ANNA UNIVERSITY CHENNAI SYLLABUS (REGULATIONS -— 2021) ME3792 COMPUTER INTEGRATED MANUFACTURING L T P c 3 0 0 COURSE OBJECTIVES 1. To provide an overview of the evolution of automation, CIM, and its principles. 2, To lear the various automation tools, including material handling systems: 3. To train students to apply group technology and FMS. 4, To familiarize the computer aided process planning in manufacturing. 5. To introduce the basics of data transaction, information integration and control of CIM. COURSE OUTCOMES At the end of the course, the students would be able to: 1. Discuss the basics of computer aided engineering, 2. Choose appropriate automation tools and material handling systems. 3. Discuss the overview of group technology, FMS and automation identification methods. 4, Design using computer aided process planning for manufacturing of various components,. 5. Aéquire knowledge in computer process control techniques. UNIT I: INTRODUCTION 9 Introduction to CAD, CAM, CAD/CAM and CIM - Evolution of CIM ~ CIM wheel and cycle — Production concepts and mathematical models — Simple problems in production models ~ CIM hardware and software — Major elements of CIM system — Three step process for implementation of CIM — Computers in CIM — Computer networks for manufacturing — The future automated factory - Management of CIM ~ Safety aspects of CIM — Advances in cM. UNIT Il: AUTOMATED MANUFACTURING SYSTEMS 9 Automated production line — System configurations, work part transfer mechanisms — Fundamentals of Automated assembly system — System configuration, Part delivery at workstations ~ Design for automated assembly. Overview of material handling equipment — Consideration in material handling system design — The 10 principles of material handling. Conveyor systems - Types of conveyors — Operations and features. Automated Guided Vehicle system — Types & applications — Vehicle guidance technology — Vehicle Management ‘and safety. Storage system performance — Storage location strategies — Conventional storage methods and equipment — Automated storage/retrieval system and Carousel storage system — Deadlocks in automated manufacturing systems — Petrinet models ~ Applications in dead lock avoidance. Smart manufacturing — Industry 4.0 — Digital manufacturirig — Virtual manufacturing.and coding, Production flow an: method ~ Benefits of GT sh Ae bins Extended baleneck Sinn, ees re PHOChss PLANNING CCasifeaion of manufacturing processes ~ Selection of primary ee ee rt Toe re Sn to pone st“ Ca required. From design to planning ~ Flow chart showing various tivities in generative PP ‘planning — Comparison of CAPP and Manual PP. UNIT V: PROCESS CONTROL AND DATA ANALYSIS 9 cess model formulation - Linear feedback ‘control systems ~ Optimal o inputer process interface ~ Interface hardware — Computer pro« Direct digital control and Supervisory computer control. Overview of aut methods ~ Bar code technology — Automatic data capture technologies. (SPC) and automated inspection. TOTAL: 45 PERIODS 1g Applications of CAM. 4.1, Computer-Aided Process Planning (CAPP). . Computer-Assisted NC Part Programmi is CIM a Concept or: Reasons for Imple Potential Benefits of ClComputer Integrated Marcy 121. Safety Aspects of CIM. 4.22, Advances in CIM... Two Marks Questions and Answer Review Questions. Nitilii/ AUTOMATED/MANUFACTURI 24. Introduction to Automat 23. enn 24, Introduction to Automated Assembly System.. 4.1. What is an Automated Assembly Sys . Components of an Automated Assembly Syst ‘Applications of Automated Assembly Systems. Example of Automated Assembly’ . Overview of Material Handling Equipmer 2.9.1. Design Consid= Computer Integrated Mare 240. The t principe af Matec amg 210.1, Planning Princigts — Ss 2. Types of Vehicle Guidance Technologies 20 47. Vehicle Managements. : ile Dispstching ——————— AT 2106. Space Ustiniion Prissice— 5 2107. System Priscigie : 2 2108. Asomstion Princigle —————~ 5 182. Terminologies in Storage System Performance — 250 2.109. Enviroomental Principle 19. tos 2.10.10.Life Cycle Cost Principle ———————~ i 2.11, Conveyor Systems 2.12. Types of Conveyors ————_—<$ 221. Belt Conveyors... 2.21.3. Applications of ASRS eee 221.4. Components and Operating Features of ASRS —————___—21 222. Carousel Storage Syste aD 2.20.1. Types of Carousel Systems ee 2.222. Applications of Carousel Systems a 223, Deadlocks in Automated Manufacturing Systems ——————————" 2.23.1, What is 8 Deadlock in AMS? nee 2.93.2. Reasons for Deadlock Oceurt e268 a 2.23.3. Impact of Deadlocks nee Jlock Detection, Prevention and Avoidance 2243, How Do Petri Nets W: 224.4, Example of eet Net 225. Applications of Petri Nets in Dead Lock Avoidan: 226, Seg 2.26.1. What is Smart Manufacturing? 2 2262. Elements of Smart Manufacturing ..Computer integrated Mansfactry Contents @ 72263. Framework of Smart Manufaetr “Advantages of Smart Manufacturit fons of Smart Manuf yrmance Measures for Machin: ye Sequences in GT Cel mene 3.52 Handling and StorComputer Integrated Manufacey ing 23.1, Functions of the Material handli 3. 3.23.2. FMS Layout Configurations 3.233. Material Handling Equipment 3234. Types of Material Handling 324, Computer Control Systetim- Functions of a FMS Computer Control rl System 3.242. Structure of FMS Application Software Syst 3243, FMS Data Files. 3.244, FMS Performance Reports 325, Human Res0urces senna 3.26, Example of Flexible Manufacturing Systettow 13.27. Applications and Benefits of FMS wurn-nnsenone 3.27.1. FMS Applicatos 3.272. Economics of FMS. 3.273, Advantages of FMS (Bent 3.274, Disadvantages of FMS. 328, Quantitative Analysis of 3.29, Bottleneck Model. 3.29.1 Teminology and Symbol Contents 42.8. Communicate Process Knowledge. 43. Information Required for Process Plam (Get of Documents Required for P 4.4, From Design to Process Planning wn. Forming by Assembly. Forming by Material 48. 49. 4.10, 4.11. Typical Process Sheet. 4.12. Approaches to Process Planning 4.13, . Advantages of Manual Process Planni 4.134, Disadvantages of Manual Process Plana4,17. Generative CAPP System. ‘What is a Generative CAPP System 5. Some Commercial Generative CAPP Systems. Selection of a CAPP System. 420, Comparison of CAPP and Manual Process Planning... Two Marks Questions and Ans} Contents ‘What is a Programmable Logic Controller (PLC)... .dvantages of PLCs over Traditional Control Systems. ‘Components of a P |. How a PLC Worl Process Monitoring System... ‘of Computer Process Monitoring System. 4. Advantages of DDC 5.15. Supervisory Computer Co ‘What is Computer Process Interface’ >. Manufacturing Process DatComputer Integrated Maroc he Reasons for Using Automat 1 Automate Identification Technolo Types of Automatic Identification Technolo . Applications of ADC Technologi 521. Quality Management (SPC) and Automat Model Question Papers wun Introduction Learning Objectives igand after studying this unit, you will be able to: ons of CAD & CAM and the importance of CAD/CAM. ‘various types of production system ‘metics and calculate the various[u Introduction ia Sau8 Y The term CAD/CAM refers to Computer ‘Manufacturing, ¥ As its name implies, CAD/CAM uses the (digital) computers to aid the design and manufacturing process. In other words, CAD/CAM is concerned with the use of digital computers to perform certain functions in design and production. ‘Now we shall discuss the basic concepts of CAD, CAM, CAD/CAM and CIM, in Design and Computer Aided .2.4. What is CAD? Y Computer aided design (CAD) is an approach to product and process design that s the power of a computer. It involves the computers to create design ings. Y CAD may be defined as any design activity that involves the effective use of the computer to create, modify, or document an engineering design. ¥ CAD covers several automated technologies such as computer graphics to examine the visual characteristics of the product and computer aided engineering (CAE) to evaluate its engineering characteristics, ¥ CAD systems are powerful tools and are used in the mechanical design and geometric modelling of products and components. ©7 1.2.2. CAD Hardware and Software CAD hardware: « The CAD hardware generally includes the computer, one or more graphical display terminals, keyboard and other peripheral equipment.=~ Computer Integrated Meri cd by electronic input and oy boards are a ‘an archival storage device, 4 in ne, ass So as shown in Fig + In CAD, the drawing ices, an electronic Pl a printer, card reader, and bard Introduction [c} @7 1.2.3. Reasons for implementing CAD ‘The four fundamental reasons for implementing a CAD system are as follows: ‘of the designer. Using CAD, the designer can visualize components, subassemblies and parts. This reduces the » analysis and documentation of the design. It reduces ‘Fig. The hardware component of atypical interactive graphics (CAD/CAM) sytem ¥ CAD software: CAD softwares consists of (0 system softwares, and (0 application software. Y @ System software: + System softwares are used to perform/control the operation of the computer. These softwares are responsible for making the hardware components to work ‘nd interact with each other and the end user, * Examples of system softwares are the operating systeriis, all kinds of hardware drivers, compilers, and interpreters, ¥ @) Application softwares: * Application softwares, also known as application programs, are used for general or customised/specialized problems, * Examples of application softwares are AutoC, i -B, ANSYS, ‘ADAMS, we "AD, Solidworks, Pro-E, ANS © 1.2.4, Benefits of CAD Table 1.1 lists some of the benefits of implementing a CAD system. Table 1.1. Potential benefits of CAD in increased design productivity by lesign, analysis and drafting. ier to prepare a set of finished set of ort time, ive CAD systems have ‘accuracy in design calculations, because of CAD dimensional control.Computer beget Marictoyy Ta documentation procedures. The sing nd iD provide a common basis for desig rating a “Analysis -tnecring drawings: AlS0, ANY {YP of view rection of engineering ravi a q mae 2) on of ented ver GucKY and ecient, ong, Geometric, ¢ the 3D model is dawn CAD system allong rendering and shading ‘Manufacturing (9 Tooland fixture desion ; (i) Generation of NC (aumerial contol) part programming (it) CAPP (computer aided process planning) ; i») Models generated canbe utilized for rapid prototyping () Computer sided inspection (0. Preparntion of assembly ists and bi (id) Group technology (in coding and el n (vii) Robotics and materials handling equipment planning (Ge) Assembly sequence planning + NC part program verification "NC machine simulation + Inspection programming | : ‘Design standards © 125. Applications of CAD | ; | ©7126. besign P cap = Table 1.2 lists some important applications of CAD in different functional areas | resign Process ‘System (Elements of CAD System) mare ¥ The conventional design process has been accomplished on drawing boards with (Source: Tiea-Chien Chang eta.) F oy ves : 1 the design being documented in the form of detailed engineering drawing. pe Some inportent cop tictions ef CAD |v The conventional design process, also known as Shigley model, consists of the following six steps/phases: | 4, Analysis and optimization,al Computer Iara Marit “Fate eretlon and correctin of engineering sean an ct - be generated very avi a (isometric, perspective, e2) 2% the 3D model is drawn. design. CAD can drastically reduce the number of steps involved in the new design proves. Benefis in manufacturing. The benef of CAD in manufacturing can be realise in the following areas: (Tool and fixture design (i) Generation of NC (numerical control) part programming (iil) CAPP (computer aided process planning) (is) Models generated canbe utilized for rapid prototyping (Computer sided inspection (i) Preparation of assembly ists (vit). Group technology (in coding and (iil) Robotics and materials handling equipment planning (G2) _Assembly sequence planning © 125. Applications of CAD Table 1.2 lists some important applications of CAD in different functional areas [Source: Tiea-Chien Chang et a.J. Table 1.2. Some important applications of CAD vo ‘Manufacturing, * Inspection programming + Robot programming and verification out 71.2.6. Design Process in a CAD System (Elements of CAD System) ¥ The conventional design process has been accomplished on drawing boards with the design being documented in the form of detailed engineering drawing. Y The conventional design process, also known as Shigley model, consists of the 4, Analysis and optimization,Computer Iterated Maraciy, mS 5. Evaluation, and oe CAD | CAD, ae Said ‘asks are performed by ® ae system, Thy ), the design m . fur stagesoxnetional areas of @ CAD delet process 1 Geometricmodelling, 2. Design analysis and optimization, 5, Design review and evaluation, nd 4 ‘Documentation and drafting. ; . above four areas correspond to the final four phases of Shigley's ¥ The design proces, as illustrated in Fig 1.2. Modelling ee ere is concerned with computer compatible mathematica omic. modell a description of geometry of an object. ¥ Themathematie description of geometry should be such that: (p the image of the object can be displayed and manipulated in the computer terminal; ; ‘modification on the geometry of the object can be done easily; be stored in the computer memory; and be retrieved back on the computer screen for review, analysis or alteration, ¥ In geometic modelling, thre types of commands are used. They are: ( Commands used to generate basic geometric entities like points, lines, circles, ete (® Commands used to do manipulation work like scaling, translation, rotation, ete, ° The models can be represented in three different ways Wire-frame, (i) ‘Surface, and (id) Solid modelling, Introduction ea ‘Traditional design process ‘Analysis and ‘optimization Evaluation The analysis can be done either by using a specific program generated for it or by using general purpose software commercially available in the market. Y Nowadays sophisticated packages (such as ANSYS, Pro-E, CATIA) having capabilities are available to compute the various performance parameters accurately. Y Because of the relative ease with which such analysis can be made, designers are increasingly willing to thoroughly analyse a design before it moves onto production,Feld measeets iy be ESET 1 determine the eg Experiments and field moast 7 Bae emperarre, an ther Variables view and Evaluation oo cater — see is review and evaluation (0 check for any inerfrENC6 ety The nest Pe cae in onder t0 avoid dificlties during assembly’ oF use of ‘and whether the moving members such as linkages are going to operate pat and w imended. , ¢ By vsing the layering procedure, every stage of produstion an be checked; by tng ednaton he working of the meshanm ean be checked. Also, dug, me, eerie, the Fart is precisely dimensioned and toleranced as required fy manufacturing it, 4 Documentation and Drafting ¥ After anslysis end review, the design is reproduced by automated draft “machines for documentation and reference. | v ‘In this phase, detailed and working drawings are developed and printed. j ¥ The important fesnmss of sutomsted drafting are automated dimensioning, scaling of the drawing, development of generating sectional views, enlargement of minute art detsils, end shility to generate different views of the object (like orthographic) oblique, isometric, and perspective views). . ee = = pom (C180 may be defined as an effective use d tte mangicaringfocton the planing management, and control ° eee ‘0 assist in all the phases of manufacturing management, and quality coat, Production planning, machining, schedule © 1.3.2. Applications of CAM ‘The applications of CAM can be divided into two broad categories: 1, Manufacturing planning, and 2. Manufacturing control. Production function, Y The computer is used o' ‘management of production ai provide information for the effective planning and (vi) Production and inventory planning (¥)_Computer-aided line balancing ‘The above manufucturing planning applications of CAM are bs below, one by one, © 1.4.1, Computer-Aided Process Planning (CAPP) ¥ Process planning is an act of preparing detailed work instruc manufieture and assembly of components into a finished produc: part manufieturing environments, Y Process planning consists of: (the selection of manufscturing processes and operations, production and jigs and fixtures. Gi) the determination of manufé.cturing parameters; andComputer Integrated Maraecarg iter ity assurance (QA) me the specification of selection criteria for the quality trois to-ensure product quality. ‘ 1 The output of a process planning process production operations and associated mae assembly of the production. ; of Soaps process planing (CAPP) is used in order 10 overcome ge drawbacks of manual process planning. / The two basic approaches or types of CAP system are: 1. Retrieval (or variant) CAPP system, and 2. Generative CAPP system. «The process planning activities and various approaches to process planning ae presented elaborately in Unit IV. route sheet, A route sheet lists th, ine tools for each component ang 271.42. Comp od NC Part Programming ¥ Numerical control part program is the planned and documented procedure by ‘which the sequence of processing steps to be performed on the NC machine, ¥ The part program is denoted by a symbol (%) which defines the sequence of the machining operations and collection of the data such as spindle speed, feed rate, tool path, et, required to produce the part. ¥ Types of part progranuming: 1 Manual part programming, and 2 Computerasssted part programming. Tn computer-ssi i In computer-asisted part programming, computers are employed to assist in the Part programming process, especially for complex part geometries. v The je ei ae Part programmer enters the program written in APT ot ‘st: The input translation component converts the coded contained jy i oe inthe program into computer usable form, preparatory Inuroducton 7 Io (i) Arithmetic calculations: ‘The arithmetic calculations unit docs all the calculations to generate the part surface. (ii) Cutter offset computation: This unit offsets the tool path from the desired part surface equal to the radius of the cutter. (iv) Post processor: The post processor is a separate computer program, written to prepare the punched tape fora specifie machine tool. ¥ The sequence of the steps in computer-assisted part programming and their relationships to the part programmer and the machine tool are shown in Fig.1.3. Part Programmer fy crt aT Comps eb ‘aos Lal oor Lo] =| calculations ofset processor a Fig, 13. Steps in computer-assisted part programming Data Systems ¥ Computer programs have been written to recommend the appropriate cutting parameters such as speed, feed and depth of cut to use for different materials. ¥ Also, several attempts have been made to computerize the machining data. A computerized data system has the following advantages over a book type data bank san store data from different sources, san use shop parameters instead of theoretical and general date. ncentrates accumulated exper The database can be kept up to dat ‘Fast retrieval of selected data is possible. ce in an easily accessible form.Computer Integrated Manuf mo et oz 4, sible. «Rapid optimization computations f° tee a ann , ive cutting condi . + Comparison of alternative cu ‘ iy a= Compan etandard macining and geomemical frMNIGES Tovey |” bere the start ofits manufacture. * Cateuation concentrated form. Jays recommendations in 2 ao 7 With the use of computers, the several steps of the cost estimating procedure are iy computerized systems allow for User specification of 7 computerized. up speeds, feeds and operation factors. Y Computerized c iting is a program that can estimate the cost of a new “ing several of the key steps required to prepare the estimate © 1.44. Computerized Work Standards Wn of labour and overhead rates to the sequence of planned loyed to determing i *7 Tere wx several computer packages that can be employ rerutons). standards for direct labour jobs in the factory: | ¥ Thus, the total cost for a new product can be estimated by the computer program V They overcome tedious manual time study and motion study used fo perforn§ fy summing up the individual component costs from the engineering bill of same ask. | mates, 1 Also, these computerized systems ee eae ee "OPE 4.4.6. Production and ventory Planing time standards, standard cost data, tooling information, J nt 8h $7 Production planning is a pre-production activity. It is the pre-determination of ¥ The computerized systems are based on the use of standard data of basic wo} manufacturing requirements such as manpower, materials, machines, and eles soe in compuer erin sdf leo nthe form of a mattensiyenutcaing process. formula. |v Production planning is concerned with: ¥ To use the package, the time study analyst first analyzes the job to be timed} (j) deciding which products to make, how many of each, and when they should dividing it into its elements and specifying the attributes of the job for be completed; clement. The computer then retrieves from the file or calculates the element ting sums the times, and applies the necessary allowances to determine the time for the total eye. scheduling the production and delivery of the parts and products; and. planning the manpower and equipment resources needed to accomplish the production plan. juction planning ac 1. Aggregate produc 2. Master production »chedule (MPS); 3. Material requirements planning (MRP); 4 ' ¥ The advantages of using a computerized system for generating time standal 7 prog, ae: @ Reduction in time required to set the standard, Greater accuracy and ‘uniformity in the time standards. a of maintaining the methods and ‘standards file. Elimination of the biased performance rating step. 5. Setting the time job gets i — ie ee before the job gets into production. lv The computers are W frecarng ee eRg database for production. planning, schedult activities. #8 labour requirements, tool control, ec, : y employed in all the above production planning | | | |= Computer Integrated Manufacy ay GS © 1.4.7. Computer-Aided Une Balancing ee ¥ The line balancing problem is concemed wit ae ‘so that all workers have an €q gram helps to find the best allocation of yoy ¥ A computer-sided line balncing ros clements among stations on an assembly line. a ¥ Such computer-aided line balancing program can cece situations where wy, line balancing problem is particularly complex and difficult, owing to the nun, of workstations, and complicating factors. / © 148. summary ; ; Table 1.3 summarises the above important applications of CAM in manufactur planning. Teble 1.3. Applications of CAM in manufacturing planning Application Description | Inureduction Application Production and inventory planning Of inventory records, stock items when inventory is depleted, production scheduling, maintaining curr ‘Computer-aided line balancing 1. | Computer-aided Y This is concerned with ereation and disseminatol process planning of route sheets that list the sequence of operatic (CAPP) and work centres required to produce the pro and its components. 2. | Computer-aided NC pon programming ¥ This application supports the creat assisted part programmes which represents a more ef Y This is concermed with eres nat of part programmes that can determine opti 3. [Computerized ‘machinability data systems cutting conditions for machine tools in the factory, 4. [Computerized work | V These are computer packages that ean be deployel standards to determine time standards for direct labour jo Cost estimating J 4.5: MANUFACTURING CONTROL APPLICATIONS OF CAM = ¥ The manufacturing control applications of CAM are concerned with developing ‘computer systems for implementing the manufacturing control fun ¥ Manufacturing control is concemed with managing and controlling the physical Process monitoring and control Quality control ‘The above manufacturing one by one. computer to monitor and control an industrial process.cess control: js used t0 Only collect sontrol, the computer ter pro’ ¥ Computer process monitoring VS COMP! epbet + In computer process monitoring: WO from the process, whereas in comput rocess r0CSS Monitor ps i 4 illustrates the difference between computer PF Monttoring ag + Fig4 i computer process control. Prone vrcbles ‘Computer = eta cobeton Ya) Computer process monitoring = — wing t ‘Computer Process Data cotocton (8) Computer process control Fig. 14. Computer process moniioring and control Y It should be noted that the computer is not used to directly control the ‘mamufacturing process. Control remains in the hands of humans who use the dis to guide them in managing and operating the process, But the data provided by ‘monitoring will result in improved supervision of the process. Teele. © Computer Process Monitoring for process monitoring. s eae {0 the technology and applications of automa! iter process. ‘Monitoring are: Introduction the dy | (i) Computer Process Control ¥ Computer process control is a process of cont variables with the use of computers so as to acl the controllable input the desired performance evaluation variables. ¥ The computer process control can be achieved by employing various control strategie 1 2 3. 4 5, 6. important process control strategies are: Feedback control strategy, . Regulatory control strategy, Feed forward control strategy, |. Preplanned control strategy, ._ Steady-state optimal control strategy, and Adaptive control strategy. © 15.2. Quality Control quality levels in the manufactured produet. ¥ Some of the modem technologies in quality control are outlined below. @) Quality engineering, (©) Quality function deployment, (Non-contact sensors such as machine Coordinate measurement machines for dimensional measurement, and for inspection. (a) Quality Engineering engineering encompasses a broad range of engineering and jective is to ensure that a product’s qualityCooper egret Manic SS (b) Quality Function Deployment sea aystem for translating. consy ¥ Quality faction deployment (QFD) F6 8 NPT som research ty = requirements into approprisie TR fecture, distribution, installati product design and development, 10 manuf 1On any marketing, sales and service. ¥ The QFD translates the voice of the requirements at every stage of design and manufacture. (0) 100% Automated Inspection , 1 100% extomated inspection isthe axtomation of one oF more of the steps involye, in the 100% inspection procedure. ee , V The 100% szomated inspection is best achieved when it is integrated into manufacturing process. j (4) Ontine inspection | ; | Y Online inspection, also known 2s in-process inspection, is achieved ‘performing the inspection procedure during the manufacturing operation, | Vln this method, es the parts are being made, the inspection “ castomers into technical and functions simultaneously measures or gatiges their dimensions. (e) Coordinate Measuring Machines (CMM) The coordinate measuring machines (CMM) are the most versatile equipment. for contact inspection of parts. These machines are controlled by computers « sumerical control systems. ¥ When a component is to be inspected for its profile and other features, the pro ot coordinate date is downloaded from a central computer. The systems ar, ‘opable of transmiting data from the measuring machine back to the computer. * The main advantages of using CMM over manual inspection methods are: @ Increased productivity, Gi) More fexiitty, ] (i) Redoed operator enor, and | Gv) Greater inherent accuracy and precision, sri identification, visual guidance and control, and safety monitoring. © 15.3. Shop Floor Control ¥ A shop floor control (SFC) sy shop floor as well as data pro. information on shop orders and Shop floor control (SFC) is concemed with: ied as @ system for utilizing data from the les to maintain and communicate status (D__ the release of production orders to the factorys, Gi) monitoring and controlling the progress of the orders through the various work centres; and iii) acquiring information on the status of the orders.= ia oa Cae ee C—O Introduction i } Lt Application. ine Bpseatea cea icon et nae ot costs of holding inventory; and maximizing production systems deliver the Hight components to downstream workstations, at 3th production operations and supplier Y The two ypes of inventory models are @_Fixed-order quantity models (Q-models), and Gi) Fixed-time period models (P-models). & 1.5.5. just-in-time Production. ‘Systems Y Sust-in-time (JIT) is a management philosophy that strives to eliminate sources of ‘manufacturing waste by producing the right part in the right place at the right time, ¥ JIT is also known as stockless production. Y The ideal JIT production system produces and delivers only the required items, at the required time, and in the required quantities. & 15.6. summary 4 summarises the above important applications of CAM in manufacturing Table 1.4. Applications of CAM in manufacturing control Factory Managoment ‘Automated Dratirg Fig. 1S, CAD/CAM Interface Y The integration of CAD functions with CAM applications gives the acronym CADICAM.mo engineering VCADICAM is concerned wil ‘manufacturing. , ¥ tu denotes an integration of design ans ‘computer systems. i ign and com) fit yuter-aided desi 1 Buettner seme ‘establish & direct link betwe ts ofa CAD/CAM interface. Jemen ¥ Figs.1.5 and 1.6 illustrate thee 1g departments share @ commoy «+ Fig1S shows that the design and manufactrin database [Source: John K. Krowse] ‘+ ‘The user can interact with eomputer all the design and manufacturing activi rt programming |_Pectprooramming | Tool dosion snared |---| DATABASE Matoale ordering ‘Manufacturing Fig 16, Elements of CAD/CAM interface Y The CAD/CAM combination allows the transfer of information from the design Stage into the stage of planning for the manufacture of a product, without the need fo re-enter the data on part geometry manually, The database developed during CAD is stored; then itis processed further, by CAM, into the necessary data and instructions for operating and contolling production machinery, material-handling equipment, and automated testing and inspection for Product qu ‘words - computer, integrated, and manufacturing. of computers in manufacturing in an integrated way. planning and design of a product ing cont computer technologies in order to manage roaches, the purpose of CIM is to transform leable goods at a minimum cost in the the design of a product (CAD) and ends ith CIM, the customary split ystems tied together by a single integrated the database, a CIM system can direct results, and maintain accurate data. So we can say on of design, manufacturing, distribution, and ‘one coherent system. © 1.72. CIM Defined ‘A number of definitions have been developed for CIM. Some of them are givenCompute Inesrated Marjo, otal integration of al com getting the 3. CIM functions of the firm as well CIM isthe Integration of the total mo = Mikell P. Groo philosophies that improve organise © 1.73.Scope of CAD/CAM and IM ; facturing planning gy includes design, manufect The scope of CADICAM i . manufacturing control a ical applications of CAD/CAM include: v srs for NC, CNC, and industrial robots sign of dies and moulds for casting for metal working operations Process planning and scheduling * Plant layout ¥ Computer Integrated Manufacturing (CIM) includes all of the engineerin functions of CADICAM, but it also includes the firm's business functions that o i technology to all operational functions in manufacturing, fr shipment, CAD/CAM, of the factory. mation processing funct ‘order receipt through design and production, to prod ‘the other hand, does not cover all the business functions —___ "this popatar dt Sovety of Manuf nen by the Compu (SM) US nae HM Automaton Systems Association (CASA) ott ved in converting FW matergg DICAM and also the busing acai enerprise through the weg] oupled with ew Manager| Integrated systems and data Commun sunel efficiency. ~ CASA/SMe] Introduction The scope of CAD/CAM and CLM ‘an off-the-shelf product, it is a concept, an environment, an objective, a lowever, we need mi technology to implement/achieve the CIM environment. Thus, CIM is also a technology. ¥ According to Vajpayee and Reiden, CIM is both a concept and a technology. For top management, CIM is a concept, a blueprint for success. For middle ‘management and line managers, CIM is a technology, a physical realization of resources that are more capable and flexible. © 1.7.5. Reasons for Implementing CIM [Why CIM?) Though there are several answers to the question ‘Why CIM?", the main five reasons are given below: 1, To mect competitive pressures Any firm, in order to survive successfully, needs to face the following competitive Pressures:Computer Ingrted Marita Gs) jn) looreased quality, a Increased repoasiveess to customers, ete : 7 a i ‘channel for Linking together the logical organisational a4 ct seis he Esp tet ove compestve DESIR msmofsctaring activ Cette pe “a ee es a ‘éexa, operational data, performance data, ef¢. associated with its use 3.To eliminate paper and the costs 7 (CIM exes information tg be sored electronically and displayed on terminaly “Thos, with document imaging and docuneat management techniques, the eliminatiog cof poper sd its associated costs is third reason for CIM. | 4 To automate communication within a factory and increase the speed (CIM sxomses communication within the factory and thus increases the speed, ‘The networks of 2 CIM implementation permit the sending of messages, memorand; oi documents by electronic mail over long distances. So the arrival of ‘nformation/messege/document is concutieat with its dispatch. | 5. To faciitate simultaneous engineering | ‘Simaltmeous or concuxent engineering is a methodology of restructuring the oduct development activity in en organisation using a cross functional team and is¢ technique adopted to improve the efficiency of product design and reduce the product esi qyle time. With CIM system, simultaneous engineering can be easily inplenented. | | © 178. Potential Benefits of CIM | ones of the various technologies makes it possible to realize the 1. Creation of a tly interactive ! uy int system that enables manufacturing functions 10 _ seen, ‘easily with other relevant functional units. | ‘courte data transferability among the manufacturi ing luce at inplanr a le cturing plant or subcontracting IntroductionCompster Integrated Mamifictring Gap be Ge evolution of computer graphies and the by Ivan Sutherland “at the Maeuteirag ‘ering RE H) Fig, 1.8, Automation Timeline ‘Source: Janes lig} Design snd Drafting) were coined and used. > Concepts of Computer Numericel Control (CNC) and Direct Numerical Control (DNC) were developed. + The phrase “ Maton ef roqutemons ‘cess planing panning (MRP) (caPp) |-+— tecrtoay 1920)rer Integrated Manufacy Introduction ——___— SOS ¥ The CIM wheel captures the concept of total integration of all industrial functions. ¥ The CIM wheel lists 21 aspects of company operation with a number of interconnecting arrows and with a central core of integrated systems architecture and information system management. + The central core—integrated systems architecture - handles the common date and is concerned with information resource management rates ed for ASME Tae intial version of CIM wheel, ast ., the radial sectors surrounding the core) represents the wufacturing such as design, material processing, and ings: manufacturing planning and control, product/process, and factory automation. ‘The outer rim represents the management functions. Those functions are grouped under four categories: strategic planning, marketing, manufacturing and human resource management, and finance, ¥ The CIM wheel emphasizes the totality of the integration as well as the requirements to have both an architecture to provide the integration and a strategy relating to the organisation and management of company information and data. (@)) 2.10. THe New, MANuFacTURiNG ENTERPRISE WHEEL ~[CASA/SME MANUFACTURING ENTERPRISE WHEEL] e x | ¥ It may be noted that the CIM wheel introduced above (Fis was devised by the Computer and Automated Systems Association of the S of Manufacturing Engineers (CASA/SME) in the 1980s. Since the manufacturing world is always changing, the CASA/SME has established the new CIM wheel addressing the changing needs requirements to CIM in the 1990s. ¥ Fig.1.10 illustrates the new C™M wheel developed by CASA/SME. The new CIM wheel, besides showing the interrelationship among all parts of an enterprise, focuses on process improvement and provides a framework process re- engineering. That's why w CIM wheel is also known os mamufécturing enterprise wheel. CIM wheel has six major areas/sections/segments, as shown in is in Fig.1.10. sheel-an embodiment of the concept of grated manufacturing {SenceheScey of act gers CASUSHE. Sento 185)computer Integrated MOMtrig 'Infrastr; Ucy @ ture LSoare The Scie of Manfactring Engineer, Dearborn Michigan Copyright 1993, Third Eatin, ‘Segment 1: * Obviously eustomer is the hub of the CIM wheel, because customer is the rimary target for all marketing, design, manufacturing, and support efforts in the erprse, | Fig. 1.10. SME New Manufacturing Enterprise Wheel Introduction The sources used to sector surroundi ‘wheel hub focuses on the shared corporate knowledge, systems, and common data used to support people and processes, ieve this goal include manual and computer tools to aid ion, documentation, decision making, and control of every tor comprises three main categories of processes: ‘manufacturing, and eustomer support. ‘group includes fifteen key processes that form the product ‘A. Product/Process definition Component design Continuous improvement B. Manufacturing 9. Assembly and test 10._ Material management ©. Customer support 11. Global organisation 12. Definition ‘the enterprise, ‘Segment 5: * The next radial sector represen ironmental obligations. 1 resources and the responsibilities of ude capital, people, materials, management, to employees, investors, and the community, as arkets, communities,Hi Computer Integrated Manufactring ipasses all finance. a tel irate, Cpl ee of personnel and ‘enterprise az its mi © 111.1. Introduction Y Production is the sequence of operat form to another is carried out “Ths transformation ffom one desired products. This oem rations whieh transform the given materials ing of different manufacturing processes. citer conor a combina 1 components (physical and conceptual) ‘ ‘ Y A system is @ logical arrangement Gesignd to asheve objectives according toa plan. concen cups fr proces expt Fig 11d. Productive systems as transformation process ¥ A production system is the framework within which the conversion of input into ‘Output occurs. At one end of the produetion system are the inputs and at the other ‘end outpus. Inputs and outputs are linked by certain operations or processes which impart value to the inputs and are called transfor A simplified transformation process is shown in Fig. Introduction 133] eee omen een DS) | © 1.11.2, Types of Production Systems According to volume and standardisation of the production of the products, the production systems are classified as: 1, Job shop production, 2, Batch production, 3. Mass production, and 4, Process or continuous production. 41. Job Shop Production Y Meaning: Job or unit production involves the manufacturing of a single complete unit as per the customer's order. This is a ‘special order’ type of produetion. Each Job or product is different from others and no repetition is involved. The work is started only when the organisation has orders on hand. . 1 to the regularity of manufucture, there are three ppes of job umber of pieces produced once. II number of pieces produced intermittently when the need arises. Very large work-in-process inventory. ; it in planning, scheduling and coordinating the productions of yerous components of wide variety.ted Marne computer Integr iting in large vas 2. Batch Production made in small batches and in InrBe Varig, Y Meaning: In a nt every batch is different from the others, ach bash contains identical ¥ Taree pes of batch production sre is intervals, when ely at irregular intervals, 4 } a ee pray ‘at known intervals, to satisfy continuoy, BA demand. Y Characteristics: ( A large variety of products are manufactured in lots or batches. (@ Both general purpose machines (for producing parts) and special purpox machines (for assembling the parts) are used. (Gi) Flow of material is intermittent. Gv) Plant layout is process type. (8) Flexible material handling system. Merits: (@ Short production runs. lant and machineries are flexible. ‘Medium variety and medium Large work-in-process inventory. G3) More number of set-ups, ii)“ Workloads on various machines / sections are unbalanced. Civ) Process and product planning is to be done for each batch. ¥ Suitabitity: Drugs, clothes, paints, parts manufactured on turret ‘machines and sheet meta presses ate afew examples of batch produ: Introduction = —_ | 3.Mass Production ¥ Meaning: In this type of production, only one type of product or maximum 2 or 3 types are manufactured in large quantities. Standardisation of products, process, ‘materials, machines and uninterrupted flow of materials are the basic features of this system. Mass production system offers economies of scale as the volume of Flow of material is continuous. Special purpose machines are used. Mechanised material handling systems such as conveyors are used. ‘The machine capacities are balanced. ‘gree of mechanization or automation is high. cost of production. electricals, automobiles, bicycles and container industries, ‘mass production industries. of production is used for the manuficture of those items continuous and high. Here single raw materials can be fferent kinds of products at different stages of the production rocessing of crude oil in refinery one gets kerosene, gasolene, se of production.¥ The characteristics, . same as those of the mass production system Y Sutabitiy:Indstes like paper, fetes =e € 4 few examples of continuous production industries rent, chemicals, autom Computer Integrated Marafacin, is ion system are 4} sts and demerits ofa continuous production System are gy , merit ee, roduetion are also known as tafermittent produc), [az] Tj sep ean nd es onan roducton tm ‘stems. The mass production and process : Fig. 112 illustrates the types of production syst used. Fig postion yout Process yout T ‘Continuous reduction Protetverety — & 20 ep Bac Productiayout tw Production Quaty tow 00 ¥0}00017900,600 igh fems and their respective la Fig. L12. Types of production and layouts used for different levels of © 1.11.3. Comparison between Types of Production ‘production quantity and product variety ‘Table 1.7 compares the differences between various production system. Table 1.7. Comparison between types of production Function of Job Batch ss | Continuoss comparison production, reduction roduction roduction enna p roduet produc eee Very low Slow Fast Very fast Production setup time Very high High Less. less a = Moderate ‘Small ‘Small in is w | Varies; Moderate High Introduction Labour control of : -, Madame the product value Very high High Mediuen Low Sem | ste [ cman | aan retncain |i] gee | St ma e.g. Medical s- lai eg. Power s Automobiles. semicals face” [Stes ce Easy Somewhat easy Very difficult | Not possible ‘Mostly general intensive) General purpose and Special Special purpose | somespecial | PPS | prmose ee ee Fixed postion Frode Tatar | Process layout | Process layout 7 Low (labour | Medium (labour | High (Capital intensive) intensive) (Gia. 27 INTRODUCTION TO MANUFACTURING METRICS ted measures that facilitates the of production.Computer Integrated Manny a DF Why use manufacturing metrics? ystemn in successive Periods (say ion = To track aoe of the producti aS eee jas of the potential new technologies ayy i fits, and demerits of = To determine the merits system; + To compare alternative methods; and + To make good decisions. . i f manufactur je ing metrics: The two basic categories of tung ¥ Categories of manufacturing metrics are: 7. Production performance measures, and 2, Manufacturing costs. 4. production Performance Measures : | 1 The production performance measures are metrics used to quantify the, prod performance. ‘The production performance measures commonly used are: . Production rate, Plant capacity, cycle Time (T,) The operation cycle time (T,) is the total time from when the operat begins 1 the point-of-time at which the operation ends. Introduction oa CM ¥ In other words, the cycle time describes how long it takes to complete a specific ‘operation from start to finish. ¥ Unit of cycle time is minutes/piece (inin/pe). ¥ Inatypical production operation, the cycle time consists of: actual processing time, workpart handling time, and tool handling time. ‘Typical cycle time for a production operation is given by T= 1+T tT, T. = Cyele time (min/pe), T, = Processing o T, = Handling time (min/pe production machine), and Ty ~ Tool handling time (min/pe) (e.g, time to change tools). we (Ll) »peration time (min/pe), -8., loading and unloading the © 1.13.2.Production Rate (Rj) Y Definition: Production rate for an individual production operation is nothing but the number of work units completed per hour. ¥ The production rate is usually expressed as an hourly rate. Thus, the unit of production rate is pe/r. Y Formulae to find production rate (R,): 1. Production Rate in Job Shop Production ¥ Injob shop production, the time to process one work piece is the sum of setup time and eyele time. ¥ The production time per work unit (T,) is given by speed fn the product needs to be produced in order to satisfy the needs of the customer. [Net Time Available for Production ‘Customer's Daily Demand! In formulate terms, TAKT time =computer Integrated Maroc) eenee) (a) where anton ime per work unit (itv) = Producti fs = setup time (min’pe) and a j ofthe machine isthe reciprocal 60 Y The production rate By (13) J, = Hourly production rte (pe/ht), and = “T= Production time per work unit (min/pe). tp Produ duction : a Se tah pocsing Be (Fy) for a batch size of Q work uniy vin is givenby se T= Tet QT. where Ty = Batch processing time (min), Ty, = Setup time per batch (min/batch), Q = Batch quantity (pc), and by where T, = Cycle time (min/pe). Now the average production time per work unit (T,) for the given machine is give oo 5) T,, = Average production time per min (min/pc). The production rate (R,) of the machine is given by 3, Production Rate In Mass Production For mass production, we ean write Setuptime ~ 0 Se Production rate = Cycle rate of the machine ¥ Therefore, the production rate (R,) in mass production is given by oo (1.6) R, = Hourly production rate of the machine (po/ts), rate of the machine (pe/hr), and T, = Operation cycle time (min/pe). where © 113.3. Production Capacity ¥ Definition: Production capacity, also known as capacity or plant capacity, is defined as the maximum rate of output that a production facility is able to produce under a given set of assumed operating conditions. The assumed operating conditions refer to the number of shifts per day (one, two, or three), number of working days in a week or month, employment levels provisions for overtime and so on. ¥ Now-a-days, automated production facilities are employed to increase the plant capacity. Y Formulae for production capacity: 2, Production capacity for production facility In which parts are made in one operation (n, = 1): PC, = n-S,-Hy-R, (LT) PC, = Weekly production capacity of the facility (units/wk), n= Number of work centres working in parallel producing in the facility, S, = Number of shifts per period (shifvk), Hy, = Number of hours per shift (hr/shift), R, = Hourly production rate of each work centre (units), and ng = Number of distinct operations/machines through which work units are routed. wherecomputer Iterated Maren 2. Plant capacity for production operations (n,? 31: ] work centres, all (Eempie ET) sduction facility has five product 7 ea ‘The faciliy operates 8 hrishif. 2 shifisday, an ene spine is 15 units/hr. Compute the i zach mac ‘5 days/wk, Average production rate of each mac cae production capacity ofthe proauction fei) ‘Number of work centres, = 3 Given data: Number of hours per shift, Hy, = 8 brishift ‘Number of). { Number of i _ | Sune fe ‘Number of shifts per week, Sy = { shi per xf daysper = 2 shifvday x 5 day/week = 10 shifweek Hourly production rate} p= 15 unit aE enae Be ~ 150i To find: Weekly production capacity (PC,) © Solution: We know that the production capacity for a production facility, PC, = n-S,-Hy-Ry = 5x10%8x5 = 6000 output unitsivk Ans. -> (U) is the ratio of the number of city. ccan also be defined as th: is operating relative to the time available unde ation of the production faci production facility re ¥ Formula: The wilizaton of te facility is given by = Qutput U Capacity * 100 Q = Actual quantity produced by the facility during a given time period (pe/wk), and PC, = Production capacity for the same time period (pe/wk). ¥ The uilization provides a measure of how well production facilities are used, they are available. tion is high, that means the facility is being operated to its full ‘week, the machine produced 775 units and was idle the remaining time. (Determine the production capacity of the machine. (i) Compute the ‘of the machine during the week under consideration? Given data: Number of work centres, n= 1 Number of shifts per week, S, = 1 shifV/day x 5 day/wk = S shifvwk Number of hours per shift, Hy, = 8 hr/shift Hourly product rate, R, = 25 univhr To finds: Production capacity (PC,), and Utilization of the machine (U). © Sotut @ To find production capacity (PC,): We know that PC, = 2-S,-HasRy = 1x 5x8x25=1000 output unitsivk Ans. “© (i) To find utilization of the machine (U): Given that actual output during the week under consideration, Q = 775 unitsComputer Integrated Manat, 715.199 = 71.5% Ans.-© vitianion,U = pox 197000" 10° 25.5. A0aTSE of reliahiliy for equipment and is usually: exPressed ay ameasure of pment in the plant ar, re of how well the equipm ity provides @ measur riced and maintained. -_ ¥ Tomas: Te availability (A) is mathematically given by MIBF_-MTIR F ‘MIBF—MTTR 100 A= SMB ‘A = Availability of plant facility (percentage), MTBF = ‘Mean time between fail lures (hr), and MTIR = Mean time to repair (hr). ¥ The MTBT indicates the average length of time the equipment runs betwee V the MTR indents the average time required to service the equipment and put ‘back into operation when a breakdown occurs. +++ (10) [Baie] exect of svitaitty and Uszatton on Plant Capacity: The production cape (cqpaion (17) aking it account the avalbliy and wlzaton ofthe machine, s given by PC = A-Us(n-Sy-Hy- Ry) [Exampte 1.3 The 48 200 hours, and the me ‘machi Given time between failures for a certain producti 1 10 repair is 5 hours, Determine the availability of te MTBF =200 hr; MTTR=5 hr. Tofind: Availability of the machine (A). © Solution: The availabilty f the machine is given by MIBF-MTTR | A= 100 Introduction = rr——CUCUCUCOCOWCONC*tCCCiéiésC = 200-5 2 300 * 100 = 97.5% Ans. -—e of the machines = 95% and the te expected plant output, ity = 95% = 0.95; utilization of the machines = 85: Given data: Refer Examp! uU=uUt To find: Plant output ie., plant capacity. © Solution: We know that the plant capacity taking into account the availability and utilization of the machines, PC, = A-U(i-S,-Hy-R,) = 0.95 x 0.85 x (5 x 10 x 8 x 15) = 4845 output units Ans. -© © 1.33.6 Manufacturing Lead Time (MLT) Y Definition: The manufacturing lea: ime (MLT) is the total time required 10 Process a given product (or work unit) through the plant. ¥ The MLT includes both operation cycle time and the non-operation cycle time (which includes handling time, time spent in temporary storage, inspection time, time last due to delays). ¥ Significance: + MLT determines the ability of the manufacturing facility to deliver the product to the customer in ihe shortest possible time. + The manufacturing firm with lower MLT will have a competitive edge, as it has the ability to deliver the product quickly to their customers. ¥ Formutae for MLT calculation: 1. MLT for Batch Production ‘The manufacturing lead time for batch production is given by MLT = n(n QT. + Toe) where, MLT = Manufacturing lead time for a part or product n, = Number of distinct operations through which work units are routed,= —- poets 7 sep eerste ES = 5 [150+ (150 x 5) +360] = 6300 min St SS ene! Conse SNES 6300 min Lo New son Gene ssoisred with the machine (tain), MLT = G60) minday 7 13425days Ans -w © 1.13.7. Work-In-Process (WIP) pop Prodan -. getpad by cuba «| ¥ Definition: Work-in-process (WIP) is the quantity of parts or products currently eS ~ eat sie far Sb shop production is obetinad Py substingy located in the factory that are either being processed or are Berween processing a atts : |.12) 55, ] oO weneng-lnepseO OF Tae sj) v WIP is inventory that is in the state of being transformed ftom raw material to | finished production. panties Pon : |v Formula: The work-in-process can be computed using the relation, ne pemenng int tae Sir Ge GEE OPE mE prediction (Gig A-U-@C)- MED Tey Oem EES sag mT =O Begs we opeion ele we - SES (15) Peete S : m Fo ge manne ete he sop hs been comsplsand end procction Beeins: | where WIP = Work-inprocess in the facility (pe), > per=tl — A= Availability, 7 U = Utilization, PC, = Weekly production capacity ofthe facility (pe'wk), FE niesion tie surge cperaion time i 5 in, cad the average Non-operaiy MLT = Manuficnsing lead ine (08), Foe Gam boeing cigs impeccions, Gx, is 6 hows for each operat Sy = Number of shifts per week (shiftw&), and Geen te mmc of dps # will tke 10 complete the batch Te H,, = Number of hours per shift (bishif). Bie sigh, ¥ The work in-process is considered as waste in the manufacturing philosophy. The @acax WIP may be reduced by automating their operations. =e (Eameee TE] A certain part is rowed trough six machines in a batch Barb se,Q = 150 mis (production plant The setup and operation times for each mackine ore given i Avmage sexy tne per beck, T,, = 25br=25x60=150 mines] Table 1.8 Juma qe Soe pe pea T, = Smin'pe Jomap mooepemion tae, T, = 6 how = 6 x 60 = 360 mi To find: Nome of days it wl take 9 comple the bench, which is nothing bt Se memos ee LT), | (© Solacion: Tos mamatacering le ne for batch production is given by MOT = 2,0.+Q-1,+T)compe erated Marian, ie the mar ° petmin the proton rte for OP ‘amber of distinct operations/machit <).na -- Through which work units ze rou Batch size, Q = 100 Ty = 12hr= 12x 60= 720 min ration 3. “Average non-operation time per machines Tosinds (0) Manufacturing lead time (MLT), and (6) Production rate for operation 3 (Ry). © Solution: ad time (MET): (@) Tofind manufacturing lead ti : ; Fit let us call the average setup time per machine oo and the average ‘operation time per machine (T,) using the data given in Table 1.8. mae : . 44248434344 ‘Average setup time per machine, Ty, = = nf = 4hr = 4% 60=240 min $4354 10419 +4.1+25 6 and average operation time per machine, T, = = 4.5 min I ‘We know that the MLT for batch production, MLT = 116(T+Q-Te+Tyo) = 6 [240+ (100 x 4.5) +720) = 8460 min or 14. hr Ans.-© () To find production rate for operation 3: In batch production, the batch processing time (T,) for operation 3 is given by } T= TatQ-T, { Here Ty, = 8hr=8x60= 480 min; T, = 10 min for operation 3, from Table 1.8 Introduction = eS eI Ty = 480+ 100 x 10~ 1480 min ‘The average production time (T,) for the machine 3 is given by T, _ 1480 Ty," 97 foo 7 48min 2+ The hourly production rate (R,) for operation 3 is given by R= R- = 405be Ans.-© [Gzmmple 17) The average part produced in a certain batch manufacharing lant must be processed sequentially through six machines on average. There are 20 new batches of parts launched each week. Other pertinent data are as follows: Average operation time = 6 minutes = Shours Average batch size = 25 parts Average non-operation time per batch = 10 hr/machine There are 18 machines in the plant working in parallel. Each of the machines can be set up for any type of job processed in the plant. The plant operates an average of 70 production hours per week. Scrap rate is negligible. Average set (@) Determine the manufacturing lead time for an average part. (®) Determine the product (©) Determine the plant @ Determine the plan (@) Determine the average level of work-in-process (number of parts-in-process) in the plant, Given data: Number of distinct coat} in. = 6 machines through which work units are routed T. = 6min 12, Tyy = Shr=5 x 60= 300 min ‘Average operat ‘Average se Average batch size, Q = 25 units= 18 18 703.33 ‘Number of workers woking in PB? mS, - Hy 70 brik im 6 = 699.3 ~700 output unitsAwk Ans. -© time = Pel eeaaaed | @ Tofind the plant utilization (0): Tofinds (a) Maoufscring lad ne MLD: | We know that the plant utilization, Production rate yi u = x10 (© Plant capacity PC.) _ utilization (U); and where Q = Actual output during the week @ Plast (©) Work-in-process (WIP). = Number of batches x Batch size : = 2025500 © Solution: Tofiad manufacturing lead time (MILT): ‘+ Utilization, U = 322 100 = 71.43% Ans. or etaing ead tine fr bic protvton is iven by a The | Tofind the average level of workcin-pracess in the plant (VIP): MLT = 1, (Tq,+Q-Te+Tno) = 6 [300+ 25 x 6)+ 600] = 6300 min or 105hr Ans,q The work-in-pro\ (EE) marinweck = (10s (70 uM) = 15 we () Tofind production rate (R): Itbatch production, the batch processing time (T,) is given by Ty = Ty tQ-T,=300+ (25 x 6) = 450 min ‘Then the average production time per work unit (T,) is given by _ —_ eee Ty 450 C ‘Vist |KEY ELEMENTS) IMPLEMENTATION) T, = Q7 95 7 18min ‘The production rate (R,) of the machine is given by 60 _ 6 Ry = 7 = 1g = 333 pefhr Ans.-o (© Toffind plant capacity (PC,): We know that the plant capacity in whi . | (> 1) is given by capecity in which part requires multiple operatiot ECTION: AeS.-Hy R, ee ga = Direct numerical control (DNC) stems,> Marketing program: 1 Finance program 1 abuse manegement yy (DBMS) program + Device drivers program + Process planning programs : + Manufecturing facilities program, 3. Office equipment to. 4. Communication hardware ‘Remote tntch terminals + Frontend processors + Trasmiters all aspects of design planning, manufacturing, distribution and management. sis, COM fae engineering functions of CAD/CAM butt 3 shows 1 : een ere cM es : ionship between 4 Mikel P. Groover) | * CM 98m in Fig.1.14 [Source during product design. production sch inventory control iputerized business systems that account for peripheral 1¢ manufacturing system. logged by an order entry system. ill of materials, and assembly engineering drawings. = Now the output from the ‘manufacturing engineering departm ign department serves as input to the use of CAD/CAM system, process are performed in detail. Process process planning (CAPP), and tool ‘The output from the manufacturing engineering department serves as input to production planning and 1 department, where aggregate planning, master requirements planning, capacity planning, performed using the computer system.Comper mers Mf step in CIM implementatic phase lays the groundwork for lanning and preparation. identifying objectives, to conduct a thorough assessment of the fying the areas where CIM will have the most » bottlenecks, and quality impact is I. control measures are 1B production workflows, ves gathering data on machine ise. The aim is to evaluate rom CIM and which areas need | | 1 NC pat programming | * Computerized work atl | | | | | | A detailed design of the furure CIM system is developed. This includes decisions on hardware (machines, sensors, robotics) and. software (CADICAM, ERP, MES syst wlation models are often used to predict the performance of the designed the cost of implementing CIM is essential. This ial setup and operational costs with potential benefits such as personnel. Employees need to be tra ms, tools, and processes. A. flow through every aspect of company's organization. well-trained workforce helps to a in CIM adoption, such as . : improper machine usage or inefficiency in process During the process, accounting and payroll jes ensure that perso product and production considerations are fully in line with pl STEP 2: SYSTEM SELECTION AND INTEGRATION ; ‘expenditure, Once the planning phase is complete, the next step is to select appropriate CIM "At process end, customer billing completes the operation of the Co{ | technologies and ines seesetediring poocesees architecture 6 Technology Eval a Design (CAD), Comput including Computer-Aided ‘Computer-Aided Process (MES) are to be researched ‘scalability, and ease of Successful CIM implementat align technological, organizational, and operat To ensure a smooth transition and effectiv divided into a three-step process: < uter-controlled mac! tomated Guided Vehicles (AG' are linked to a central sys coordinated m: il Al i ‘and Computer- 8. Software Integr: tems like Computer-Aided Design (CAD) ‘Aided Manufacturing (CAM) are integrated to streamline the design _and ion and integration; and (id) Implementation and optimization,Introduction 3) eee appropriate technologies, and ignificant benefits in terms of SS computer megrated Marfa Network o i jifferent machines Ethernet, ie Tonmnision I Ne and genie. machines. industrial comm! etn dat exchne ened dete manages atabase aad Dats 3 stem al information about productig | 10. Di 1p or ad rece CHES, ystems (MES) and Prod inventory, 204 ines re go manage this data. These Systems hel Lies Mange ota uly and machinery erformanes 944m STE SINLENENTATION AND OFTIBGATION ciples te sete CM 7 a ly pining esse fr ss Tr iepementatin Tis Se # ee EI ele cooled evo a ee ee ition Systems: At this point, most of the manual work in the is replaced by automated systems. Flexible Manufacturing ‘State Iz Implementation and Optimization are deployed to handle various product configurations and cant delays or changes in equipment. | ‘+ Real-Time Monitoring and Control: Automation extends beyond production |, ‘end includes real-time monitoring systems such as Supervisory Control and Data}, ‘Aca yn equipment. SCADA ee Fig. 118. A framework ofthe design and implementation of CLM 7 ive training to employees on how to use th so, a support system to address any quest 14, Retum on Investment (RO anaiysis. 17, COMPUTERS IN CIM ¥ Computers have revolutionized the manufacturing industry, providing the digital backbone for Computer Integrated Manufacturing (CIM ¥ CIM is a system that uses computers and automation to integrate all aspects of manufacturing, from design to production. Computers play a crucial role in CIM, enabling efficient communication, data management, and control of various manufacturing processes. ¥ Some of the key roles of computers in CIM are listed in Table 1.10. Analysis: The ROL of CIM im 6 of iplementation by Performance indicators such as producti measured, provements in key uality rates, and cost savings arepea af computers in CIM rate 118 ers re a Monitoring and Com! from sensors and other 1 Baa Ape Prin COTES COU ration about ma 0 Sem be azteca POSES. TA conditions ; jected data is analyzed and interpreteg ‘manufacturing, finance, and human resources. systems help manage the flow of materials and ‘throughout the supply chain. 3. Computer-Aided Manclactaring (CAM): : | 7 CAM sysexs use computer systems to control machinery and production process Coxpsers ease precision and efficiency in tsks such 2s toolpath generation, machig operation, and quality control. | CAM systems convert CAD models into instructions that guide CNC — through computers minimizes human es. use of CAM and CNC systems leads to high-quality, consistent products with tight tolerances. ptimize the use of resources, reducing material (© Production Scheduling: MES systems optimize production schedules based & paan idean pct sad rsoue sally. [Giisiaiconruren NevwonvsroaManuractonne 2) Reat-time Monitoring: MES systems monitor man a pivotal role in modem manufacturing systems, riding visibility into productiComputer inert Mony| ystems, allowing seamless data exchang, | a secs, machines, and 9HEMS A _s woe’ eee ars eH ing =e ened computer nerwork 9 8 nm Ga wees aii 8 esi SPP cenhance efficiency, :al@bit9+ management functions: and cc ofcompurr networks i Manufacturing ncn © 1:18: Importance ae som id — Sara mponents of the production an operators. Key benefits j In Manufacturing of networks commonly used in manufacturing, each sed on the complexity of the system and the nature of the eovork allows seamless data sharing across different departm ty production, lpistis, and quality assurance, improving decision-making q coordination. | 4. Centralized control: A computer network in manufacturing supp centralized control and monitoring of distributed machines and pr 1 ‘This enables manufacturers to manage multiple operations from a location, reducing the need for manual intervention and enhancing "7 4. Scalability: As production lines grow and evolve, a robust network manufacturers to easily integrate new machines, sensors, or systems into existing infrastructure without significant reconfiguration. | (@ Single building LAN © 1.18.2, Components of Computer Networks for Manufactur | A brie computer network for manuftctoring consists of the following componet (. Nodes: ‘These ore devices connected to the network, such ms, programmable logic controllers (PI computers, servers robots, and sensors (8) Multiple building LAN Fig. 116. LANJel for connecting systems og nd Human-Machine Inet “ * doction processes and quigy prod rks allow for the communication of io frequencies. Technologies like Networks (LPWAN) are becoming je area than a LAN, offen conneg, | larger geographic area mec aire diferent locations processing plants, or energy systems. SCADA networks provide operators with visual interfaces trol and analysis of operations, Fig 117, WAN Applications in manufacturing: WANs axe used to link multiple plants g ‘production sites, enabling centralized control of dispc operations. Fi example, a company may use a WAN to monitor production lines in differd locations from a central headquarters. ” 3. Industrial Ethernet | ~ What is it?: Industrial Ethemet is a variant of traditional Ethernet net designed to handle the harsh environments and real-time requirements of industri settings. I provides high-speed communication between machines, controllers, ef enterprise-level systems. Y Applications in mansfacturing: Industrial Ethernet is used for connect opti Logie Cones (LCS), sensors, and robots on the factory fo d speed make it ideal for environments where real-time 66 exchange and precise timing are critical, ‘des are connected to a central hub or ple and reliable configuration, but the ipt the entire network. Fig. 1.18. A star topology= aa | ? computer Integrated Mir 2, Ring Topotoey? 1 ‘with each node 0¢ does the fire of ingle HORS | dificult todd Fig. 118-4 om 44 Bus Topology: In this architecture, all nodes are connected to a single s cable (Fig.1.20). This is a simple and inexpensive configuration, but it can st from performance degradation as the number of nodes increases. Fig. 1.20. Bus topology >mbines elements of different topologies to crest! work, les are: Star bus and star ring, fa pologies are linked together using a ated in Fig. 1.21 Introduction L St is, two or bus trunk (called a backbone), ee” Be GE Ge Bus cable Hub Fig, 1.21. Star bus 2. Star ring: In this, two or more star topologies are linked together using a central hub, as illustrated in Fig.1.22.Computer Integrated Mamfectirng | pntroduetlon it quality and reduce pep 1¢ monitoring. * Defining the scope: Determining which processes and functions will be adapt to changing market demand, «Resource allocation: ted factories can be reconfigurey technology, personnel, rocesses. | Timeline establishment: Setting realistic deadlines for each phase of bor costs, reduced waste, ang) implementation, savings. | Integration and Coordination; Managing CIM requires the seamless (o) Improved safety: By automating hazardots tasks and implementing sey mn chs CAD, CAMS ERF and SCM (Spy Cina feat i reate a safer working environment fy hb le: features, automated factories can Seen iceceat: cancie te ane nem oe lity of necessary resources, including (iv) Reduced costs: Au improved energy efficiency, resulting in overall ‘employees. | and work together. ©71.19.3. Challenges and Considerations = Data consistency: Maintaining uniform data across all platforms to avoid While the future automated factory holds immense promise, there are sever) discrepancies. callenges to overcome: | « Process synchronization: Aligning production schedules and workflows across Initial investment: oplementing automation technologies can requte sign jan integrated systems. 3. Change Management and Training: Introducing CIM involves significant to tab duplacements Cosces about changes 10 existing processes and workflows. Effective change management addressed through retraining and upskilling programs. | cases a smoeth transition: oe nployee training: Providing comprehensive training programs to ensure that all staff members are proficient with new tec! + Stakeholder engagement: Involving all stakeholders, from top management to shop floor workers, in the change process to gain their support and minimize pee Cybersecurity: Protecting sensitive data and ensuring the security of interconnected systems is crucial. ‘and standardization: Integrating various technologies and ensuring) wy (i) Integration compatibility can be complex. | ‘of communication to address concerns tation process. Continuous monitoring and CIM systems. This involves: ifs 4.20, MANAGEMENT oF Cio i i ‘The successful implementation and oper mn of CIM require effective managemell 4 Perrormance Mo strategies. Managing CIM involves integrating various components evatuation ae crucial f ‘manufacturing, from planning and execution to monitoring and continuow Se a ae «Key Performance Indicators (KPIs): Establishing metrics to measure the J implementation, such as production efficiency, quality control, improvement, ¥ Key Aspects of CIM management: Some of the key aspects of CIM manag Conducting periodic reviews of systems and processes to improvement.Computer Integrated Mamifcturig menting mechanisms for collec rand other stakeholders to inform dec! ‘The management of CIM is an ongoin PTOCESS thy + Feedback loops: feedback from em jus Improvement: at ; . ie ono {improvement efforts. This includes: = Innovation and updates: Staying abreast oft nological advancements ang integrating new solutions as they become available = Process refinement: Regularly reviewing and refining processes {0 cenhaneg efficiency and effectiveness. « Sustainability practices: Yacorporating sustainable practices (0 reduc, ‘cavironmental impact and improve overall sustainability. ‘Thus, managing CIM effectively involves a comprehensive approach thy integrates planaing, coordination, change management, performance evaluation, an, continuous improvement. By focusing on these key aspects, organizations ca, cchieve a cohesive and efficient manufacturing system that meets the demands of <éynamic market. Ensuring safety within CIM environments is paramount for protecting both humay ‘workers and machinery. The integration of advanced technologies and automatiog necessitates a comprehensive approach to safety. | W Key Safety Aspects in CIM: The key safety considerations in a CIM environmes, are given below. | 1. Worker Safety in Automated Environments | ¥ As machines and robots are integrated into the manufacturing process, the risk o human injury due to unintended machine operation increases. | ¥ CIM systems need to be designed with advanced safety protocols, such as: = Emergency stop mechanisms: Machines must be equipped accessible emergency stop buttons that can halt immedi = Safety barriers and light curtains: These crea or optical boundariet that stop the machines if « human breaches ihe designated safe zone. - + Collaborative robots (Cobots): Cobots jigned to work safely alongside low them to slow down or stop if 2, Machine Safety and Maintenan «dangerous conditions, both for the equipment and the personnel. ¥ Key consi + Predict ToT sensors, CIM systems can monitor the con scheduling maintenance to avoid dangerous breakdowns. ~ + Self-diagnosis systems: Machines should be capable of running self-diagnostics to detect any malfunction, abnormal performance, or mechanical wear, ensuring carly intervention and reducing the risk of accidents. 3. Cybersecurity and Data Integrity ¥ With the integration of digital systems, CIM environments are susceptible 0 cyberattacks that could manipulate machine operation or disrupt production. Ensuring cybersecurity is a safety concem that protects both the operation and personnel, ¥ Measures include: © Network security protocols: Strong firewalls, encryption, and authentication procedures help protect the communication between systems. = Access control: Only authorized personnel should have access to sensitive systems and control mechanisms. «Regular software updates: Ensusing that the control systems and software are vp to date is vital for preventing vulnerabilities that cyberattacks can exploit. 4, Ergonomics and Operator Safety ergonomics:Computer Integrated Manufacy ty nsure that operators’ workstations are designey risks. CIM systems should include i faces (HMIs) that allow operators to interact with y jscommunication or errors. + User-friendly tive control pang ‘and human-m: system without 5, Risk Management in Automated Sys ‘Y Managing risk in a CIM environment involve implementing safeguards. ¥ Risk management techniques such as: | » Hazard analysis and risk assessments (HARA): Regular assessments hey identify weak points in the system, allowing for the installation of safe) measures before accidents occur. » Safety-integrated functions: These are fail-safe measures built into machine, like automatic shutdowns or speed reduction, to prevent accidents duriy ms 5 identifying potential hazards ay abnormal conditions. 6. Fre Safety and Hazardous Material Handling: + CIM systems, particularly in manufacturing environments that deal with c orhigh temperatures, must address fie safety and hazardous material hi fire suppression systems: These systems are vital for de re, reducing the risk of damage to equipment and personnel : Automated factories should have proper ventilation system 1p of hazardous fumes. | + Safe storage of hazardous materials: Speci ‘mechanisms should be incorporated to manage V ety aspects of CIM are comprehensive, addressing human-machis |, machine health, cybersecurity, and emergency preparedness. ystems become more advanced and widespread, these safety features wi , ensuring that future factories remain safe, productive, and secu environments for both personnel and equipment. substances safely. | production se 173) ee ———. it advancements in recent years, driven by tesinlopcalinovains and evling indy demands. These sdvanconet have enhanced the efficiency, flexibility, and competitiveness of manufacturing processes. ¥ Key Advances in CIM: Some of the key advances in CIM that are shaping the future of manufacturing are listed below. 4.1nternet of Things (IoT) and industry 4.0 fed Machines: loT-enabled devices and sensors collect and transmit data on machine performance, product quality, and operational # Smart Factories: Industry 4.0 leverages IoT, big data analytics, and artificial sence (Al) to create highly connected and automated manufacturing igence and Machine Learning = Intelligent Systems: Al-powered systems ean optimize production schedules, improve quality control, and automate complex tasks. = Machine Learning Algorithms: Machine tearing algorithms can analyze vast ‘amounts of data to identify pattems and trends, leading to improved decision- making. + Autonomous. Robots: Autonomous robots equipped with AI and machine ‘can perform tasks with greater precision and flexibility 3. Additive Manufacturing (3D Printing) + Rapid Prototyping: 3D printing allows for rapid protoryping of new detent reducing development time and costs. © Customization: Additive manufacturing ensb! customized products, meeting individual customer needs.Computer Integrated Marat, 1 printing can create complex geometries that gy = Complex Geometries: 3 “0 rare or mmpossbl to produce using traditional ‘manufacturing methods, 44. Robotics and Automation : = Collaborative Robots (Cobots}: Cobots work alongside human operaton, ‘enhancing productivity and safety. more capable of performing tacky + Advanced Robotics: Robots are becoming ‘hat were previously the domain of human wor = Automation of Repetitive Tasks: Automation of improves efficiency and reduces the risk of injuries. 1 55, cloud Computing and Data Analytics | Clou Based CIM Systems: Cloud-based CIM systems offer scalabiliy, flexibility, and reduced infrastructure costs. + Big Data Analytics: Analyzing lange datasets provides valuable insights ing snanufacturing processes, enabling data-driven decision-making. | + Real-time Monitoring: Cloud-based systems can pro -time monitoring] ae evanufseturing operations, allowing for timely intervention and problem, solving. 6. Viet (VR) and Augmented Reality (AR) | + Training and Simulation: VR, and AR can be used for training employees oa) complex manufacturing processes, redesing the risk of errors and accidents, # Design Visualization: VR and AR allow for immersive visualization of produ ilitating collaboration and innovation. | 2: VR and AR can enable remote assistance from experts, repetitive and hazardous tasty {improving problem-solving and reducing downtime. 7. Sustainability and Green Manufacturing ~ | = Energy-offcient production systems: [oT and AI technologies are being used to monitor energy consumption and optimize production schedules to minimize energy use. © Circular manufacturing: CIM systems are increasingly being designed 10) support recycling and reuse of materials, promoting a circular economy witbia the manufacturing industry. Introduction [rez] a ¥ These advancements are transfo organizations to achieve gre ¥ As CIM continues to evol latest technologies and their + Sustainable supply chains: Advances in CIM enable better integration and transparency across the supply chain, allowing for more sustair is : =n re nie or and material handling practices * a engineers to stay updated on the wufacturing. On CAD, CAM & CAD/CAM. L 2. What are the components /. Define CAM. Define CAD. Computer aided design (CAD) may be defined as any design activity that involves the effective use of the computer to create, modify, or document an engineering design. List the fundamental reasons for implementing a CAD systent. [A.U., Nov/Dec 2011; Nov/Dec 2013; Apr/May 2015] 1, To increase the productivity of the designer. 2. To improve the quality of design. 3. To improve communicatic 4, To create a database for system? [A.U,, Nov/Dec 2011] 1, Geometric modelling, 2. Design analysis and opt 3. Design review and eval 4. Documentation and drafting. g: Computer aided manufacturing (CAM) may be defined as an effective use of ani control of computers and computer technology inthe planning management the manufacturing functi List any four manufactur (Computer-aided process planning (C slanning applications of CAM: “APP)