7/27/2019 Module 4_Product Design and Process Technologies
1/18
ISAT 211 CIM-1 1997-2000 M. Zarrugh
Computer-Integrated Manufacturing (CIM):
What It Is and Key Issues*
Definition:The use of computer control and information technology tointegrate 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
processPlanning, scheduling and control (high-level) of
factory resources (materials, labor and machines)
Communications and data management capabilities
*Read: (CAD/CAM Module by M. Zarrugh, pp. 1-14)
7/27/2019 Module 4_Product Design and Process Technologies
2/18
ISAT 211 CIM-2 1997-2000 M. Zarrugh
Computers in Manufacturing:
Key Systems
Computer system(Communications
Data Management
Control)
Design
Automation(CAD/CAE/
Tech. Pubs.)
MFG Process
Automation(CAM/CAPP/CAT/
Robotics)
MFG Resource
Planning
(MRP/MRPII)
Engineering Manufacturing
Management
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
7/27/2019 Module 4_Product Design and Process Technologies
3/18
CIM System: Basic Processes
Common Database,
Management,
Control System
Computer
Control & Communications
PDM(manage
product
data andconfigurations)
MRP
or
MRPII(manageMFG
resources)
Engineering
ManufacturingCAD
(design automation)Geometric modeling
Product structureAutomated draftingGroup technology
CAE(simulation)
StructuralThermal
Kinematic/DynamicLogic/Timing
Tech. Publishing(writing, multi-media)
Word-processingManuals
Documentation
CAM
(process automation)Process planning
NC/CNC
Industrial robots
FMS
CAT(automated test)Prototype testingIn-process testing
InspectionCMM
MRP(factory MGMNT)Production control
PurchasingReceiving/warehouse
Materials tracking
1997-2000 M. Zarrugh ISAT 211 CIM-3
7/27/2019 Module 4_Product Design and Process Technologies
4/18
ISAT 211 CIM-4 1997-2000 M. Zarrugh
Design Automation:
CAD
What is it?CAD is an automated technology forelectroniccapture ofgeometry (form and fit) of parts and how the parts arearranged 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
7/27/2019 Module 4_Product Design and Process Technologies
5/18
ISAT 211 CIM-5 1997-2000 M. Zarrugh
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 Drafting:
Generation of format detail and assembly drawings
through 2D projections and x-sections of 3D geometric
models
7/27/2019 Module 4_Product Design and Process Technologies
6/18
ISAT 211 CIM-6 1997-2000 M. Zarrugh
Design Automation:
Computer-Aided Engineering(CAE)
CAE is the application of scientific lawsto 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. Structuralanalysis uses finite elements
(FE) to predictsmalldeformations and
stresses for known geometry, boundary
conditions, loads and elastic properties.
7/27/2019 Module 4_Product Design and Process Technologies
7/18ISAT 211 CIM-7 1997-2000 M. Zarrugh
CAE:
More Types of Engineering Simulations
FE and finite difference models, used inthermalsimulations, 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 specificmotions and forces.
Electronic circuit designers use CAE tools
to verify the logic and timingof ICs, VLSI
devices and circuit boards. Show Ideas video clip
7/27/2019 Module 4_Product Design and Process Technologies
8/18ISAT 211 CIM-8 1997-2000 M. Zarrugh
Design Automation:
Technical Publishing
Product definition requires many documents created ondesktop 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 archivalof the documents.
Format translators and plug-ins required from
transferring documents across systems.
7/27/2019 Module 4_Product Design and Process Technologies
9/18ISAT 211 CIM-9 1997-2000 M. Zarrugh
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 processdevelopment and production cost.
Automation reduces errors, rework and promotes use of
existing solutions which shortens time-to-market.
7/27/2019 Module 4_Product Design and Process Technologies
10/18ISAT 211 CIM-10 1997-2000 M. Zarrugh
CAM Processes:
Computer-Based Automation in Manufacturing
Numerical Control (NC) and Computer NumericalControl (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)
7/27/2019 Module 4_Product Design and Process Technologies
11/18ISAT 211 CIM-11 1997-2000 M. Zarrugh
Computer Automation in Manufacturing:
NC/CNC
Numerical Control (NC) is the control of machinetools by a series of numerical instructions encoded
in an NC part program.
Computer Numerical Control (CNC) is directcontrol 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,
7/27/2019 Module 4_Product Design and Process Technologies
12/18ISAT 211 CIM-12 1997-2000 M. Zarrugh
Computer Automation in Manufacturing:CNC Essential Features
CADSTATION
IdeasOld DesignsCreativity
Standards
PartGeometry CAM
STATION
NC Programming
NCPrograms
NC or CNCMachine Tool
Speeds/FeedsMaterial & SizeTooling
Parts
Show video clip
7/27/2019 Module 4_Product Design and Process Technologies
13/18ISAT 211 CIM-13 1997-2000 M. Zarrugh
Computer Automation in Manufacturing:
Automated Process Planning (CAPP)
Computer Aided Process Planning (CAPP)is acomputer assisted process of preparing instructions onhow to fabricate a part or build an assembly.
CAPP begins with interpreting design data (geometryand 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 automatedyet since it requires human input to provide detailed
knowledge of current practices and capabilities.
7/27/2019 Module 4_Product Design and Process Technologies
14/18ISAT 211 CIM-14 1997-2000 M. Zarrugh
Computer Automation in Manufacturing:
Industrial Robots
Industrial robots are articulatedmachines that can move and
process materials under computercontrol in the factory.
Robots give consistentperformancein repetitive tasks: machineloading, inspection, monitoring,assembly, etc.
Robots can work in hazardous orunpleasant environments: spray
painting, arc welding, grinding,sanding, cleaning, handling
hazardous material
7/27/2019 Module 4_Product Design and Process Technologies
15/18ISAT 211 CIM-15 1997-2000 M. Zarrugh
Computer Automation in Manufacturing:
Industrial Robots
Robots can reduce cost since theywork at about the same rate as people,but cost about 1/2 as much as labor tooperate per hour.
Robots can increase productivity sincethey can work 24 hrs/day, do not needbreak or call in sick.
Robots can improve flexibility andsince tasks can be changed by a merechange of program, but people need tobe trained or retrained
7/27/2019 Module 4_Product Design and Process Technologies
16/18ISAT 211 CIM-16 1997-2000 M. Zarrugh
Computers Automation in Manufacturing:
Automated Testing and Inspection
Testing and inspection close the loop around processesto insure that they are producing the desired results.
Prototype testing reduces the number of design
iterations and quickly checks conformance to designspecifications.
Automated test equipment is used in electronicmanufacturing to insure that devices and circuit boards
are manufactured and assembled correctly.
Vision, Coordinate Measuring Machines (CMM) androbotic inspection systems are used in discrete and
process manufacturing to inspect parts and products.
7/27/2019 Module 4_Product Design and Process Technologies
17/18ISAT 211 CIM-17 1997-2000 M. Zarrugh
Computers Automation in Manufacturing:
Flexible Manufacturing Systems (FMS)
An FMS is a computer-based system in which machine tools andworkstations are arranged in groups orcells.
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 isflexibility:
Producing a mix of different parts on-demand
Dynamic routing of parts to maintain work load balance
Accommodating changing production volumes
7/27/2019 Module 4_Product Design and Process Technologies
18/18ISAT 211 CIM-18 1997 2000 M Zarrugh
Computers in Manufacturing:
Conclusions
Because of intensifying competition and acceleratingrate of change, CIM emerges as a strategic weapon withwhich business can adapt and survive in an everchanging and increasingly competitive businessclimate.
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