Chapter 6

“Computer Integrated Manufacturing

and Technology Driven Practices”

Miss. Neepa M. Patel, MPSTME 1

Introduction, Evolution, Objective

CIM Hardware and Software

CIM Benefits

Nature and role of elements of CIM

CIM Needs

Database requirements of CIM

Miss. Neepa M. Patel, MPSTME 2

Role of CAD/CAM in CIM

Obstacles of CIM, Future CIM systems

Rapid prototyping, Virtual prototyping

Design for Manufacturing

Design for Assembly.

Miss. Neepa M. Patel, MPSTME 3

Computer Integrated
Manufacturing (CIM)
Challenges in Manufacturing

Miss. Neepa M. Patel, MPSTME 5

 CIM Background

 Various tastes of customers

 Reduction of cycle time

 Requesting integrated systems for

improving both technology and quality

Miss. Neepa M. Patel, MPSTME 6

 CIM-In General
 Computer – Database
 Integration – Network
 Manufacturing – Rapid development of
new products

 Use of computer technology to tie together

the design, production, marketing and
delivery of a product into a totally
integrated system

Miss. Neepa M. Patel, MPSTME 7

It includes :-

1. CAD/CAM, computer-aided design/computer-

aided manufacturing,.
2. CAPP, computer-aided process planning,.
3. CNC, computer numerical control machine tools.
4. DNC, direct numerical control machine tools
5. FMS, flexible machining systems,
6. AS/RS, automated storage and retrieval systems,
7. AGV, automated guided vehicles.
8. Use of robotics and automated conveyance.
9. Computerized scheduling and production control.
10. A business system integrated by a common data
base.

Miss. Neepa M. Patel, MPSTME 8

Manufacturing Systems
Integration Program

Miss. Neepa M. Patel, MPSTME 9

 Introduction
 CAD/CAM does not deal with the business function of
the factory. In earlier days, the business functions were
restricted to the management and kept isolated from the
factory operations.
 But now a days, in a present era of globalization and
competitive market, customer is a center of focus.
 CIM is the complete integration and Automation of all
functions of factory. i.e. Design,
Manufacturing and
Business Functions.
 The two terms CAD/CAM and CIM are very closely
related. However, the scope and coverage of CIM is
broader than that of CAD/CAM. Because it includes all
factory functions including Business function also.

Miss. Neepa M. Patel, MPSTME 10

 CIM Definition
Basically it’s a combination of these 3
islands
Computer  CAD,
Aided  CAM,
Design  Business Functions.

CIM
which increases,
Computer
Business  Productivity,
Aided
functions  Product Quality and
Manufacturing  Plant efficiency.

Miss. Neepa M. Patel, MPSTME 11

 Evolution of CIM
 The concept of CIM has been evolving since the mid 1970s
 It started developing as a technology since 1980s.
 All manufacturing industries are started competing with
each other, due to globalization of economy.
 And this transformed the market from the seller driven to
the buyer driven.
 The customers started demanding more product variety,
better product quality and low cost products.
 This has led to the emergence of CIM.
Invention Year/s

Numerical Control 1952

Mainframe computers (DNC) 1960s

CNCs 1970s

FMS Miss. Neepa M. Patel, MPSTME 1980s 12

Development of CIM

Miss. Neepa M. Patel, MPSTME 13

 Need/Objectives Of CIM
 Easy financial management
 Development & advancement of CNC,FMS
and automation technologies
 Development of cost effective and high
speed computer systems
 Market challenges such as high labor cost,
global competition and buyer driven market,
 Increasing volume of sales
 Customers demands such as product
variety, better quality and low cost product.

Miss. Neepa M. Patel, MPSTME 14

 CIM Needs
 Increased productivity
 High cost of labor
 Labor shortages
 Trend of labor toward the service sector
 High cost of raw materials
 Improved product quality
 Reduced manufacturing lead time

Miss. Neepa M. Patel, MPSTME 15

 CIM Hardware
CIM Hardware comprises the following:
 Manufacturing equipment such as CNC machines
or computerized work centers, robotic work cells,
DNC/FMS systems, work handling and tool
handling devices, storage devices, sensors, shop
floor data collection devices, inspection machines
etc.
 Computers, controllers, CAD/CAM systems,
workstations / terminals, data entry terminals, bar
code readers, printers, plotters and other peripheral
devices, modems, cables, connectors etc.

Miss. Neepa M. Patel, MPSTME 16

 CIM Software
CIM software comprises computer programmes to
carry out the following functions-
 Management Information System
 Sales
 Marketing
 Finance
 Database Management
 Modeling and Design
 Analysis
 Simulation
 Communications
 Monitoring
 Production Control
 Manufacturing Area Control

Miss. Neepa M. Patel, MPSTME 17

 Job Tracking
 Inventory Control
 Shop Floor Data Collection
 Order Entry
 Materials Handling
 Device Drivers
 Process Planning
 Manufacturing Facilities Planning
 Work Flow Automation
 Business Process Engineering
 Network Management
 Quality Management

Miss. Neepa M. Patel, MPSTME 18

Refer PDF for below questions
 Benefits Of CIM.

 Explain Product Life cycle with CIM.

OR
 Explain step by step Evaluation of Product cycle with
CIM.

 Role of CAD/CAM in CIM :

Note : for above question, write down all activities covered
in CAD/CAM and combine it.

Miss. Neepa M. Patel, MPSTME 19

Nature and Role of the Elements of CIM
 Nine major elements of a CIM system are :
1. Marketing
2. Product Design
3. Planning & Purchase
4. Manufacturing Engineering
5. Factory Automation Hardware
6. Warehousing
7. Logistics and Supply Chain Management
8. Finance
9. Information Management

Miss. Neepa M. Patel, MPSTME 20

Elements of CIM

Miss. Neepa M. Patel, MPSTME 21

Elements of CIM
1 Marketing :
The need for a product is identified by the marketing division. The
specifications of the product, the cost of the product, customer
feedback are also decided by the marketing dept.
2. Product Design :
With the help of initial data base and CAD, new product design is
generated by the design engineer. In CIM, after doing the above
process, the design process should constrained by the cast also.
3. Purchase:
This dept. is responsible for placing the purchase orders and follows
up, receive the items, arrange for inspection and supply the otems to
the stores

Miss. Neepa M. Patel, MPSTME 22

Elements of CIM
4. Manufacturing Engineering:
If we involve CIM, in manufacturing Engg. then all activities like NC
Programming, simulation and Computer aided Scheduling of the
production activity are covered to assure continuous production activity.
5. Factor Automation Hardware:
In CIM, the computer controlled m/cs such as CNC m/c, FMS, Robots,
AS/RS, AGVs all are working together to carry out the production
process.
6. Ware housing:
It is the function involving storage and retrieval of raw materials,
components, finish goods as well as shipment of items.
7. Finance:
Planning of investment, working capital, cash flow control, accounting
and allocation of funds are the major tasks of the finance dept.

Miss. Neepa M. Patel, MPSTME 23

Elements of CIM
8. Planning:
In CIM system, this planning process should be constrained by the
production cost and by the production equation and process capability,
in order to generate an optimized plan
9. Information Management :
It is one of the crucial tasks in CIM. This involves master production
scheduling, data management, communication, manufacturing system
integration and management information system.

Miss. Neepa M. Patel, MPSTME 24

Data Base Requirements of CIM
 Product Data: data about parts to be manufactured. It
includes text and geometry data.

 Manufacturing Data : The information as to how the

parts are to be manufactured is available in production data

 Operational Data: nearer to manufacturing data but

describes the things such as lot size, schedule, assembly
sequence etc.

 Resource Data: similar to operational data, but describe the

resources involved in operations, such as materials, m/cs,human
resource and money.

Miss. Neepa M. Patel, MPSTME 25

Obstacles of CIM
Major challenge facing the implementation of CIM is
to establish the type of data needed to bridge the
mechanical design and manufacturing functions.

 Preparing production drawing of assemblies,

individual parts, tooling, fixtures and other
manufacturing facilities
 Creating analytical models of parts for structural,
kinematics and thermal analysis
 Calculation weights,volumes,centres of gravity, and
cost of manufacturing
 Preparing parts list and bill of materials

Miss. Neepa M. Patel, MPSTME 26

Obstacles of CIM
 Classifying existing parts according to shape ,function and
process by which they are manufactured and retrieving these
parts from the parts library on demand (GT and Coding).
 Preparing process plans for individual part manufacture and
assembly
 Programming CNC m/cs for processing complete parts(CAM)
 Preparing programs to handle components like robots etc.
 Preparing programs for inspection & testing like CMM etc.
 Designing work cells and programming the movement of
components in those cells using work handling devices like
robots, conveyors, AGVs, AS-RS etc.

Miss. Neepa M. Patel, MPSTME 27

CIM wheel

Miss. Neepa M. Patel, MPSTME 28

CIM wheel
 CAD:
• Computer Aided Design
• Computer Aided Drafting & Documentation.
• Geometric Modeling
• Engineering Analysis
• Simulation
 CAM : it is divided into two areas :- CAMPC and CAM
• 1.CAM Planning and Control
• Production Planning
• CAPP, CAQC, Master Scheduling,
• Material Requirement Planning
• Material Resource Planning
• Inventory Management

Miss. Neepa M. Patel, MPSTME 29

CIM wheel
2.CAM
• Computer Aided Manufacturing by FMS
• Computer Aided Quality Assurance
 Business Functions:
• Purchase
• Stores
• Cost planning & Control,
• Marketing and Sales,
• Packaging and Forwarding,
• Finance and Accounts,
• Plant Maintenance,
• Human Resources and Developments

Miss. Neepa M. Patel, MPSTME 30

CIM Wheel

Miss. Neepa M. Patel, MPSTME 31

Prototype ???

Miss. Neepa M. Patel, MPSTME 32

Define Prototype
 What is a prototype?
 Looks like a finished product
 Behaves like a finished product
 May have small faults or missing functionalities

 Prototypes can be used in many ways

 To try out new features of an application
 Especially important is to use prototyping, when
new product concepts are introduced

Miss. Neepa M. Patel, MPSTME 33

Rapid Prototyping Systems
 The term rapid prototyping (RP) refers to a class of
technologies that can automatically construct physical
models from Computer-Aided Design (CAD) data.
 These "three dimensional printers" allow designers to
quickly create tangible prototypes of their designs, rather
than just two-dimensional pictures.
 Most prototypes require 3 to 72 hours to build,
depending on the size and complexity of the object.
 In the Rapid prototyping, the production of a physical
model from a computer model is to be done without the
need of any jig or fixture or NC programming.

Miss. Neepa M. Patel, MPSTME 34

Rapid Prototyping Systems

Miss. Neepa M. Patel, MPSTME 35

Rapid Prototyping Systems
 This may seem slow, but it is much faster than the
weeks or months required to make a prototype by
traditional means such as machining.
 These dramatic time savings allow manufacturers to
bring products to market faster and more cheaply.
 Such models have numerous uses:
 Excellent visual aids for communicating
 Prototypes can be used for design testing.
 Used to make tooling
 Used to make production-quality parts

Miss. Neepa M. Patel, MPSTME 36

All RP techniques follow the same basic
five-step process.
1. Create a CAD model of the design
2. Convert the CAD model to STL format
(stereolithography)
3. Slice the STL file into thin cross-sectional
layers
4. Layer by Layer Construction : RP machines build
one layer at a time from polymers, paper, or powdered
metal.
5. Clean and finish the model
 STL files describe only the surface geometry of a three-dimensional object
without any representation of colour, texture or other common CAD model
attributes.
Miss. Neepa M. Patel, MPSTME 37
The Stereolithography Machine

Miss. Neepa M. Patel, MPSTME 38

Picture of a statue using Stereolithography

Miss. Neepa M. Patel, MPSTME 39

Virtual prototyping
 Virtual prototyping is a method in the process of
product development. It involves using computer-aided
design (CAD), computer-automated design (CAutoD)
and computer-aided engineering (CAE) software to
validate a design before committing to making a physical
prototype.
 Virtual prototyping (VP) is the analysis and simulation

carried out on a computer model, It is also sometimes

referred to as computer-aided engineering(CAE) or
engineering analysis simulation.

Miss. Neepa M. Patel, MPSTME 40

Virtual prototyping
 Similarly, VP is defined as the subsequent manipulation
of a solid CAD model as a substitute for a physical
prototype for the purposes of simulation and analysis,
and is not inclusive of the construction of the solid 3D
model. VP includes the following functions:
 1. Finite element analysis.
 2. Mechanical form, fit and interference checking.
 3. Mechanical simulation.
 4. Virtual reality applications.
 5. Cosmetic modelling.

Miss. Neepa M. Patel, MPSTME 41

 Virtual Prototyping
 A virtual prototype is a computer simulation
model of a component or system.
 specifically it is applied to the role of:
 exploring design alternatives,

 Testing for requirements

satisfaction/correctness
 early removal of design errors through
simulation, correction, and regression testing
 early verification of software at the block
functional level and at more detailed levels
 Provides for early design verification through
simulation
 Helps remove requirements and specifications
errors earlier in the design process

Miss. Neepa M. Patel, MPSTME 42

Virtual prototype

Mercedes F700

Miss. Neepa M. Patel, MPSTME 43

Rapid vs Virtual Prototyping

Miss. Neepa M. Patel, MPSTME 44

 DFMA (refer DFMA ppt )
 DFMA stands for Design for Manufacture and
Assembly.

 DFMA is the combination of two methodologies;

1. Design for Manufacture, which means the

design for ease of manufacture of the parts that
will form a product.

2. Design for Assembly, which means the design of

the product for ease of assembly.

Miss. Neepa M. Patel, MPSTME 45

 Design for Manufacturing
–(refer DFMA ppt )
 DFMA is used as the basis for concurrent
engineering studies to provide guidance to the design team
in simplifying the product structure, To reduce
manufacturing and assembly costs, and to quantify
improvements.

 The practice of applying DFMA is to identify, quantify and

eliminate waste or inefficiency in a product design.

 DFMA is therefore a component of Lean Manufacturing.

 DFMA is also used as a benchmarking tool to study

competitors’ products, and as a should cost tool to assist in
supplier negotiations

Miss. Neepa M. Patel, MPSTME 46

 Design for Assembly (DFA)
 concerned only with reducing product assembly
cost
 minimizes number of assembly operations

 individual parts tend to be more complex in

design

 Design for Manufacturing (DFM)

 concerned with reducing overall part production
cost
 minimizes complexity of manufacturing
operations
 uses common datum features and primary axes

Miss. Neepa M. Patel, MPSTME 47

 Design for Assembly
Design for Assembly Principles -

 Minimize part count

 Design parts with self-locating features
 Design parts with self-fastening features
 Minimize reorientation of parts during assembly
 Design parts for retrieval, handling, & insertion
 Emphasize ‘Top-Down’ assemblies
 Standardize parts…minimum use of fasteners.
 Encourage modular design
 Design for a base part to locate other components
 Design for component symmetry for insertion

Miss. Neepa M. Patel, MPSTME 48

Key DFMA Principles –

 Minimize Part Count

 Standardize Parts and Materials
 Create Modular Assemblies
 Design for Efficient Joining
 Minimize Reorientation of parts during Assembly
and/or Machining
 Simplify and Reduce the number of
Manufacturing Operations
 Specify ‘Acceptable’ surface Finishes for
functionality

Miss. Neepa M. Patel, MPSTME 49

 University Questions
1. With neat sketch of CIM wheel, explain the salient features of
CIM system.

2. Short note on –Design for manufacturing(DFM)

3. Short note on –Design for Assembly (DFA)

4. What are general application guidelines of CIMS.

5. What are benefits of CIMS?

6. What are various Data files associated with CIM? Or data base
requirement of CIM.

7. Short note on –Rapid Prototyping with suitable block diagram.

8. Explain major functions in CIM along with block diagram.

Miss. Neepa M. Patel, MPSTME 50

 University Questions
9. Different between Design and manufacturing attributes.

10. What are the various elements of CIM and functions in the
improvement of quality and quantity of production?

11. Write a note on CIM Hardware and CIM software.

12. Role of CAD/CAM in CIM

13. Short note on Virtual prototyping

Miss. Neepa M. Patel, MPSTME 51

Miss. Neepa M. Patel, MPSTME 52
Thank You…

Miss. Neepa M. Patel, MPSTME 53