Pankaj Baishnab, Industrial Engg. & Management NATIONAL INSTITUTE OF TECHNOLOGY, KKR

DEFINITION:Computer Integrated Manufacturing (CIM) is the method of manufacturing in which whole manufacturing process is controlled by the integration of total manufacturing enterprise by computer.

HISTORY:In the 1980s, CIM was developed and promoted by machine tool manufacturers and the SME (Society for Manufacturing Engineers).

COMPONENTS OF CIM:C D,C TI C E GT D M

TQM

PRODUCT DESIGNCE S STEM M N GEMENT

C PP U R

B R CODES

CIMM NU CTURE

PROCESS P NNING

M NU -CTURINGM P, STEP

JIT

NNC/CNC MS ROBOTICS GV, SRS

CAD/CATIA:Computer Aided Design (CAD) is the application of computer to aid the design process. Computer Aided Three Dimensional Interactive Application (CATIA) is the development of CAD. CATIA was developed by IBM. Can be run on Windows, Linux etc. CATIA provides free-style shapes and workbench facility. CAD provides fewer functions and makes them easier to use.

STEP:Standard for the Exchange of Product Model Data is ISO 10303 standard of International Organization for Standardization.

Used for exchange of data b/n CAD, CAM, CAE etc.CAE

CAD

CAD

Step data transfer Step C transfer

CAM

C C

CURRENT PRACTICE:CAD CADD CAM IGE S PATH CL PLANNING FILE Undocumented fixes added POST CNC

STEPDESIGN DETAILING

RS 274D

MANUFAC-TURING

Incomplete information

Partial geometry

Machine specific translator

Machine specific control file

NEW METHOD:CAD CADD CAM CNC

AP 203DESIGN

AP 203 PATH DETAILING e2 PLANNING

AP 238

MANUFAC-TURING

Design model

Add GD & T

Add manufacturing Feature & tool path data

Control file for any Machine with reqd. resources

OBJECTIVES OF STEP:To reduce new model construction effort. To improve model accuracy and fidelity. To transfer & retain information completely. Avoid duplication of effortIt has been already modeled, why do it again? Former modeler is richer in shape creation than later.

CNC:Computer Numerical Control (CNC) represents all production machines that use on-board computers to control the movement of tooling with production programs.ControlFrom operator or machine interface To operator or machine interface

Input

emory

utput

rithmetic

NUMERICAL DATA (NC CODE)

MANUFACTURING OPERATOR

NUMERICAL CONTROLLERDrive Control

PROCESSED PART MACHINE UNIT

Automatic Guided Vehicles:Equipped with AG Equipment Equipments may be electromagnetic

or optical Powered by Electric Motors using Batteries

Types of AGVs:a. Wire navigated b. Guide tape navigated c. Laser target navigated d. CE.NET on IPC/Mi

Fig. Wire Navigated AVG

BENEFITS:Self-corrective navigation. Extremely accurate. Simple layout engineering (based on CAE/CAD techniques). Fast, clean and accurate installation of floor wires Less floor space needed

AGV Guide Tape

Fig. Guide tape navigated AVG

BENEFITS:Highly accurate. Cost-effective. Limited number of magnet required.

DEMARITS:Can t be used in highly traffic areas Tapes get damaged quickly Dusts affect the tape

Receiver

Camera

Fig. Laser navigated AVG

BENEFITS:Flexible systems, can be used in different environments. Flexible positioning of reflector beacons. Adjustments to drive paths are possible without changing beacon positioning. Limited amount of beacons needed. Installation doesn t require cutting in floor surface.

CE.NET ON IPC/MI: Equipped with powerful IPC processor that can perform complex calculations. A low cost processor can also be used. Processors are programmed as per the need.

Benefits of CE.NET AGVs:Accurate execution of transport orders. Easy loading of program in vehicles memory Combination of different navigation method. Easy adaptation of future navigation method. Control of complex material handling devices. Easy software maintenance through remote connections.

FUNCTIONS OF AGV SYSTEM:Guidance Routing Traffic management Load transfer System management

TRAFFIC MANAGEMENT:For minimizing the interference & collision with other AGVs three techniques are used Zone control Forward sensing Combination control

Zone 2 Zone 4 Convergence point Zone 3

Decision Point A Zone 1 Decision Point B Zone 7 Zone 8

Zone 5

Zone 6

Zone 3

Fig. Traffic management

SHOULD AVG BE EMPLOYED?Yes, for five or more of the following conditions1. There s lost or late delivery of materials to work centers more than 5% of time. 2. Ten or more pickup and delivery locations exist in the facility 3. Total material movement activity at all work centers fall between 35 & 200 loads per hour 4. Three or four forklifts are currently required on a minimum of two shifts

SHOULD AVG BE EMPLOYED?5. Over 300 feet of conveyor is currently in use. 6. The level of in-process inventory on the shop is high. 7. Automation introduced requires an automated material movement system 8. Damage during manual material handling creates significant quality problem.

Automated Storage and Retrieval System: components: Storage rack Input and output systems Storage & retrieval equipment Computer management system

TYPES OF AS/R SYSTEM:Totally automatedThey operate on unit load transfer basis

Human-on-boar AS/RSHave human riding in carriage or picking of specific parts from compartments.

Miniload & automatic item retrieval AS/RSPermit single item retrieval from AS/RS

Carousal Storage System.

CAROUSAL STORAGE SYSTEM:Ma al sse ly tati Ma al sse ly tati Ma al sse ly tati Ma al sse ly tati

t tary ar

sal

Ma al sse ly tati

Ma al sse ly tati

Ma al sse ly tati

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What Employees say:Importance of CIM1.4% 1.4% 10.8 39.6%

46.8%

Very Important Unimportant

Essential Somewhat Important

No Answer

Key Challenges:Varying of ComponentsDifferent suppliers supply different components Varying length of battery working and charging time

Data IntegrityVariety of data types Safeguarding the data

Process ControlSkilled engineer is needed to handle the process

any

QUERIES, COMMENTS, SUGGESTIONS??