Unit 1 Introduction CIM

ANNA UNIVERSITY

FACULTY DEVELOPMENT PROGRAMME11TH to 23rd JUNE 2007

ME1403 COMPUTER INTEGRATED MANUFACTURING

UNIT – IINTRODUCTION

CAD-Computer aided design. The use of computer methods to develop the geometric model of the product in three-dimensional form, such that the geometric and manufacturing requirements can be examined.

CAM-Computer aided manufacturing. Generally refers to the computer software used to develop the Computer Numerical Control part programs for machining and other processing applications.

CAD/ CAM – CAD/CAM is the integration of the Design and Manufacturing activities by means of computer systems.

CIM – Computer integrated manufacturing includes all of the engineering functions of CAD/CAM, but it also includes the firms business functions that are related to manufacturing.

WHAT is …… ???

The Scope of CAD / CAM and CIM

Computer-integrated manufacturing (CIM) is a method of manufacturing in which the entire production process is controlled by

computer.

CIM relies on closed-loop control processes, based on real-time input from sensors.

CIM is also known as flexible design and manufacturing.

Computer Integrated Manufacturing

COMPUTERS IN MANUFACTURING

ENVIRONMENT

The Meaning and Scope of CIM

"The term computer-integrated manufacturing does not mean an automated factory. "

-Joseph Harrington

"CIM is an amorphous beast. It will be different in every company.

-Leo Roth Klein, Manufacturing Control Systems, Inc.

EVOLUTION OF CIM

EVOLUTION OF CIM

CIM has been evolving since the mid-1970s; however, until 1980 it was merely a concept.

The 1980s, especially the second half, saw CIM expand into a technology.

By now, industry has realized that

CIM is a necessity rather than a luxury.

EVOLUTION OF CIM

Primary factors that have led to the development of the CIM concept and associated technologies include

1. Development of numerical control (NC)

2. The advent and cost-effectiveness of computers.

3. Manufacturing challenges, such as global competition, high labor cost, regulations, product liability, and demand for quality products.

4. The capability-to-cost attractiveness of Microcomputers.

CIM WHEEL

PRINCIPLES OF COMPUTER INTEGRATED MANUFACTURING

PRINCIPLES OF COMPUTER INTEGRATED MANUFACTURING

MANUFACTURING ENTERPRISE

"CIM is the integration of total manufacturing enterprise by using integrated systems and data communication coupled

with new managerial philosophies that improve organizational and personnel efficiency."

-Society of Manufacturing Engineers

PLANNING…WHY ??

NEED

&

IMPORTANCE

PLANNING LEVELS

Disaggregate Planning –

0 to 2 months, Aggregate Planning -

More than2 – 18 months Strategic planning –

Over 18 Months – N months

THE ENTERPRISE AREAS

MANUFACTURING ENTERPRISE WHEEL

CIM - Vs

Manufacturing Methodologies

Three components distinguish CIM from other manufacturing methodologies:

*Means for data storage, retrieval, manipulation and presentation;

*Mechanisms for sensing state and modifying processes;

*Algorithms for uniting the data processing component with the sensor/modification component.

Bottom Line ???

"CIM is the integration of total manufacturing enterprise by using integrated systems and data communication coupled

with new managerial philosophies that improve organizational and personnel efficiency."

CIM –SUB SYSTEMS

CAD/CAM (Computer-aided design/Computer-aided manufacturing) CAPP, (Computer-aided process planning) ERP (Enterprise resource planning) CNC (computer numerical control) machine tools DNC, direct numerical control machine tools FMS, flexible machining systems ASRS, automated storage and retrieval systems AGV, automated guided vehicles Robotics

Automated Conveyance System A business system integrated by a common database

Automated conveyance systems Project management software|computerized scheduling and production control CAQ (Computer-aided quality assurance) A business system integrated by a common database

CHALLENGES

TO DEVELOPMENT OF A

CIM OPERATION

OBSTACLES TO CIM IMPLEMENTATION

EXTERNAL CHALLENGES

CHALLENGES TO DEVELOPMENT OF A CIM OPERATION

Challenge-1

Integration of components from different suppliers

•''' When different machines, such as CNC machines, conveyors and robots, are supplied from different companies, integrating them

together can be quite complex. They may use different communications protocols. In the case

of AGVs, even differing lengths of time for charging the batteries may cause problems.

CHALLENGE - 2

'''Data integrity:'''

The higher the degree of automation, the more critical is the integrity of the data used to control the machines. While the CIM system saves on labor of operating the machines, it requires extra human labor in ensuring that there are proper safeguards for the data signals that are used to control the machines.

'''Process control'''

•Computers may be used to ''assist'' the human operators of the manufacturing facility, but there must always be a competent engineer on hand to

handle circumstances which could not be foreseen by the designers of the control

software.

CHALLENGE -3

CHANGING

MANUFACTURING

AND

MANAGEMENT SCENE

CHANGING MANUFACTURING AND MANAGEMENT SCENE

Automation and control technologies.Material handling technologies. Manufacturing systems.Quality control systems.Manufacturing support systems.

Automation and control technologies

•Industrial computer control,

•Control system components,

• Numerical control,

•Industrial robotics,

•Programmable logic controllers.

Material handling technologies

• Conveyor systems,

• Automated guided vehicle systems,

• Automated storage systems, • Automatic identification and data

capture.

Manufacturing systems

Single station cells,

Group technology,

Flexible manufacturing systems,

Assembly lines, transfer lines

Quality control systems

Statistical process control,

inspection principles and technologies

Manufacturing Support Systems

•CAD/CAM,

•Process planning,

•Production planning,

•Production planning and control,

•Lean production and agile manufacturing.

Importance of CIM –Survey Report

CIM Benefits –Survey Report

Communication System.


•External communication •Islands of automation and

software•Dedicated and open systems

• Manufacturing automation protocol


The New "M“ & Communication

Manufacturing was thought to require four basic inputs-man, machine, material, and money. These inputs have classically been known as the four "M’s" of production.

Today, another input-data, or information-has become critical. We can call the new input “Message" so that it be comes the fifth "M" of production.

Messages are either stationary or mobile. The stationary data are stored in databases. The fundamentals relating to the mobility of data, is, communication.

Success

Blinks..

????

COMMUNICATION SYSTEM

CIM requires that the engineering and manufacturing information be communicated to proper points within the operation.

All the data and information that flow through the CIM enterprise are generated, acquired, or collected prior to their storage in databases. From there they are retrieved whenever needed.

CIM requires that the engineering and manufacturing information be communicated to

proper points within the operation.

Take Care.

COMMUNICATION SYSTEM

Communication of digital Signals between CNC machine tools and Other equipment in Manufacturing Systems is Very important for Running the operations smoothly.

Serial and parallel communications are the most common methods employed in computing equipment.

Serial communication is used by CNC machine tools because of its ability to communicate over long distances and linking with dissimilar equipment.

CONCEPTUAL COMPONENTS

CIM requires that the engineering and manufacturing information be communicated to proper points within the operation.

All the data and information that flow through the CIM enterprise are generated, acquired, or collected prior to their storage in databases. From there they are retrieved whenever needed.

Communications comprises three conceptual components :

Representation of data, The medium (through which data flow), and Networking (of the devices).

THREE FAMILIES OF COMMUNICATORS UNDER CIM

COMPUTERS(C)

MACHINES /PROCESSES(M)

PERSONNEL(P)

DATA FLOW FROM ENGINEERING TO SHOP FLOOR VIA MANUFACTURING

MOBILE DATA

Mobile data are either •(a) Commands that instruct the recipient-machine, operator, or material handling system such as an automated guided vehicle (AGV); or

•(b) Reports from-the sources to the central computer or upper management. •(c) Commands flow downstream to lower levels, whereas reports travel upstream in the reverse direction. •(d) In a hierarchical system, the communicating pairs are connected bi-directional as downlinks for downstream messages and as uplinks for upstream messages.

LOCAL AREA NETWORK

ELEMENTS OF LOCAL AREA NETWORK

TRANSMISSION MEDIA CABLE ( CABLING)

NETWORK TOPOLOGY

NETWORK TOPOLOGIES

NETWORK TOPOLOGIES

Limitations & Remedies

A lack of standardization among the devices used in manufacturing has been the biggest stumbling block to the proliferation of CIM.

This limitation is being addressed under the Manufacturing Automation Protocol (MAP) and also through de velopments in local area networks (LANs).

Both MAP and LAN, as well as the International Standards

Organization's (ISO) Open Systems Interconnection (OSI) model.

Communication Between Computing Devices( Serial and Parallel transmission)

LSB – Least Significant. Bit.MSB – Most Significant. Bit

COMMUNICATION LINE( Point to Point connection between two devices)

COMMUNICATION LINE(Star Configuration)

COMMUNICATION NEEDS OF CIM( Matrix – 3 x 3 Combinations)

Source – Sink Matrix

The informational needs of manufacturing represented by a three-by-

three source-sink matrix. (a) Person-to-person (P-P) (b) Computer-to-computer (C-C) (c) Machine-to-machine (M-M) (d) Person-to-computer or computer-to-person (P-C and C-P) (e) Person-to-machine or machine-to-person (P-M and M-P) (f) Computer-to-machine or machine-to-computer (C-M and M-C)

DNC Control Operation

DNC Operation

Enhanced DNC Operation Linking the Tool and Work Preparation areas with

CNC Machine Tools

ISO -OPEN SYSTEM INTERCONNECTION ( ISO –OSI)

Open System Interconnection Model Seven Layers

Why layered structure ?

A layered structure is desirable for several reasons.such a structure facilitates

modification in one layer without affecting the others.

OSI Layer Characteristics

PROTOCOL:The protocol comprises the set of rules for operating a data Communication system.

SYNTAX : The syntax of information in a protocol is analogous to the language used in person to person communications.

SEMANTICS: The Semantics of a protocol is like the rules that determine when and how people say certain things.In Conversation, for example the answering party’s response is hello or Hi – not Bye , Which is reserved to signal the end of conversation.

PHYSICAL LAYER - 1

Level one is the physical layer. It defines the physical connection between the computer and network communication system.

The connection includes cables,connectors,modulation equipment and specifies the frequencies and voltages of connectors.

The Bandwidth of the cable transmission and the physical layout (topology) are defined in this layer.

DATA LINK LAYER -2

Level 2 defines how the data is to be packaged when it is sent between physical connection.

This layer defines the network access control mechanism.

NETWORK LAYER - 3

This layer defines switching and routing information between network and how packets

of data are exchanged between different

LAN s.

TRANSPORT LAYER -4

The transport layer defines network addressing and the way in which connection between

networks can be linked or Unlinked.

SESSION LAYER -5

The primary function of this layer is to define an application interface to the transport layer.this layer maps names to network

addresses so that applications can use names to communicate with devices.

PRESENTATION LAYER - 6

This layer defines the translation formats from an application to the network and the manner in which software applications enter the network.

Hand Shaking Methods Between Communicating Devices

APPLICATION LAYER - 7

This layer contains several programs that define the network applications that support file serving.

Communication Between different Applications

Computing Environment

NETWORK STANDARDS

NETWORK STANDARDS

DECNET –Trade mark of digital equipment corporation.

SNA – System network architecture. MAP –Manufacturing Automation protocol. TOP –Technical office protocol.

REFERENCE MODEL FOR OPEN SYSTEM INTERCONNECTION ( OSI)

MAP Application of the OSI Reference Model

MAP Installation Linking the FMS with that of the Other Information systems

MRP-Material Req Planning. BR- Bridge. FMT –FMS Terminal TS – Terminal Server. .FMS DB –FMS Database . MHS –Material Handling System .

AS/RS-Automatic Storage and retrieval System. L / UL – Load / Unload

MAP

Pin / Circuit Description

Pin / Circuit Description

Computer Integrated Manufacturing

HARDWARE &

SOFTWARE


CIM HARDWARE

Manufacturing equipment such as CNC machines or computerized Workcentres. Robotic work cells. DNC / FMS Systems. Work handling and Tool handling devices Storage devices Sensors Shop Floor data collection devices Inspection machines etc.. Computers, Controllers, CAD / CAM Systems, Workstations / terminals, Data entry terminals. Bar Code readers, Printers, plotters Modems,Cables, Connectors etc..

CIM Software & Functions

Management Information Systems. Sales. Marketing. Finance. Database management. Modeling and Design. Analysis. Simulation. Communications. Monitoring. Production Control

CIM Software & Functions

Manufacturing area and control. Job tracking. Inventory Control. Shop floor data Collection. Order entry. Material handling. Device Drivers Process planning. Work Flow automation. Business Process Engineering. Network Management. Quality Management.

CIM SOFTWARE

PROCESS PLANNING SOFTWARE

What is Process planning?

Process planning is concerned with determining the sequence of individual

manufacturing operations needed to produce a given part or product.

The resulting operation sequence is documented on a form typically referred to

as operation sheet.

AUTOMATED PROCESS PLANNING

The Automated process planning provides the opportunity to

generate production routings which are rational,consistent and perhaps

even optimal.

Structure of a Process planning Software

The modules are not necessarily arranged in the proper sequence but can be based on importance or decision sequence.

EACH MODULE MAY REQUIRE EXECUTION SEVERAL TIMES IN ORDER

PRODUCTION PLANNING.

Production planning

Production planning is one of the key functions in modern industries. Although other functions

may be optimized, the success of a manufacturing company relies heavily on

the performance of production decisions.

Manufacturing System - SUCCESS ???

The ability of making the right product at the right time and at the lowest possible cost, still remains the key to success for a manufacturing company.

Production Planning and Scheduling are among the key functions allowing a manufacturing company to meet such an objective.

MARKETING ENGINEERING

"…marketing can now exhibit its scientific muscle and move from opinions-based decision-making to data based decision making. Marketing Engineering will spawn a new discipline within marketing.“

Prof. Philip Kotler, Northwestern University

Marketing Engineering

Marketing Engineering is computer assisted marketing analysis and planning .

Several forces are transforming the nature, scope, and structure of the marketing profession.

Marketers are seeing increasingly faster changes in the marketplace and are barraged with an ever increasing amount of information.

Many view traditional marketing as art and some view it as science, the New marketing increasingly looks like Engineering.

Marketing Engineering :Steps

MARKETING MANAGEMENT TOOLS

MARKETING ENGINEERING MODEL & FACTORS

Marketing Engineering - Demand

Marketing Engineering - Demand

Questions ???

BUSINESS AND FINANCIAL MANAGEMENT

Management -Definition

“Management is guiding human and physical resources in to dynamic organizational units

which attain their objectives to the satisfaction of those served and with a high degree of

morale and sense of attainment on the part of those rendering service”.

-American Management Association.

Business Management

Components Of Business Management

PLANNING

“ Planning is deciding in advance what is to be done.It involves the selection of objectives,

policies,procedures,And programmes from among alternatives” -M.E.Hurley

Nature and characteristics of planning

Planning is Goal oriented. Planning is a primary function. Planning is all-perspective. Planning is an intellectual process. Planning is a continuous process. Planning is is forward -looking. Planning involves choice. Planning is an integrated process. Planning is directed towards efficiency.

ORGANISING

“ The Grouping of activities necessary to attain objectives , the assigning of each grouping to managers with authority to supervise,and provision for co ordination horizontally and vertically in the enterprise structure”

-Koontz

Elements of Organization

Common purpose. Division of Labor. Authority structure. People. Communication. Coordination. Environment. Rules and regulation.

ADMINISTRATION ,MANAGEMENT & ORGANISATION

Administration pre-determines the specific goals and lays down the broad policies within which these goals are to be

attained. ADMINISTRATION IS A DETERMINATIVE FUNCTION

Management is an executive function, which is mainly concerned with carrying out the broad policies laid down by

the administration.

Organization is the machinery through which the co-ordination is established between the administration and

management.

STAFFING

Staffing is a process of matching the jobs with individuals.After organizing the total activities to be done, management is in a

position to know the man power requirements of the company at

different levels of organization.

DIRECTING

Directing is providing all guidance and inspiration to the people at work to carry out

their assigned duties and responsibilities

DIRECTING IS MANAGEMENT IN ACTION

DIRECTION FUNCTION

LeadershipSupervision Motivation Communication Co-ordination

DIRECTING FUNCTION

CONTROLLING

“ Control consists in verifying whether everything occurs in conformity with the plan adopted,instructions

issued and the principles established.” -Henry fayol

FINANCIAL MANAGEMENT

FINANCE FUNCTION

The finance function in a business as simply the task of providing funds needed by the enterprise on terms that are most favorable

in the lights of the objectives.

Finance is concerned with cash, and that since nearly every business transaction involves cash directly or indirectly.

Finance function as procurement of funds and their effective utilization in the business.

Guess ???????…

Who takes care of finance function in business?

Financial Manager / + ??

The financial officer in a company is known as controller or treasurer.

It is customary for the treasurer /Controller to perform financial functions of some kind,important aspects of financial management

are often handled outside his/her office.

In a company basic financial decisions are made by managing director / agent of the company , in another by a committee of the

board of directors, in another by the financial controller or treasurer.

CLASSIFICATION OF FINANCE FUNCTION

Executive Finance function:

-Requires administrative skill in planning and execution.

Incidental finance function:

-Covers routine work,chiefly clerical,that is necessary to carry in to effect financial decisions at the executive level.

Executive Finance Function

1. Establishing asset management policies.

2. Determining the allocation of net profits.

3. Establishing and controlling cash flows and requirements.

4. Deciding upon needs and sources of new outside financing.

5. Carrying on negotiations for new outside financing.

6. Checking upon financial performance.

Thank you.

Documents

Unit 1 Introduction CIM