Computer Integrated Manufacturing

(BMHA202L)
(2-0-0-2)
Introductory Class/Module 1
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 Conduct of the Course
❖ Two hours per week including lectures, discussion, and tutorials

❑ There are homework problems, Digital Assignments, Quizzes, two Continuous

Assessment Tests and a Final assessment Test.
❑ There will be a great deal of discussion in the class.
❑ History has shown regular attendance is necessary to be successful in the class.
❑ Quizzes, if any, will be short

• Listen, and prepare notes

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 Industrial revolution: Milestones in technology
Industrial Revolution- The process of change from an agrarian and handicraft economy to one
dominated by industry and machine manufacturing.

Arnold Toynbee
James Watt

Industrial revolution timeline

(Courtesy: Shutterstock)
Thomas Alva Edison
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Charles Babbage
 The Wireless
Guglielmo Marconi, Italian physicist
Spinning jenny James Watt's steam engine and radio pioneer.

Computer
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 Patrick Hanratty Ivan Sutherland (Courtesy: Trending Technology, LinkedIn)
(Courtesy: NIHF)
Father of CAD/CAM
(Courtesy: UCE)

John T. Parsons
(Courtesy: STAR RAPID)
(Courtesy: IEEE)
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 Say Hello to CIM?

“Digital manufacturing" became prominent in the early 1970s, with the release
of Dr. Joseph Harrington's book, Computer Integrated Manufacturing.
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 Manufacturing
• Manufacturing is the process of converting raw materials, components or parts into
finished goods that meet a customer's expectations or specifications.

• Manufacturing is a value-adding process allowing businesses to sell finished products

at a premium over the value of the raw materials used.

• It is a series of interrelated activities and operations involving design, material

selection, planning, production, quality assurance, management, and marketing of
discrete consumer and durable goods.

Economical Definition
Technological Definition
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 Traditional Product Cycle
Overview of stages in the traditional
product cycle:
• Idea Generation
• Conceptual Design Idea Generation

• Detailed Design
• Prototype Development
• Testing
• Production
• Distribution
Conceptual and detailed design
(CAD and CAE)
Prototype
Development Shi, D., Watanabe, K., Naito, J., Funada, K. and Yasui, K., 2022. Design
optimization and application of hot-stamped B pillar with local patchwork
and testing blanks. Thin-Walled Structures, 170, p.108523.
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 Product Life Cycle

(Courtesy: TWI)

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 Current Production Needs

Current production need

• Rapid prototyping • Customization • Cost reduction • Integration and

and flexibility and efficiency automation

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 The Production System

❑ Collection of people, equipment, and procedures

organized to accomplish the manufacturing operations
of a company
Two categories:
❑ Facilities – the factory and equipment in the facility and
the way the facility is organized (plant layout)
❑ Manufacturing support systems – the procedures used
by a company to manage production and to solve
technical and logistics problems in ordering materials,
moving work through the factory, and ensuring that
products meet quality standards

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 Production System Facilities

Facilities include the factory, production machines and tooling, material handling
equipment, inspection equipment, and computer systems that control the
manufacturing operations
• Plant layout – the way the equipment is physically arranged in the factory
• Manufacturing systems – logical groupings of equipment and workers in the
factory
– Production line
– Stand-alone workstation and worker

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 Categories of Manufacturing Systems
Three categories in terms of the human participation in the processes performed by the manufacturing system:
1. Manual work system - a worker performing one or more tasks without the aid of powered tools, but
sometimes using hand tools
2. Worker-machine system - a worker operating powered equipment
3. Automated system - a process performed by a machine without direct participation of a human

(a) Manual work system, (b) worker-machine system, and (c) fully automated system

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 Manufacturing Support Systems
Manufacturing support involves a sequence of activities that consists of four functions:
1. Business functions - sales and marketing, order entry, cost accounting, customer billing
2. Product design - research and development, design engineering, prototype shop

Sequence of Information-Processing Activities in a Manufacturing Firm

3. Manufacturing planning - process planning, production planning, M R P, capacity

planning
4. Manufacturing control - shop floor control, inventory control, quality control

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 Automation in Production Systems
Two categories of automation in the production system:
1. Automation of manufacturing systems in the factory
2. Computerization of the manufacturing support systems
Examples:
❑ Industrial robots that perform processing or assembly
❑ Automated machine tools
operations
❑ Transfer lines
❑ Automated material handling and storage systems to
❑ Automated assembly systems integrate manufacturing operations

❑ Automatic inspection systems for quality control

• The two categories overlap because manufacturing support systems

are connected to the factory manufacturing systems
– Computer-Integrated Manufacturing (C I M)

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 Computer Integrated Manufacturing (CIM)

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 Introduction to CIM
What is CIM ?
❑ Computer-integrated manufacturing (CIM) is the manufacturing approach of using computers to
control entire production process. This integration allows individual processes to exchange information
with each other and initiate actions.
❑ Computer-integrated manufacturing (CIM) makes the use of computer-controlled machineries and
automation systems in manufacturing products. CIM combines various technologies like CAD and CAM
to provide an error-free manufacturing process that reduces manual labor and automates repetitive tasks.

❑ The term "computer-integrated manufacturing" is both a method of manufacturing and the name of a
computer-automated system in which individual engineering, production, marketing, and support
functions of a manufacturing enterprise are organized.
❑ In a CIM system functional areas such as design, analysis, planning, purchasing, cost
accounting, inventory control, and distribution are linked through the computer with factory floor
functions such as materials handling and management, providing direct control and monitoring of all
the operations.

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

• CADD - computer aided design and drafting. Combining the CAD function with drafting to generate the
production drawings of the part for the purpose of downstream processing.

• CAE - computer aided engineering. The use of computer methods to support basic error checking,
analysis, optimization, manufacturability, etc., of a product design.

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

• CAPP - computer aided process planning. The use of computer to generate the process plans for the
complete manufacture of products and parts.

• CATD - computer aided tool design. Computer assistance to be used for developing the tools for
manufacture such as jigs and fixtures, dies, and moulds.

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 • CAP - computer aided planning. The use of computer for many of the planning functions such as material
requirement planning, computer aided scheduling, etc.
• CAQ – Computer Aided Quality assurance. The use of computer and computer controlled equipment for
developing the quality control and assurance functions.
• CAT – Computer aided testing refers to the software tools that can take a system through its various phases of
operations and examine the response against the expected results.

Computer-aided
technologies

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 Design Process
• Design is an activity that needs to be well organized and should take into account all
influences that are likely to be responsible for the success of the product under development.

• Product Engineering • Manufacturing Engineering

• Product functions • Process planning

• Product Specifications • Process sheets
• Conceptual design • Route sheets
• Ergonomics and Aesthetics • Tooling
• Standards • Cutting tools
• Detailed Design • Jigs and Fixtures
• Prototype development • Dies and Moulds
• Testing • Manufacturing Information Generation
• Simulation • CNC Part programmes
• Analysis • Robot Programmes
• Inspection (CMM) programmes
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 Stages of Design Process

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 Computer Assisted Design
Process

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 CIM Elements

Nine major elements of a CIM system

• Marketing
• Product Design
• Planning
• Purchase
• Manufacturing Engineering
• Factory Automation Hardware
• Warehousing
• Logistics and Supply Chain Management The scope of CAD/CAM and CIM, and the computerized
• Finance elements of a CIM system.
• Information Management

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 Computer Assistance

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 Data flow in CIM

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 CIM Wheel

CIM is recognized as Islands of Automation.

They are
1. CAD/CAM/CAE/GT
2. Manufacturing Planning and Control.
3. Factory Automation
4. General Business Management

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 Processes Involved
The various processes involved in a CIM are listed as follows:
•Computer-aided design
•Prototype manufacture
•Determining the efficient method for manufacturing by calculating the costs and considering the production
methods, volume of products, storage and distribution
•Ordering of the necessary materials needed for the manufacturing process
•Computer-aided manufacturing of the products with the help of computer numerical controllers
•Quality controls at each phase of the development.
•Product assembly with the help of robots
•Quality check and automated storage
•Automatic distribution of products from the storage areas to awaiting
lorries/trucks
•Automatic updating of logs, financial data and bills in the computer system.

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 Advantage of CIM
3. Flexibility
1. Error Reduction With CIM companies quickly react to market
Elimination of human error in many conditions and then return to previous settings
assignment and reporting functions on when market conditions change.
factory floor operations drastically
reduces the error rate.

2.Speed 4. Integration
CIM environments reduce the time it CIM offers a degree of integration
takes to perform manufacturing that enables the flexibility, speed and
fabrication and assembly, allowing error reduction required to compete
quicker flow of product to customers and lead markets. Integrating factory
and increased capacity. floor operations with enterprise
software enables employees to do
higher value functions for their
companies.
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 CIM Usages

1. Industrial and Production Engineering

2. Mechanical Engineering

3. Electronic Design Automation

1) Printed Circuit Board design
2) Integrated Circuit design
https://www.123rf.com/profile_macrovector

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Challenges 3. Process Control
1. Integration of components from different Computers may be used to assist the human
suppliers: operators of the manufacturing facility, but there
must always be a competent engineer on hand to
When different machines, such as CNC, conveyors handle circumstances which could not be
and robots, are using different communications foreseen by the designers of the control software.
protocols (In the case of AGVs, even differing
lengths of time for charging the batteries) may cause
problems.

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

http://www.technologystudent.com/rmprp07/intman1.html

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 Sub-Systems in CIM:
Some or all of the following
Computer Aided Manufacturing (CAM)
subsystems may be found in a CIM Flexible Manufacturing Systems (FMS)
operation: Computer Aided Process Planning
(CAPP) Computer Aided Engineering
(CAE) Computer-Aided Quality Assurance
(CAQ) Production Planning and Control
1.Computer-aided techniques (PPC) Enterprise Resource Planning (ERP)

2.Devices and equipment required

3.Technologies

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Sub-Systems in CIM
Technologies:
Devices and equipment required: • FMS, (flexible manufacturing system)
• CNC, Computer numerical controlled machine tools • ASRS, automated storage and retrieval system
• DNC, Direct numerical control machine tools • AGV, automated guided vehicle
• PLCs, Programmable logic controllers • Robotics
• Robotics • Automated conveyance systems
• Computers
• Software
• Controllers
• Networks
• Interfacing
• Monitoring equipment

Automated Guided Vehicles(AGV)

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 Product cycle in Computerized Manufacturing environment

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 The common databases various for computerized applications

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Present scenario
1. Smart manufacturing:
Smart manufacturing is a broad category of manufacturing that employs computer-
integrated manufacturing, high levels of adaptability and rapid design changes, digital
information technology, and more flexible technical workforce training. Other goals
sometimes include fast changes in production levels based on demand, optimization of
the supply chain, efficient production and recyclability.

https://blog.ifsworld.com/2018/08/era-of-the-smart-factory-how-can-manufacturers-get-to-the-future-quicker/

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 2. Digital Manufacturing:
Digital manufacturing is the use of an integrated, computer-based system comprised of simulation, 3D
visualization, analytics and collaboration tools to create product and manufacturing process definitions
simultaneously.
Digital manufacturing evolved from manufacturing initiatives such as design for manufacturability (DFM),
computer-integrated manufacturing (CIM), flexible manufacturing and lean manufacturing that highlight the
need for collaborative product and process design.

https://www.wileymetal.com/3-elements-of-digital-manufacturing/

https://www.intelizign.com/blog/2019/01/10/industry-4-0-with-digital-manufacturing/
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 3. Internet Of Things (IOT):
1.There are essentially two different roles that the IOT can play in manufacturing. It can connect the “things” that
make your product— machines and equipment—to potentially make your manufacturing processes run more
smoothly.
2.Or you can tap into data collected or generated by your products, making them “smart” products.
3. IOT has multitudes of applications in manufacturing plants. It can facilitate the production flow in a
manufacturing plant, as IOT devices automatically monitor development cycles, and manage warehouses as well
as inventories.

IOT in manufacturing
https://www.scnsoft.com/blog/iot-in-manufacturing
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 4. Artificial Intelligence (AI) :
Artificial intelligence technology is now making its way into manufacturing.

“AI will perform manufacturing, quality control, shorten design time, and reduce materials waste,
improve production reuse, perform predictive maintenance, and more,” says Andrew Ng, the creator of
the deep-learning Google Brain project and an adjunct professor of computer science at Stanford
University.

https://www.effra.eu/events/2-july-2019-workshop-artificial-intelligence-manufacturing-presentations-and-report-available

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 Future Prospects
Cloud based manufacturing :

❑ Cloud models come as infrastructure, platform, and services. Manufacturers can opt for the solution of
choice and strategize migration in stages. This makes cloud a flexible and convenient choice.

❑ Cloud allows the synchronization of data from multiple sources into a single dashboard. Hence it relieves
executives from the burden of manually transferring data from one system to another.

Order-winning Criteria are:

◼ Price
◼ Quality
◼ Delivery speed
◼ Innovation ability

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 Thank you.

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