Computer-Integrated Manufacturing (CIM): What It Is and Key Issues*

Definition:
The use of computer control and information technology to integrate and automate basic product development and production activities in a manufacturing enterprise.

Key Issues: Automation of product development activities Planning and control (low-level) of manufacturing process Planning, scheduling and control (high-level) of factory resources (materials, labor and machines) Communications and data management capabilities
1997-2000 M. Zarrugh

* Read: (CAD/CAM Module by M. Zarrugh, pp. 1-14)

ISAT 211 CIM-1

Computers in Manufacturing: Key Systems

Design Automation
(CAD/CAE/ Tech. Pubs.)

MFG Process Automation

(CAM/CAPP/CAT/ Robotics)

Engineering

Computer system
(Communications Data Management Control)

Manufacturing

CAD Computer Aided Design CAE Computer Aided Engineering CAM Computer Aided Manufacturing CAPP Computer Aided Process Planning CAT Computer Aided Testing MRP Manufacturing Resource Planning
1997-2000 M. Zarrugh

MFG Resource Planning (MRP/MRPII)

Management

ISAT 211 CIM-2

CIM System: Basic Processes

CAD
(design automation)
Geometric modeling Product structure Automated drafting Group technology

Manufacturing
Computer Control & Communications

CAM
(process automation)
Process planning NC/CNC Industrial robots FMS

PDM
(manage product data and configurations)

CAE
(simulation)
Structural Thermal Kinematic/Dynamic Logic/Timing

MRP or MRPII
(manage MFG resources)

CAT
(automated test)
Prototype testing In-process testing Inspection CMM

Tech. Publishing
(writing, multi-media)
Word-processing Manuals Documentation

Common Database, Management, Control System

MRP
(factory MGMNT)
Production control Purchasing Receiving/warehouse Materials tracking

Engineering

1997-2000 M. Zarrugh

ISAT 211 CIM-3

Design Automation: CAD

What is it?
CAD is an automated technology for electronic capture of geometry (form and fit) of parts and how the parts are arranged to form subassemblies and assemblies.

Its Benefits: Electronic form permits easy modification, distribution and reuse of the data Removes drudgery from drawing process No need to re-enter data in downstream applications Electronic documents easier to track than paper Can be done by engineers so development is faster
1997-2000 M. Zarrugh

ISAT 211 CIM-4

CAD: Geometric Modeling

Wireframes:

2D 3D 3D + surfaces
Solids:

B-rep (define boundary and fill it) CSG (Boolean operations on conic primitives) NURBS (analytical definition of surfaces and intersections)
Automated

1997-2000 M. Zarrugh

Drafting: Generation of format detail and assembly drawings through 2D projections and x-sections of 3D geometric models ISAT 211 CIM-5

Design Automation: Computer-Aided Engineering (CAE )

CAE

is the application of scientific laws to physical systems to predict their behavior under a variety of conditions without ever building actual hardware. The geometry, captured in CAD as a solids model, can be used in many downstream simulations. Structural analysis uses finite elements (FE) to predict small deformations and stresses for known geometry, boundary conditions, loads and elastic properties.
1997-2000 M. Zarrugh

ISAT 211 CIM-6

CAE: More Types of Engineering Simulations

FE

and finite difference models, used in thermal simulations, determine temperature changes and distributions resulting from known heat loads and thermal properties. Kinematic and dynamic simulations consider large displacements of interconnected rigid bodies (linkages or mechanisms) in response to specific motions and forces. Electronic circuit designers use CAE tools to verify the logic and timing of ICs, VLSI devices and circuit boards.
1997-2000 M. Zarrugh

Show Ideas video clip

ISAT 211 CIM-7

Design Automation: Technical Publishing

Product

definition requires many documents created on desktop publishing systems. The documents may specify applicable standards, describe:
special materials or processing conditions summarize test results and test and inspection methods use and repair methods.
Standards

needed to simplify the storage and archival of the documents. Format translators and plug-ins required from transferring documents across systems.
1997-2000 M. Zarrugh

ISAT 211 CIM-8

Manufacturing Automation: Computer-Aided Manufacturing (CAM)

What is it?
Originally CAM referred to numerical control of machine tools. Now CAM includes all automated processes in MFG.

Its benefits:
Automation

technology facilitates meeting customer's and regulatory requirements. CAM increases productivity which reduces process development and production cost. Automation reduces errors, rework and promotes use of existing solutions which shortens time-to-market.
1997-2000 M. Zarrugh

ISAT 211 CIM-9

CAM Processes: Computer-Based Automation in Manufacturing

Numerical

Control (NC) and Computer Numerical Control (CNC) of machine tools Automated (or Computer-Aided) Process Planning (CAPP) and tooling and fixturing design Machine loading, machining, assembly and inspection using industrial robots Automated materials handling, storage and retrieval Automated test and inspection Flexible Manufacturing Systems (FMS)
1997-2000 M. Zarrugh

ISAT 211 CIM-10

Computer Automation in Manufacturing: NC/CNC

Numerical

Control (NC) is the control of machine tools by a series of numerical instructions encoded in an NC part program. Computer Numerical Control (CNC) is direct control of machine tools using a dedicated computer on board. Part programs can be generated and edited at the machine tool. CNC machine tools are often equipped with automatic tool changers and part loader to minimize waiting and setup times,
1997-2000 M. Zarrugh

ISAT 211 CIM-11

Computer Automation in Manufacturing: CNC Essential Features

CAD STATION
Ideas Old Designs Creativity Standards

Part Geometry

CAM STATION
NC Programming

NC Programs Speeds/Feeds Material & Size Tooling

NC or CNC Machine Tool

Parts

1997-2000 M. Zarrugh

Show video clip

ISAT 211 CIM-12

Computer Automation in Manufacturing: Automated Process Planning (CAPP)

Computer

Aided Process Planning (CAPP) is a computer assisted process of preparing instructions on how to fabricate a part or build an assembly. CAPP begins with interpreting design data (geometry and materials) into manufacturing processes. The output of CAPP is a part routing or a "process plan" detailing specific processing sequence, machines, tools, fixtures and cutting conditions (speeds and feeds). The generation of process plans is not fully automated yet since it requires human input to provide detailed knowledge of current practices and capabilities.
1997-2000 M. Zarrugh

ISAT 211 CIM-13

Computer Automation in Manufacturing: Industrial Robots

Industrial

robots are articulated machines that can move and process materials under computer control in the factory. Robots give consistent performance in repetitive tasks: machine loading, inspection, monitoring, assembly, etc. Robots can work in hazardous or unpleasant environments: spray painting, arc welding, grinding, sanding, cleaning, handling hazardous material
1997-2000 M. Zarrugh

ISAT 211 CIM-14

Computer Automation in Manufacturing: Industrial Robots

Robots

can reduce cost since they work at about the same rate as people, but cost about 1/2 as much as labor to operate per hour. Robots can increase productivity since they can work 24 hrs/day, do not need break or call in sick. Robots can improve flexibility and since tasks can be changed by a mere change of program, but people need to be trained or retrained
1997-2000 M. Zarrugh

ISAT 211 CIM-15

Computers Automation in Manufacturing: Automated Testing and Inspection

Testing

and inspection close the loop around processes to insure that they are producing the desired results. Prototype testing reduces the number of design iterations and quickly checks conformance to design specifications. Automated test equipment is used in electronic manufacturing to insure that devices and circuit boards are manufactured and assembled correctly. Vision, Coordinate Measuring Machines (CMM) and robotic inspection systems are used in discrete and process manufacturing to inspect parts and products.
1997-2000 M. Zarrugh

ISAT 211 CIM-16

Computers Automation in Manufacturing: Flexible Manufacturing Systems (FMS)

An FMS is a computer-based system in which machine tools and workstations are arranged in groups or cells. Cells produce a limited variety of part types obtained from applying group technology (GT). The cell layout minimizes waiting, part transfer and setup times. An FMS can "randomly" produce a pre-determined variety of parts having similar processing requirements.

Computers

control schedules and track materials. The major benefit of an FMS is flexibility:
Producing a mix of different parts on-demand Dynamic routing of parts to maintain work load balance Accommodating changing production volumes
1997-2000 M. Zarrugh

ISAT 211 CIM-17

Computers in Manufacturing: Conclusions

Because

of intensifying competition and accelerating rate of change, CIM emerges as a strategic weapon with which business can adapt and survive in an ever changing and increasingly competitive business climate. CIM brings automation and integration which results in:
shorter product development cycle lower product development cost lower production costs responsiveness to changing markets and technologies increased process and product quality
ISAT 211 CIM-18

1997-2000 M. Zarrugh