Computer Integrated Manufacturing
Computer Integrated Manufacturing
CIM stands for a holistic and methodological approach to the activities of the
manufacturing enterprise in order to achieve vast improvement in its performance.
Manufacturing engineers are required to achieve the following objectives to be
competitive in a global context.
Reduction in inventory
Lower the cost of the product
Reduce waste
Improve quality
Increase flexibility in manufacturing to achieve immediate and rapid response to:
Product changes
Production changes
Process change
Equipment change
Change of personnel
Robots:
- development in the area of operation,
- expected to increase applications in the field of assembly, textile
and wood industry,
process industry and services,
- increasing the use of sensors to identify,
- increasing the use of artificial intelligence.
Sensors:
- non-contact dimensional measurement of objects,
- identify colors,
- speech recognition,
- determination and forecasting tool life by analyzing vibration
spindle and tool.
There are only 3 robots per 10,000 employees in India, according to the 2017 World
Robot Statistics issued by the International Federation of Robotics (IFR) . By comparison,
the average robot density in the world was 74 in 2016. South Korea, the number one
country on the leaderboard since 2010, was the most automated country in 2016 with
631 robots per 10,000 workers.
Expected trends in the development of application
specific hardware components of CIM systems
Computers:
- increase capacity on-chip,
- in addition to GUI applications increase MUI
(multimedia),
- the fifth generation of computers and neural
computers,
- optical memory,
- the development of communication,
- open systems,
- parallel computers and computer of the fifth
generation
Trends in the development of software
components CIM are
Integrated information systems (IIS):
- development of new software tools for rapid
development of information systems,
- integration method DSS (decision support on) in IIS,
- the integration of CA packages of software systems in
IIS,
- directly taking analog data from the monitoring of
manufacturing processes and their
conversion to digital data processing and monitoring in
IIS.
Trends in the development of software
components CIM are
CAD software packages and software systems
The CAD system that has the most significant application of all the CA program packages and
software systems are expected: the increasing use of PCs and workstations, the
development of the theory of the construction and its applications in CAD systems, the
development of new concepts of CAD applications.
The CAP system is expected greater use of artificial intelligence in selecting and defining a
work plan and improving links with CAD, CAM and PPS software systems.
The CAM system is expected to better integration with CAD, CAP and PPS systems,
application software maintenance by the state and the TPM, to develop the model for
production management.
The CAQ system is expected to further the development and installation of sensors and
diagnostic systems in the manufacturing process, the integration of CAT systems as well as
integration with PPS, CAD and CAM systems.
The PPS system lacks quality relationship with CA software packages and programming
systems, expected greater use of optimization algorithm (OI), the development of models for
rapid feedback of the progress of the plan, the greater use of expert systems and neural
networks.
Trends in the development of software
components CIM are
Communications software and protocols:
- increasing the speed of transmission,
- neural networks,
- widespread use of ISDN,
- EDI for office automation,
- jobs' 'at home'',
- communication faster transmission speeds (ATM, etc).
Artificial intelligence:
- the development of expert systems for manufacturing
processes,
- development not distinct systems
Concurrent engineering in manufacturing industry
In this competitive environment, organizations should use a flexible,
adaptive and responsive paradigm.
Concurrent Engineering (CE) is a management philosophy and is not
restricted to manufacturing companies only.
It involves systematic and simultaneous approach in developing a product
or process while bringing up all the people who need to be involved in the
first place.
Global competitive pressure has motivated many companies to change to
a more rapid form of product development such as concurrent
engineering (CE).
By executing design in parallel, improvements occur in many areas such
as communication, quality, production processes, cash flows, and
profitability.
Concurrent engineering (CE) is undertaken to improve the product design
process with the intention of improving organisation performance.
Conventional information flow in
engineering design and manufacture
Development of manufacturing technology
Traditional Process
a) conventional, b) DFA
DFM Guidelines
1. Design for a minimum number of parts
2. Develop a modular design
3. Minimize part variations
4. Design parts to be multifunctional
5. Design parts for multiuse
6. Design parts for ease of fabrication
7. Avoid separate fasteners
8. Minimize assembly directions; design for top-down
assembly
9. Maximize compliance; design for ease of assembly
10. Minimize handling; design for handling presentation
11. Evaluate assembly methods
DFM Guidelines
12. Eliminate adjustments
13. Avoid flexible components; they are difficult to handle
14. Use parts of known capability
15. Allow for maximum intolerance of parts
16. Use known and proven vendors and suppliers
17. Use parts at de-rated values with no marginal overstress
18. Minimize subassemblies
19. Use new technology only when necessary
20. Emphasize standardization
21. Use the simplest possible operations
22. Use operations of known capability
23. Minimize setups and interventions
24. Undertake engineering changes in batches
Understanding manufacturing
Designers should know the process that will be
used to build their designs. No one would be
impressed with recipes created by someone who
has never cooked Similarly, designers should be
familiar with all the processes they are specifying.
This is the only way they can choose the right
process, specify the right tolerance, utilise existing
factory process, minimise setup changes, and
assure smooth product introduction. All of these
will minimize labour costs.
Stages of design for manufacturability
Design
improvements
by the DFA
process
Scope of the Methodologies known as
Design For Excellence (DFX)
PLM
• In industry, product lifecycle management (PLM)
is the process of managing the entire lifecycle of a
product from inception, through engineering
design and manufacture, to service and disposal
of manufactured products.
• Product lifecycle management (PLM) may sound
like one of those deep-in-the-weeds business
terms, but it has become one of the most
important arenas for accelerating product
deliveries, reducing costs, and generating more
revenues in major manufacturing industries
Why is PLM so important?
• Product development has become
strategically crucial to the financial
performance of these manufacturing
companies so they are investing more in it.
• They understand and appreciate problems
PLM addresses and the benefits it can reap
such as lower production costs, as well as
accelerations in new product designs and
launch schedules and engineering cycle times.
Why is PLM so important
1. Better CAD/BOM integration
Building or changing a CAD file should automatically generate or change a
corresponding bill of materials (BOM). This ensures that there’s a clear link
between what’s being designed and what’s actually needed to build it and
keeps everyone on the same page.
But often, that’s not the case. BOMs are generated later, updated manually,
or exist only as a spreadsheet.
PLM software helps keep these two critical documents united and in sync
automatically.
2. Reduce revision errors
Design is a fundamentally iterative process. That means for every project,
there are multiple versions of the same thing. Plus, as designs naturally
evolve over time, there becomes a backlog of what you’ve produced
previously. It’s a lot to keep straight, and you don’t want to send the wrong
version to production, a costly and time-consuming mistake.
PLM software reduces this risk by creating a shared record of all file versions
automatically, so the production-ready file goes to the production floor.
Why is PLM so important
3. Improved document tracking & handling
Just like there are multiple versions of the same thing, complex manufacturing
processes can generate hundreds of documents over the course of a product lifecycle.
Even a simple engineering change might generate:
Picture files of the original problem
Text files explaining the problem
An official ECR
An approval of the ECR
The original CAD drawing
The new CAD drawing
The original BOM
The new BOM
Various cost, timeline, and production impact spreadsheets and files.
Once you start to think about it, the volume of paperwork starts to truly cascade.
PLM software automatically tracks and organizes these files in a shared environment
that can be accessed from anywhere by any relevant team member.
Why is PLM so important
4. Remove human error
Human error is a tremendous cost to production and is a surefire way to stretch out a
product lifecycle. Without PLM software, there are thousands and thousands of micro-
risks that can cause production to either grind to a halt or (worse!) produce products
that are not up to spec.
For example, even a small typo in a manually-generated BOM can cause serious issues
down the line. PLM software automates many of these mundane and repetitive
manual tasks, make mistakes less likely (and making staff happier).
5. PLM software improves communication
Collaboration across the globe is challenging at the best of times. And if you’re only
using email and VoIP, it’s really difficult to build cohesion across global work groups.
PLM software facilitates a single version of the truth throughout the product lifecycle.
It also creates a shared repository for files, comments issues, and feedback rather than
spreading it around multiple email accounts that are only accessible to the people
copied on them. Granular privacy controls allow team leaders to restrict or allow
access as needed, and role assignments allow team members to know exactly what
they’re working on at any given time.
Why is PLM so important
6.Better error recovery
Even the best-laid plans are prone to error and mistake. That’s why one of the
most important things a PLM offers is rapid and easy error recovery.
For instance, imagine that an ECR was put through but it affected a different
part of production. With PLM software, the engineering and design teams
could quickly look at what was changed, restore a previous (functional)
version, get the reversion approved, and get the restored specs to production
in literally 10 minutes.
In contrast, it might take half a day to trawl through spreadsheets, emails, and
attachments to get the same result without a PLM system.
There’s a reason OEMs like Ford or GM and huge brands like Apple or Cervelo
use PLM software — it works. The only difference is, now it’s available to
much, much smaller organizations for hundreds of dollars a year, not millions.
It might come with short-term challenges, but a new PLM program keeps
organizations on the right path to long-term success.
Essential elements of PLM
Management of design and process documents
PLM data is usually created and managed by engineering in cooperation with other product
managers in purchasing, production, quality, service and sales. It's the container for how to buy,
fabricate, assemble, test, calibrate, inspect, install, repair and even sell the end product. PLM is a
cross-department information storehouse, and its data is often exported to manufacturing systems
and supply chain partners.
PLM manages objects – parts, documents, change forms, and supporting data – within a database.
These objects have:
Descriptive attributes like owning organization, identifying number, name/title, revision (technical
content) and lifecycle (business rules for what can be done with that content), weight and unit of
measure. CAD files (and any other files) can be attached to database records to further describe the
object.
Relationships to other objects: parts have requirements, specifications, inspection procedures, etc.;
assemblies have components with quantities; purchased parts have approved sources; designed
parts have design drawings.
These attributes and relationships are created, reviewed and approved using system rules and
change workflows.
Differences between PLM and PDM
PDM manages CAD files within a computer file system
1. CAD drawings are files, and reside principally in a computer's file
system or on a network share. A CAD file often represents a single
part, but several files may represent one part or one file can
represent multiple parts.
2. Product data management ("PDM") is a specialized file system
manager, somewhat like a CAD-oriented Windows Explorer. PDM's
primary job is to manage mechanical CAD files, and the linkages
between related files. These related files (the "model") are usually
in a proprietary format defined by the CAD vendor.
3. PDM assists in organizing the mechanical aspects of a product, but
it's the CAD model (or its derivative drawings), and not PDM itself,
that has utility to downstream users.
CPD
• Collaborative product
development (collaborative product design)
(CPD) is a business strategy, work process and
collection of software applications that
facilitates different organizations to work
together on the development of a product.
• It is also known as collaborative
product definition management (cPDM)
collaborative
product
development
collaborative product development &
PDM