Numerical Controller (NC) first time
that hardware and software were
combined successfully in one control unit
à machining of complex parts
üProcess, business and Programmable
controllers à elements of programmable
automationàcontrol a manufacturing
process.
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A further step à “Smart Factory” (Fourth Industrial Revolution) and DFM.

Information (sensorization, communication) + Production system integration (concurrent
development (integration of Concept, Design, Development and Production stages)
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Nowadays Challenges to overcome by means of integration

üGlobalization: Strong international and global
competitors
How to take the market first and for a long time
How to compete with other countries with low
labour cost
üOutsourcing and Contract Manufacturing
Outsourcing local and international suppliers
Contract Manufacturing à Companies focus on
manufacturing (they do not design)
Source: ChinaDaily
üDemand of High Quality Products
üEfficiency to reduce costs
Approach to overcome these challenges: Automation and integration of production systems
Manufacturing systems + Material handling technologies + Quality programs + CIM
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Production Systems
“A collection of people, equipment, and procedures organized to accomplish the manufacturing

operations of a company” [1]
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Components:
Product
Workers Design
Facilities
Business
Functions Support Manufacturing
Planning
Equipment:
production,
Plan Layout
handling,
inspection
Manufacturing
Control
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• Facilities
Source: Factory Design Suite Autodesk.
ü Manufacturing systems: group workers & equipment to accomplish production processes

Manual, Worker-machine, Automated systems
ü Plan layout: How to arrange equipment and workers in the factory.
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• Support: procedures to manage the production process.
Involves a cycle of information-processing

activities that consists of four functions:
ü Business functions: sales and marketing,

order entry, cost accounting, customer billing
ü Product design: research and development,

design engineering, prototype shop
ü Manufacturing planning: process planning,

production planning (MPS), MRP, capacity
planning
Source [1]. ü Manufacturing control: shop floor control,

inventory control, quality control
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CIM: Computer Integrated Manufacturing.
Production
CIM
System
Facilities Automation
Support Computers
Automation of Facilities, Computerization of support + Integration
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• Automated Manufacturing Systems

General classification
Product Variety
Programmable
Automation
Flexible
Automation
Fixed
Automation
100 10000 100000
Product Quantity
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• Programmable Automation [1]
One programmable machine. Between batches, system can be programmed. The physical setup
must also be modified. Examples: CNC machines, robots.
Typical features:
ü High investment in general purpose equipment

ü Lower production rates than fixed automation
ü Flexibility to deal with variations and changes in product configuration
ü Most suitable for batch production
ü Physical setup and part program must be changed between jobs (batches)
• Flexible Automation [1]
Set of machines whose can be programmed to produce different products. If the set of products
are similar, there are not changeovers. Examples: Manufacturing cells and flexible systems.
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Typical features:
ü High investment for custom-engineered system
ü Continuous production of variable mixes of products
ü Medium production rates
ü Flexibility to deal with soft product variety
• Fixed Automation [1]
A set of machines with an specific setup so that there are not changeovers but the sequence of
operations is unique. Examples: transfer lines https://www.youtube.com/watch?v=Hg-FjrD6Bbo
Typical features:
ü Suited to high production quantities
ü High initial investment for custom-engineered equipment
ü High production rates
ü Relatively inflexible in accommodating product variety
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• Automation and Engineering support via computers.
o Business functions - sales and marketing, order entry, cost accounting, customer billing
o Product design - research and development, design engineering, prototype shop
o Manufacturing planning - process planning, production planning (MPS), MRP, capacity
planning
o Manufacturing control - shop floor control, inventory control, quality control
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• Integration via CIM
o Integration Manufacturing start with

Concurrent Engineering and DFMA à Low
cost, High quality, Less time to market.
•Computerized •CAD
Bussiness •Analysis
Systems o CIM à semi- or totally automated factory
processes integrated & controlled by
Bussiness
Functions
Design
computer.
o CIM is concerned about data flow, data

Manufacturing
Control
Manufacturing
Planning processing and data dissemination in a
•CAM •CAM, NC plant.
•Process control •CAPP
and monitoring •MRP
•CAQ
o CIM Tools: Models, artificial intelligence
methods, software engineering aids,
computers, interfaces to man & machines
as well as interfaces between machines.
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Integration advantages What to automate
• To increase labor productivity • Combined operations

• To reduce labor cost • Simultaneous operations
• To mitigate the effects of labor • Integration of operations
shortages • Increased flexibility
• To reduce or remove routine manual • Improved material handling and
and clerical tasks storage
• To improve worker safety • On-line inspection
• To improve product quality • Process control and optimization
• To reduce manufacturing lead time • Plant operations control
• To accomplish what cannot be done
manually
• To avoid the high cost of not
automating
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When is manual labor justified?
o Some countries have very low labor rates and automation cannot be justified
o Task is too technologically difficult to automate
o Short product life cycle
o Customized product requires human flexibility
o To cope with ups and downs in demand
o To reduce risk of product failure
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References
[1]. M.P. Groover. Automation, Production Systems, and Computer-Integrated Manufacturing.
Pearson New International Edition, 2014
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Integrated Manufacturing Systems Topic 1.IMSs - 1.

CHAPTER 1. INTEGRATED MANUFACTURING SYSTEMS:

Evolution and Nowadays Challenges

Production Systems: Support and facilities

Computer Integrated Manufacturing – Integrated Manufacturing Systems

Historical Evolution: Several Ideas

Manufacturing evolution. Fuente: http://www.mr-automation.at/en-eu/competence/Industry_4_0.php

First Industrial Revolution: Human energyàSteam Energy + Mechanical control

Second Industrial RevolutionàMass production: Interchangeability and division of labour +

Third Industrial Revolution à Looking for

A further step à “Smart Factory” (Fourth Industrial Revolution) and DFM.

Nowadays Challenges to overcome by means of integration

“A collection of people, equipment, and procedures organized to accomplish the manufacturing

Source: Factory Design Suite Autodesk.

ü Manufacturing systems: group workers & equipment to accomplish production processes

• Support: procedures to manage the production process.

Involves a cycle of information-processing

ü Business functions: sales and marketing,

ü Product design: research and development,

ü Manufacturing planning: process planning,

Source [1]. ü Manufacturing control: shop floor control,

CIM: Computer Integrated Manufacturing.

Automation of Facilities, Computerization of support + Integration

• Automated Manufacturing Systems

• Programmable Automation [1]

ü High investment in general purpose equipment

• Automation and Engineering support via computers.

• Integration via CIM

o Integration Manufacturing start with

o CIM is concerned about data flow, data

Integration advantages What to automate

• To increase labor productivity • Combined operations

When is manual labor justified?

o Task is too technologically difficult to automate

o Short product life cycle

o Customized product requires human flexibility

o To cope with ups and downs in demand

o To reduce risk of product failure

Pearson New International Edition, 2014

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