UNIVERSITI TEKNOLOGI MARA

FACULTY OF MECHANICAL ENGINEERING

Computer Integrated
Manufacturing (CIM)

prepared by RJ

CHAPTER 1:
1.0 Introduction to CIM
1.1 Fundamentals of CAD/CAM
1.2 Automation and Control Technologies
1.3 Types of Manufacturing Systems
1.4 Integration of Manufacturing Systems
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Computer Integrated Manufacturing

(CIM)

System that applies computer and

communications technology to all the
operational functions and information
processing functions in manufacturing
from order receipt through design and
production to product shipment.

Major Applications of CIM

Computer Numerical Control (CNC)

Adaptive control
Industrial robots
Automated handling of materials
Automated and robotic assembly systems
Computer-aided process planning
Just-in-time production
Group technology
Artificial intelligence
3

Why Use CIM?

Responsiveness to rapid changes in market

demand and product modification.
Better use of materials, machinery, personnel,
reduction inventory.
Better control of production and management of
the total manufacturing operation.
The manufacture of high-quality products at low
cost.
4

Modern Manufacturing Approaches

and Technologies (Chapter 1)

Automation - use of automated equipment instead of

labor to decrease labor time, cost, production cycle
time, increase product quality and consistency.
Material handling technologies - because
manufacturing usually involves a sequence of
activities performed at different locations in the plant.
Manufacturing systems - integration and coordination
of multiple automated/manual workstations/material
handling technology. No independent operation of
individual workstations.
5

Modern Manufacturing Approaches

and Technologies

Flexible manufacturing - to compete in the lowvolume/high-mix product categories.

Quality programs - to achieve high quality
expected by today's customers by employing
techniques such as six sigma, etc.
CIM - to integrate design, production, and
logistics. Technologies such as CAD, CAM &
computer networks.
Lean production - more work with fewer
resources.
6

Production System Defined

A collection of people, equipment, and
procedures organized to accomplish the
manufacturing operations of a company.
Two categories/levels:
Facilities the factory and equipment in
the facility and the way the facility is
organized (plant layout).

Production System Defined

Manufacturing support systems the set of procedures

used by a company to manage production and to solve
technical and logistics problems in ordering materials,
moving work through the factory, and ensuring that
products meet quality standards.

Production System Facilities

Facilities include the factory, production machines and

tooling, material handling equipment, inspection
equipment, and computer systems that control the
manufacturing operations.
Plant layout the way the equipment is physically
arranged in the factory.
Manufacturing systems logical groupings of equipment
and workers in the factory.
Production line
Stand-alone workstation and worker
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Manufacturing Systems
Three categories in terms of the human participation in
the processes performed by the manufacturing system:
1. Manual work systems - a worker performing one or
more tasks without the aid of powered tools, but
sometimes using hand tools.
2. Worker-machine systems - a worker operating
powered equipment.
3. Automated systems - a process performed by a
machine without direct participation of a human
worker.
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Manufacturing Systems

11

Manufacturing Support Systems

Involves a cycle of information-processing activities that
consists of four functions:
1. Business functions - sales and marketing, order entry,
cost accounting, customer billing.
2. Product design - research and development, design
engineering, prototype shop.
3. Manufacturing planning - process planning,
production planning, MRP, capacity planning.
4. Manufacturing control - shop floor control, inventory
control, quality control.
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Information Processing Cycle in

Manufacturing Support Systems

13

Automation in Production Systems

The automated elements of the production systems are:
1. Automation of manufacturing systems in the factory.
2. Computerization of the manufacturing support
systems.
The two categories overlap because the automated
manufacturing systems are implemented by computer
systems and connected to the computerized
manufacturing support systems and management
information system.

14

Automated Manufacturing Systems

Perform operations such as processing, assembly,

inspection & material handling. Reduced level of human
participation.
Examples: automated machine tools that process parts,
automatic material handling & storage systems to
integrate manufacturing operations, automatic inspection
system for quality control, etc.
Three basic types: (1) fixed, (2) programmable & (3)
flexible automation.

15

Computerized Manufacturing
Support Systems

Use of computer systems to design the

products, plan the production, control the
operations & perform various functions.
Examples: CAD, CAM, CAD/CAM, etc.
These uses computer systems to
support/perform functions for product
design or manufacturing engineering.
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Reasons for Automating

Think???

17

Automation & Control Technologies

(Chapter 4)

Overview of automation
Elements of an automated system
Control system
Levels of enterprise

Later chapters will cover on the NC,

industrial robotics, PLCs.

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Automation Defined

Automation is the technology by which a

process or procedure is accomplished
without human assistance.
Basic elements of an automated system:
1.

2.
3.

Power - to accomplish the process and operate

the automated system.
Program of instructions to direct the process.
Control system to actuate the instructions.
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Elements of an Automated System

20

Power to Accomplish the

Automated Process

Power for the process:

To drive the process itself
To load and unload the work unit
Transport between operations
Power for automation:
Controller unit
Power to actuate the control signals
Data acquisition and information processing
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Program of Instructions

Set of commands that specify the sequence of steps in the

work cycle and the details of each step
Example: CNC part program
During each step, there are one or more activities
involving 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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Control System
Two types of control:
1. Closed-loop (feedback) control system a system in
which the output variable is compared with an input
parameter, and any difference between the two is used to
drive the output into agreement with the input
2. Open-loop control system operates without the feedback
loop
Simpler and less expensive
Risk that the actuator will not have the intended effect

23

(a) Feedback Control System and

(b) Open-Loop Control System

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5 Levels of Automation & Control in

Manufacturing
1.

2.

3.
4.
5.

Device level actuators, sensors, and other hardware

components to form individual control loops for the next
level
Machine level CNC machine tools and similar
production equipment, industrial robots, material handling
equipment
Cell or system level manufacturing cell or system
Plant level factory or production systems level
Enterprise level corporate information system

25

Levels of Automation

26

Types of Manufacturing Systems

(Chapter 13)

Components of a manufacturing system

Material Handling System
Computer Control System
Classification scheme for manufacturing
systems

27

Manufacturing System Defined

A collection of integrated equipment and human

resources, whose function is to perform one or more
processing and/or assembly operations on a starting raw
material, part, or set of parts.
Equipment includes
Production machines and tools
Material handling and work positioning devices
Computer systems
Human resources are required either full-time or
periodically to keep the system running.
28

Examples of Manufacturing Systems

Single-station cells
Machine clusters
Manual assembly lines
Automated transfer lines
Automated assembly systems
Machine cells (cellular manufacturing)
Flexible manufacturing systems
29

Components of a
Manufacturing System
1.
2.
3.

4.

Production Machines plus tools & fixtures

Material Handling System
Computer system to coordinate and/or control the
preceding components
Human workers to operate and manage the
system (direct labour, eg. Computer
programmers, maintenance & repair personnel,
etc.)
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(1) Production Machines

In virtually all modern manufacturing systems,

most of the actual processing or assembly work is
accomplished by machines or with the aid of
tools.
Classification of production machines:
1. Manually operated machines are controlled or
supervised by a human worker

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(1) Production Machines

1.

2.

Semi-automated machines perform a portion

of the work cycle under some form of program
control, and a worker tends the machine the
rest of the cycle
Fully automated machines operate for
extended periods of time with no human
attention

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(2) Material Handling System

In most manufacturing systems that process or assemble

discrete parts and products, the following material
handling functions must be provided:
1. Loading work units at each station
2. Positioning work units at each station
3. Unloading work units at each station
4. Transporting work units between stations in multistation systems
5. Temporary storage of work units
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Automated Handling of Materials

Manual handling is very costly.

Working process and environment could be
danger to human being.
Automated handling can minimized the
risk of getting injured.
More efficient and accurate.
Reduction in cost
34

Work Transport Between Stations

Two general categories of work transport in multi-station

manufacturing systems:
1. Fixed routing
Work units always flow through the same
sequence of workstations
Most production lines exemplify this category
2. Variable routing
Work units are moved through a variety of
different station sequences
Most job shops exemplify this category
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(a) Fixed Routing and

(b) Variable Routing

36

(3) Computer Control System

Typical computer functions in a manufacturing system:

Communicate instructions to workers for specific work.

Download part programs to computer-controlled machines.

Control material handling system to coordinate activities with

those of the workstations.

Schedule production.

Failure diagnosis when malfunctions occur.

Safety monitoring.

Quality control. To detect and reject defective work units.

Operations management. Overall operations of the

manufacturing system.

37

Classification of
Manufacturing Systems

Factors that define and distinguish

manufacturing systems:
1.
2.
3.
4.

5.

Types of operations
Number of workstations
System layout
Automation and manning level
Part or product variety
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Types of Operations Performed

Processing operations on individual work or assembly operations to

combine parts.
Type(s) of materials processed. This affect the type of equipment &
handling method.
Size and weight of work units. Bigger parts require bigger equipment
& higher safety required.
Part or product complexity

For assembled products, number of components per product.

For individual parts, number of distinct operations to complete

processing.
Part geometry

Machined parts, can be rotational or non-rotational

39

Three Cases of Product Variety

in Manufacturing Systems

(a) Single-model case, (b) batch model case, and (c) mixed-model
case

40

Controllers in Manufacturing

NC and industrial robotics are primarily concerned with

motion control. (NC, CNC, DNC & ROBOTICS)
Discrete control uses two principal industrial controllers
programmable logic controllers (PLCs) and personal
computers (PCs).
PLCs applications are used in both process industries
(food production, chemical processing) and discrete
manufacturing (controlling of machines, automatic
storage system, etc).
Function of PLCs: logic control, sequencing, analog
control, arithmetic functions, etc.
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Numerical Control (Chapter 7)

A form of programmable automation of a machine tool

(eg. drilling, milling, etc.) other equipment (non-machine
such as assembly, inspection).
Generate a punched paper tape directly or to program in a
computer-typed language (Automatically Programmed
Tool) and process this source program off-line on a
computer, which translate it into a machine readable block
format program on punched paper tape. The NC machine
will read the tape and repeatedly use for every part
produced.
42

Computer Numerical Control

Each NC machine comes with a computer (MCU).

Features: storage of more than one part program, program
editing at the machine tool, communications interface, etc.
CNC MCU: central processing unit, memory, I/O
interface, controls for machine tool axes and spindle
speed, sequence controls for other machine tool functions.
CNC Software: operating system, machine interface &
application.

43

DNC

Direct numerical control (DNC) control of

multiple machine tools by a single (mainframe)
computer through direct connection and in real
time
1960s technology
Two way communication
Distributed numerical control (DNC) network
consisting of central computer connected to
machine tool MCUs, which are computers (CNC)
Present technology
Two way communication

General Configuration of a
Direct Numerical Control System

Connection to MCU is behind the tape reader

(BTR). In distributed NC, entire programs are
downloaded to each MCU, which is CNC rather
than conventional NC.

Distributed Numerical Control

Configurations

Switching
network

Distributed Numerical Control

Configurations

Local area network (LAN)

Computer-Aided Design (CAD)

One of the fundamental building blocks of

a CIM system. It is an important
technology for an integrated product
development/design process.
Define: application of computers and
graphics software to aid or enhance the
product design from conceptualization to
documentation.
48

Computer-Aided Design (CAD)

Application of CAD to manufacturing systems:

Used for design function. Eg. Design of product, fixtures for

machining, gauges, material handling pallets, etc.

Drafting: creation of working drawings

2 components:

Hardware platform. Started with mainframe system to single

user workstation

CAD software: stated with 2D, 3D capability to solid modelling.

49

Production Data Management

Aka Product Lifecycle Management (PLM) /

Product Development Management (PDM)
Store and organize CAD data.
Control the master BOM (parts list) of product,
sub-assembly (product structure).
Technique used is relational database where part
data are linked to numerous files related to part,
assembly & product.
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Data Interfaces

Process:

(1) creating product with CAD

(2) converting CAD part geometry &
attributes to format required by others
(3) saving all the different format / file
versions in the PDMs relational database

51

Computer Aided Engineering (CAE)

Define: The analysis & evaluation of the engineering

design by using computer-based techniques to calculate
product operational, functional and manufacturing
parameters too complex for classic manual methods.
Is in the design process (from synthesis to evaluation).
The output is used to determine the quality of the product
design. Eg. Analysis FEA (motion, temp, static,
dynamic) & mass properties (centroid, moment of inertia,
volume), evaluation (produce prototype model)

52

Computer Aided Manufacturing

(CAM)

Define: Effective use of computer. technology in the

planning, management & control of production for the
enterprise.
One major application is to extract information directly
from design-drawing data. The part geometry created with
CAD in the design engineering area is used with CAM
software to create machine code capable to machine the
part on a CNC machine - CAD/CAM).

53

CAD/CAM

Use CAD/CAM software to test the program in a

simulated machining process. Will construct a drawing of
the machined part on the display screen. Upon
satisfaction of the program, the computer can issue the
program on a CNC machining station for execution and
store the program on disk for future production runs. It
can also generates three view drawings, dimension data,
& programming for industrial robots to handle the product
from machine to machine during production.

54

Drawing Interchange File Format

Autocad - .dxf, CATIA - .IGES, send to

CAM software (MasterCAM) to prepare
NC/CNC programs to cut the part. Change
the .dxf to its own CAM file format (APT).

55

Questions

Differences between NC, CNC & DNC.

Benefits of CNC.
Define CAD.
How does CAD interface with PDM?
Describe the function of PDM systems.
Define CAD/CAM.
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