Evolution of CIM

The evolution of Computer-Integrated Manufacturing (CIM) reflects the technological

advancements and changing needs in the manufacturing industry.

1. Early Automation (1950s-1960s)

• Introduction of Numerical Control (NC): The first steps towards automation in

manufacturing began with the development of NC machines, which used punched
tape to control machine tools.
• Basic Automation: Simple automated systems were introduced to perform repetitive
tasks, reducing the need for manual labor.

2. Development of CAD/CAM (1970s-1980s)

• Emergence of CAD: The development of computer-aided design (CAD) systems

allowed designers to create detailed and accurate designs using computers.
• Introduction of CAM: Computer-aided manufacturing (CAM) systems were
developed to automate the manufacturing process, using the digital designs created by
CAD systems.
• Integration of CAD and CAM: The integration of CAD and CAM systems enabled
a more seamless transition from design to manufacturing, improving efficiency and
accuracy.

3. Growth of Flexible Manufacturing Systems (FMS) (1980s)

• Flexible Manufacturing Systems: These systems combined CAD/CAM with

automated material handling and storage systems, allowing for more flexible and
efficient production processes.
• Robotics and Automation: The use of industrial robots became more widespread,
further automating manufacturing tasks and increasing productivity.

4. Emergence of Computer-Integrated Manufacturing (CIM) (1990s)

 • Integration of Various Systems: CIM integrated various components of
manufacturing, including design, production planning, inventory control, quality
assurance, and production management, into a cohesive system.
• Real-time Data and Control: CIM systems provided real-time data and control over
the entire manufacturing process, allowing for better decision-making and improved
efficiency.

5. Advancements in Information Technology (2000s)

• Internet and Networking: The advent of the internet and advances in networking
technologies enabled better communication and collaboration between different parts
of the manufacturing process.
• Enterprise Resource Planning (ERP): ERP systems integrated various business
processes, including manufacturing, into a single system, further enhancing the
capabilities of CIM.

6. Industry 4.0 and Smart Manufacturing (2010s-Present)

• Internet of Things (IoT): IoT technologies enabled the connection of machines and
devices, allowing for real-time monitoring and control of the manufacturing process.
• Big Data and Analytics: The use of big data and analytics provided valuable insights
into manufacturing processes, helping to optimize production and reduce waste.
• Artificial Intelligence (AI) and Machine Learning (ML): AI and ML technologies
were used to predict maintenance needs, optimize production schedules, and improve
quality control.
• Cyber-Physical Systems: The integration of physical processes with digital systems
created smart factories, where machines and systems could communicate and
collaborate autonomously.

7. Future Trends

• Advanced Robotics: Continued advancements in robotics will further enhance

automation and flexibility in manufacturing.
• Additive Manufacturing: Technologies like 3D printing will become more
integrated into CIM systems, allowing for more customized and efficient production.
 • Sustainable Manufacturing: CIM systems will increasingly focus on sustainability,
optimizing resource use and reducing environmental impact.
• Human-Machine Collaboration: The future of CIM will see greater collaboration
between humans and machines, with advanced interfaces and augmented reality (AR)
technologies enhancing this interaction.

CIM wheel

CIM Wheel

1. Product Design and Engineering:

o Computer-Aided Design (CAD): Tools and systems for designing products
and creating detailed drawings and specifications.
o Computer-Aided Engineering (CAE): Simulation and analysis tools to
evaluate and optimize product designs.
2. Production Planning and Control:
o Material Requirements Planning (MRP): Systems for planning the
materials needed in the manufacturing process.
o Manufacturing Resource Planning (MRP II): Extends MRP to include
additional resources such as labor and machine capacity.
o Enterprise Resource Planning (ERP): Integrates all aspects of the business,
including production, finance, and human resources.
3. Manufacturing Process:
 o Computer-Aided Manufacturing (CAM): Tools and systems for controlling
and automating manufacturing processes.
o Flexible Manufacturing Systems (FMS): Systems that allow for the
production of different products with minimal reconfiguration.
4. Quality Assurance:
o Statistical Process Control (SPC): Techniques for monitoring and
controlling manufacturing processes to ensure quality.
o Total Quality Management (TQM): A holistic approach to long-term
success through customer satisfaction.
5. Logistics and Supply Chain Management:
o Just-In-Time (JIT) Manufacturing: Minimizes inventory and delivers
components as they are needed.
o Supply Chain Management (SCM): Coordinates the flow of materials,
information, and finances among suppliers, manufacturers, and customers.
6. Human-Machine Interface:
o Systems and tools that allow operators and engineers to interact with machines
and computer systems effectively.

CIM Cycle

The CIM cycle represents the continuous and iterative nature of the manufacturing process
within a CIM system. It emphasizes the dynamic and ongoing interaction between different
components and stages of production.

1. Design:
o Initiates with product design using CAD and CAE tools.
o Ensures that the product meets functional, aesthetic, and manufacturing
requirements.
2. Planning:
o Involves production planning and scheduling using MRP and ERP systems.
o Determines the materials, resources, and timelines needed for production.
3. Manufacturing:
o Executes the production plan using CAM systems and FMS.
o Involves actual manufacturing processes such as machining, assembly, and
quality control.
4. Monitoring and Control:
o Uses SPC and other monitoring tools to ensure that the manufacturing process
remains within specified parameters.
o Collects data for continuous improvement and real-time adjustments.
5. Feedback and Improvement:
o Analyzes data collected during the manufacturing process to identify areas for
improvement.
o Feeds back into the design and planning stages to refine and optimize future
production cycles.
Production Concepts

1. Automation:
o Computer-Aided Design (CAD): Using computers to design products.
o Computer-Aided Manufacturing (CAM): Using computers to control
machine tools and related machinery in the manufacturing of components.
o Computer-Aided Engineering (CAE): Using computer software to simulate
performance, improve designs, and aid in the engineering process.
2. Flexible Manufacturing Systems (FMS):
o Systems that can adapt to changes in the type and quantity of the product
being manufactured.
3. Just-In-Time (JIT) Manufacturing:
o Reducing in-process inventory and associated carrying costs by producing
items only as they are needed in the production process.
4. Lean Manufacturing:
o Focusing on minimizing waste within manufacturing systems while
simultaneously maximizing productivity.
5. Total Quality Management (TQM):
o A continuous improvement process involving all employees to enhance
product quality and performance.

Mathematical Models

1. Queuing Theory:
o Used to predict wait times and optimize the flow of parts through the
production system.
2. Linear Programming:
o Used for optimizing resource allocation, such as determining the best way to
use labor and materials.
3. Simulation Models:
o Computer simulations that model the production process to test changes and
predict outcomes without disrupting actual production.
4. Inventory Control Models:
o Economic Order Quantity (EOQ): Determines the optimal order quantity to
minimize total inventory costs.
o Just-In-Time (JIT) Models: Focus on reducing inventory holding costs and
improving efficiency.
5. Network Models:
o PERT (Program Evaluation Review Technique) and CPM (Critical Path
Method): Used for project planning and scheduling.
6. Statistical Process Control (SPC):
o Using statistical methods to monitor and control a process to ensure it operates
at its full potential.
7. Markov Chains:
o Used to model random processes that undergo transitions from one state to
another on a state space.
Major Hardware Components:

1. Computers and Servers:

o Function: Act as the central processing units for data storage, processing, and
control.
o Interaction: They host the software applications that control the
manufacturing processes and store the data generated by various sensors and
machines.
2. CNC Machines (Computer Numerical Control):
o Function: Automate machining processes with precise control over tools like
lathes, mills, and routers.
o Interaction: Receive instructions from the central computer systems and
execute them to produce parts with high precision.
3. Robots:
o Function: Perform tasks such as assembly, welding, painting, and material
handling.
o Interaction: Operate based on pre-programmed instructions and real-time
data from sensors, often coordinated by a central control system.
4. Sensors and Actuators:
o Function: Collect data (e.g., temperature, pressure, position) and perform
actions (e.g., moving parts, activating switches).
o Interaction: Provide real-time feedback to the central system, enabling
adaptive control of the manufacturing process.
5. Automated Guided Vehicles (AGVs):
o Function: Transport materials and components within the manufacturing
facility.
o Interaction: Follow predefined paths or dynamic routing instructions from the
control system, ensuring timely delivery of materials.
6. Human-Machine Interfaces (HMIs):
o Function: Enable operators to interact with the CIM system.
o Interaction: Provide visual displays, controls, and inputs for monitoring and
managing the manufacturing processes.

Major Software Components:

1. CAD (Computer-Aided Design):

o Function: Design products and create detailed engineering drawings.
o Interaction: Interfaces with CAM software to translate designs into
manufacturing instructions.
2. CAM (Computer-Aided Manufacturing):
o Function: Plan and control manufacturing processes based on CAD designs.
o Interaction: Generates toolpaths and machine instructions for CNC machines
and robots.
3. MES (Manufacturing Execution Systems):
o Function: Manage and monitor production operations on the shop floor.
o Interaction: Collects data from various hardware components, coordinates
activities, and ensures efficient execution of production plans.
4. ERP (Enterprise Resource Planning):
o Function: Integrate all facets of an operation, including planning, purchasing,
inventory, sales, marketing, finance, and HR.
 oInteraction: Provides a unified view of business processes and supports
decision-making by integrating data from the MES and other systems.
5. SCADA (Supervisory Control and Data Acquisition):
o Function: Monitor and control industrial processes remotely.
o Interaction: Collects data from sensors and equipment, provides real-time
monitoring, and allows for remote control of processes.
6. PLC (Programmable Logic Controllers) Software:
o Function: Control machinery and processes by following programmed
instructions.
o Interaction: Interfaces with sensors and actuators to execute control logic and
ensure proper operation of equipment.

Major elements of CIM system

• Computer-Aided Design (CAD): Tools for designing products and components,

including 2D and 3D modeling. CAD systems are used for creating detailed design
specifications and visualizations.

• Computer-Aided Engineering (CAE): Software for simulating and analyzing product

performance and behavior under different conditions. CAE tools help in evaluating the
design's functionality and feasibility.

• Computer-Aided Manufacturing (CAM): Systems that manage and control

manufacturing processes, including CNC machines and robotics. CAM software generates
machine instructions from CAD designs.

• Manufacturing Execution System (MES): Software that monitors and controls the
production process on the shop floor. MES systems manage production scheduling,
inventory, quality control, and work orders.

• Enterprise Resource Planning (ERP): Integrated software for managing business

processes, including procurement, production planning, inventory management, and order
processing. ERP systems ensure alignment between production and business objectives.

• Product Lifecycle Management (PLM): Systems that manage the entire lifecycle of a
product, from initial concept through design, manufacturing, and end-of-life. PLM tools
ensure that product data is consistent and accessible throughout its lifecycle.

• Data Management and Integration: Systems for managing and integrating data across
various functions and levels of the organization. This includes databases, data warehouses,
and data exchange protocols.

• Automated Storage and Retrieval Systems (AS/RS): Systems for automated handling
and storage of materials and products, improving efficiency and reducing human
intervention.

• Robotic Systems: Robots used for tasks such as assembly, welding, painting, and material
handling. Robotics are integrated into the CIM system to enhance automation and precision.
• Quality Management Systems (QMS): Tools for ensuring product quality through
inspection, testing, and compliance with standards. QMS systems help in tracking and
improving quality metrics.

• Human-Machine Interface (HMI): Interfaces that allow operators to interact with CIM
systems, including graphical user interfaces (GUIs) and control panels.

• Communication Networks: Infrastructure for connecting various components of the CIM

system, including network protocols, communication standards, and data exchange formats.

### Major Elements of a CIM System

A Computer Integrated Manufacturing (CIM) system is composed of several key elements

that work together to streamline manufacturing processes through automation and integration.
These elements include:

1. **Computer-Aided Design (CAD):**

- CAD systems are used to create detailed 2D and 3D models of products.

- They facilitate design changes and optimize product designs for manufacturability.

2. **Computer-Aided Manufacturing (CAM):**

- CAM systems translate CAD designs into machine-readable instructions for

manufacturing equipment.

- They help in planning, managing, and controlling production operations.

3. **Computer-Aided Process Planning (CAPP):**

- CAPP systems assist in developing process plans for manufacturing products.

- They ensure optimal sequencing of operations and selection of tools and materials.

4. **Manufacturing Resource Planning (MRP II) and Enterprise Resource Planning (ERP):**
 - These systems manage and coordinate all resources, information, and functions of a
manufacturing organization.

- ERP extends MRP II functionalities by integrating other business processes like finance
and HR.

5. **Flexible Manufacturing Systems (FMS):**

- FMS consists of automated machines, workstations, and material handling systems.

- They enable the production of a variety of products with minimal manual intervention.

6. **Robotics:**

- Robots perform tasks such as welding, assembly, and material handling.

- They enhance productivity, accuracy, and safety in manufacturing processes.

7. **Automated Storage and Retrieval Systems (AS/RS):**

- AS/RS are used for automated inventory management and material handling.

- They improve storage efficiency and reduce retrieval times.

8. **Supervisory Control and Data Acquisition (SCADA):**

- SCADA systems provide real-time monitoring and control of industrial processes.

- They collect data from sensors and control equipment on the factory floor.

9. **Quality Control Systems:**

- These systems use tools like Statistical Process Control (SPC) to monitor and maintain
product quality.

- Automated inspection systems ensure that products meet specified standards.

10. **Communication Networks:**

 - These networks facilitate data exchange between different components of the CIM
system.

- Examples include Local Area Networks (LAN), Wide Area Networks (WAN), and
Industrial Ethernet.

Step 1: Planning and Preparation

1. Assessment and Analysis:

o Conduct a comprehensive analysis of the current manufacturing processes,
workflows, and systems.
o Identify the areas that can benefit most from integration and automation.
o Evaluate the existing infrastructure, including machinery, software, and
network capabilities.
2. Defining Objectives and Goals:
o Establish clear objectives for the CIM implementation, such as improving
production efficiency, reducing costs, enhancing product quality, and
increasing flexibility.
o Set measurable goals to track the progress and success of the implementation.
3. Developing a Strategy and Roadmap:
o Create a detailed implementation plan outlining the steps, timelines, and
resources required.
o Determine the scope of the project, including which processes and systems
will be integrated.
o Develop a phased approach to implementation, starting with pilot projects or
specific areas of the manufacturing process.
4. Selecting Technology and Vendors:
o Research and select appropriate hardware and software solutions that align
with the defined objectives and goals.
o Evaluate potential vendors and partners based on their expertise, track record,
and compatibility with existing systems.

Step 2: Implementation and Integration

1. System Design and Customization:

o Design the integrated system architecture, including hardware, software, and
network components.
o Customize the chosen technologies to fit the specific needs of the
manufacturing processes.
o Develop interfaces and protocols for communication between different
systems and machines.
2. Installation and Configuration:
o Install the selected hardware and software components.
o Configure the systems to ensure seamless communication and data exchange.
o Integrate the new systems with existing infrastructure, such as ERP, MRP, and
CAD/CAM systems.
3. Testing and Validation:
 o Conduct thorough testing of the integrated system to ensure it functions
correctly and meets the defined objectives.
o Validate the performance and reliability of the system under various operating
conditions.
o Identify and resolve any issues or bottlenecks that may arise during testing.

Step 3: Operation and Optimization

1. Training and Change Management:

o Provide comprehensive training to employees on the new systems and
processes.
o Address any resistance to change by communicating the benefits and
importance of CIM.
o Develop a change management plan to ensure a smooth transition to the new
system.
2. Monitoring and Maintenance:
o Continuously monitor the performance of the CIM system to ensure it operates
as intended.
o Implement regular maintenance schedules to keep the hardware and software
in optimal condition.
o Use real-time data and feedback to identify areas for improvement and make
necessary adjustments.
3. Continuous Improvement:
o Analyze the data generated by the CIM system to identify trends,
inefficiencies, and opportunities for optimization.
o Implement continuous improvement initiatives to enhance the performance
and capabilities of the system.
o Stay updated with the latest advancements in CIM technologies and
incorporate them as needed.

Role of Computers in CIM:

1. Integration of Manufacturing Processes:

o Design and Engineering: Computer-Aided Design (CAD) systems are used
to create precise drawings and models of products. These designs can be
directly used in manufacturing processes.
o Process Planning: Computer-Aided Process Planning (CAPP) helps in
determining the most efficient processes and routes for manufacturing.
o Production Management: Manufacturing Resource Planning (MRP II) and
Enterprise Resource Planning (ERP) systems help manage resources,
schedules, and production workflows.
o Quality Control: Statistical Process Control (SPC) and other quality
management systems use computers to monitor and maintain product quality.
2. Automation:
o Robotics: Robots perform repetitive, dangerous, or precise tasks, reducing
human error and increasing efficiency.
 o Numerical Control (NC) and Computer Numerical Control (CNC):
Machines are controlled by computer programs that dictate their operations
with high precision.
o Automated Material Handling: Systems like Automated Guided Vehicles
(AGVs) and conveyors move materials through the production process.
3. Data Management and Communication:
o Database Management Systems (DBMS): Centralized databases store
information on products, processes, inventory, and more, facilitating data
access and decision-making.
o Real-time Monitoring and Control: Systems like Supervisory Control and
Data Acquisition (SCADA) provide real-time monitoring and control of
industrial processes.
4. Decision Support Systems:
o Artificial Intelligence (AI) and Expert Systems: These systems can analyze
data and provide recommendations or make decisions to optimize
manufacturing processes.
5. Supply Chain Management:
o Coordination with Suppliers and Customers: Computers facilitate
communication and coordination along the supply chain, improving efficiency
and responsiveness.

Types of Computer Networks Used in Manufacturing:

1. Local Area Network (LAN):

o Connects computers within a single manufacturing facility.
o Enables data sharing and communication among machines, control systems,
and workers.
o Typically used for intra-plant operations like linking CNC machines, PLCs,
and workstations.
2. Wide Area Network (WAN):
o Connects multiple manufacturing facilities across different locations.
o Facilitates communication and coordination between different plants,
suppliers, and distribution centers.
o Supports enterprise-wide applications like ERP systems.
3. Industrial Ethernet:
o A robust and reliable network designed to handle the harsh conditions of
industrial environments.
o Used for real-time communication between devices on the factory floor.
o Supports protocols like EtherNet/IP, PROFINET, and Modbus TCP/IP.
4. Wireless Networks:
o Used for connecting devices without the need for physical cables.
o Facilitates mobility and flexibility in the manufacturing environment.
o Common technologies include Wi-Fi, Bluetooth, and Zigbee.
5. Fieldbus Networks:
o Specialized networks for industrial communication between sensors, actuators,
and control devices.
o Examples include PROFIBUS, DeviceNet, and ControlNet.
o Enable real-time data exchange and control in automated systems.
6. Internet of Things (IoT) Networks:
 o Connects various devices and sensors to the internet for data collection and
analysis.
o Enables predictive maintenance, remote monitoring, and advanced analytics.
o Common protocols include MQTT, CoAP, and OPC UA.

y to market demands and maintain a competitive edge.

Management Aspects

1. Integration and Coordination:

o Data Management: CIM systems require effective management of data across various
functions such as design, production, and logistics. This involves integrating CAD,
CAM, ERP, and other systems.
o Resource Allocation: Efficient allocation and utilization of resources, including
machines, materials, and human resources, are crucial.
o Process Optimization: Continuous monitoring and optimization of processes to
enhance productivity and reduce costs.
o Decision Support: CIM provides real-time data and analytics, aiding management in
making informed decisions.
2. Human Resource Management:
o Training and Development: Employees must be trained to work with advanced CIM
systems, which may include understanding new software, hardware, and processes.
o Change Management: Effective strategies are needed to manage the transition to
CIM, addressing resistance to change and ensuring smooth implementation.
3. Supply Chain Management:
o Inventory Control: CIM systems help in maintaining optimal inventory levels through
real-time tracking and automation.
o Vendor Coordination: Enhances collaboration with suppliers and vendors by sharing
real-time data and production schedules.
4. Quality Management:
o Standardization: Ensuring that all processes adhere to defined quality standards.
o Continuous Improvement: Utilizing feedback from CIM systems for continuous
process and product improvement.

Safety Aspects

1. Workplace Safety:
o Automation: Reduced human intervention in hazardous tasks, leading to a safer
working environment.
o Monitoring Systems: Implementation of real-time monitoring systems to detect and
mitigate safety risks.
2. System Reliability and Maintenance:
o Predictive Maintenance: CIM systems can predict equipment failures and schedule
maintenance, reducing the risk of unexpected breakdowns.
o Safety Protocols: Integration of safety protocols within the CIM system to ensure safe
operation of machinery and equipment.
3. Compliance:
o Regulatory Compliance: Ensuring that all operations comply with industry safety
standards and regulations.
o Environmental Safety: Monitoring and controlling environmental parameters to
ensure safe and sustainable manufacturing practices.
Recent Advances in CIM Technologies

1. Internet of Things (IoT):

o Connectivity: IoT enables the interconnection of various devices and systems within a
CIM environment, facilitating real-time data exchange and enhanced process control.
o Smart Sensors: Use of advanced sensors for monitoring and controlling
manufacturing processes, leading to improved efficiency and reduced downtime.
2. Artificial Intelligence and Machine Learning:
o Predictive Analytics: AI algorithms analyze historical data to predict future trends
and anomalies, aiding in proactive decision-making.
o Autonomous Systems: Development of self-optimizing and self-correcting systems
that can operate with minimal human intervention.
3. Advanced Robotics:
o Collaborative Robots (Cobots): Designed to work alongside human workers,
enhancing productivity and safety.
o Flexible Automation: Use of adaptable robots that can perform multiple tasks,
reducing the need for multiple specialized machines.
4. Cloud Computing:
o Data Storage and Processing: Leveraging cloud platforms for storing and processing
large volumes of data generated by CIM systems.
o Remote Monitoring: Enables remote monitoring and control of manufacturing
processes, providing flexibility and scalability.
5. Additive Manufacturing (3D Printing):
o Prototyping: Rapid prototyping capabilities, allowing for quick design iterations and
validation.
o Customization: Facilitates mass customization by enabling the production of complex
and bespoke parts.
6. Cyber-Physical Systems (CPS):
o Integration: CPS integrates physical processes with digital control systems, creating a
seamless interaction between the two.
o Real-Time Feedback: Provides real-time feedback and control, enhancing the
responsiveness and adaptability of manufacturing systems.
7. Blockchain Technology:
o Transparency: Ensures transparency and traceability in supply chain management.
o Security: Enhances data security and integrity by providing a decentralized and
tamper-proof record of transactions.