ME8751

COMPUTER INTEGRATED
MANUFACTURING SYSTEMS
UNIT 1
INTRODUCTION

INTRODUCTION

Today's industries cannot survive worldwide competition unless they

introduce new products with better quality (quality, Q), at lower cost (cost,
C), and with shorter lead time (delivery, D).

Accordingly, they have tried to use the computer's huge memory

capacity, fast processing speed, and user-friendly interactive graphics
capabilities to automate and tie together otherwise cumbersome and
separate engineering or production tasks, thus reducing the time and
cost of product development and production.

F. Taylor 1900 s

Individual specialized workers carried only a portion of

work. [ instead of entire product]

Jobs were broken down into parts

Concept of craftsman disappeared.

Advantage work force divided into worker, supervisor,

foreman & manager.

This specialization and division of labour

result

mass

production.

Increase

the

output

mass

production

brought

standardization.

Disadvantage increase the output lacking in the loss of

quality . It is necessary to inspect all the product at end of

Brief introduction to CAD

and CAM
Computer-aided design (CAD) is
defined as any design activity that
involves the effective use of the
computer to create, modify, analyze, or
document an engineering design.

There are several good reasons for using a CAD system to support the
engineering design function
To improve the quality of the design
The use of a CAD system with appropriate hardware and software
capabilities permits the designer to do a more complete engineering
analysis and to consider a larger number and variety of design
alternatives. The quality of the resulting design is thereby improved.
To improve design documentation
The graphical output of a CAD system results in better
documentation of the design than what is practical with manual drafting.
The engineering drawings are superior, and there is more standardization
among the drawings, fewer drafting errors, and greater legibility.
To increase the productivity of the designer
Helps reduce the time required bf the designer to synthesize,
analyze, and document the design.
To create a manufacturing data base
In the process of creating the documentation for the product design
(geometric specification of the product, dimensions of the components,
materials specifications, bill of materials, etc.), much of the required
data base to manufacture the product is also created.

DESIGN PROCESS USING CAD

 Geometric modeling involves the use of a CAD system

to develop a mathematical description of the geometry of
an object.
The mathematical description, called a geometric model,
is contained in computer memory.
There are various types of geometric models used in CAD.
One classification distinguishes between two-dimensional
(2-D) and three-dimensional (3-D) models.

Finally, two other features in CAD

system models are color and animation.
Some CAD systems have color
capability in addition to black-andwhite.

Engineering Analysis
The term computer-aided engineering (CAE)
is often used for engineering analyses
performed by computer.
Examples of engineering analysis software in
common use on CAD systems include:
Mass property analysis
Interference checking
Tolerance analysis
Finite elemental analysis
Kinematic and dynamic analysis
Discrete-event simulation

Design Evaluation and

Review

Automatic dimensioning
Error checking.
Animation of discrete-event simulation solutions
Plant layout design scores

New Approaches:
1.
Rapid prototyping and
2.
Virtual prototyping,

Automated Drafting
The fourth area where CAD is useful
(step 6 in the design process) is
presentation and documentation.
CAD systems can be used as automated
drafting machines to prepare highly
accurate engineering drawings quickly.
It is estimated that a CAD system
increases productivity in the drafting
function by about fivefold over manual
preparation of drawings.

CAM
Computer-aided manufacturing
(CAM) is defined as the effective use of
computer
technology
in
manufacturing
planning
and
manufacturing control.

Manufacturing Planning
Computer-aided process planning
(CAPP)
Computer-assisted NC part
programming
Computerized machinability data
systems
Development of work standards
Cost estimating
Production and inventory planning

Manufacturing Control

Process monitoring and control

Quality control
Shop floor control
Inventory control
Just-in-time production systems

CAD/CAM
CAD/CAM is concerned with the engineering
functions in both design and manufacturing.
Product design, engineering analysis, and
documentation of the design (e.g.. drafting)
represent engineering activities in design.
Process planning, NC part programming, and
other activities associated with CAM represent
engineering activities in manufacturing.
CAD/CAM denotes an integration of design
and manufacturing activities by means of
computer systems.

CONCURRENT
ENGINEERING
Concurrent engineering refers to an
approach used in product development
in which the functions of design
engineering,
manufacturing
engineering, and other functions are
integrated to reduce the elapsed time
required to bring a new product to
market. Also called simultaneous
engineering

SEQUENTIAL
ENGINEERING

CONCURRENT
ENGINEERING

Concurrent engineering include several

elements:
Design for Manufacturing and
Assembly
Organizational changes
Design principles and guidelines

Design for Quality

Design for Product Cost
Design for Life Cycle

Computer Integrated
Manufacturing

Meaning of CIM
The integration of business engineering, manufacturing and
management information's that spans company functions from
marketing to product distribution.
Some writers coining CIM also called Computer integrate
enterprise (CIE), Computer integrated mechanical enterprise
(CIME).
Why CIM?
To meet a companys business strategy
CIM means to an end, and the end is the achievement of
particular business strategy.

CUSTOMER
FOCUSED
MANUFACTURING

CIM example

Manufacturing Models and Metrics

Production Rate
The production rate for an individual
processing or assembly operation is
usually expressed as an hourly rate, ie.,
parts or products per hour.

Tc = operation cycle time (min/pc).

To = time of the actual processing or
assembly operation (min/pc).
Th = handling time (min/pc)
Tth = tool handling time(min/pc)

Tb = batch processing time (min),

Tsu = setup time to prepare for the batch
(min),
Tp = average production time per minute
(min/pc).
Tr = time to transfer work units
between stations each cycle
(min/pc),
Rp =hourly production

Production Capacity
Production capacity is defined as the maximum rate of output
that a production facility (or production line, work center, or group
of work centers) 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 days in the week (or month)
that the plant operates, employment levels, and so forth.

PC = production capacity of the facility (output units/wk)

n = number of work centers producing in the facility
S = number of shifts per period (shift/wk)
H = hr/shift(hr)
Rp= hourly production rate of each work center (output units/hr)
no = number of distinct operations

Utilization and
Availability
Utilization refers to the amount of output of a production
facility relative to its capacity.

Availability is a common measure of reliability for

equipment. It is especially appropriate for automated
production equipment. Availability is defined using two
other reliability terms, mean time between failure (MTBF)
and mean time to repair (MTIR). The MTBF indicates the
average length of time the piece of equipment runs
between breakdowns. The MTTR indicates the average
time required to service the equipment and put it back into
operation when a breakdown occurs.

Manufacturing Lead
Time
Manufacturing Lead Time (MLT) as the total time
required to process a given part or product through
the plant

MLTi = manufacturing lead time for part or product j (min)

T suji = setup time for operation i (min)
Qj = quantity of part or product j in the batch being processed
(pc)
Tcji = operation cycle time for operation i (min/pc)
Tnoji = non operation time associated with operation i (min)
i indicates the operation sequence in the processing

Work-In-Process
Work in process (WIP) is the quantity
of parts or products currently located
in the factory that are either being
processed or are between processing
operations.
WIP is inventory that is in the state
of being transformed from raw
material to finished product.

COSTS OF MANUFACTURING OPERATIONS

Fixed and Variable Costs

TC = FC + VC(Q)
TC = total annual cost ($/yr),
FC = fixed annual cost ($/yr),
VC = variable cost ($/pc),
Q = annual quantity produced (pc/yr)

Direct labor, Material, and

Overhead
The direct labor cost is the sum of the wages
and benefits paid to the workers who operate
the production equipment and perform the
processing and assembly tasks.
The material cost is the cost of all raw
materials used to make the product.
Overhead costs are all of the other expenses
associated with running the manufacturing firm.
Factory overhead
Corporate overhead

Cost of Equipment Usage

The trouble with overhead rates as
we have developed them here is that
they are based on labor cost alone.
To deal with this difficulty, it is
appropriate to divide the cost of a
worker running a machine into two
components:
(1)direct labor and
(2)machine.

BASIC ELEMENTS OF AN AUTOMATED

SYSTEM

Automation is the technology by

which a process or procedure is
accomplished
without
human
assistance.
Power to Accomplish the Automated
Process
Program of Instructions
Control System

LEVELS OF AUTOMATION

LEAN PRODUCTION
Lean production can be defined as an
adaptation of mass production in which
workers and work cells are made more
flexible and efficient by adopting methods
that reduce waste in all forms.
1.
2.
3.
4.

Minimize Waste
Perfect First-time quality
Flexible Production lines
Continuous Improvement

Minimize Waste
Ohno's list of waste forms can be listed as
follows
(1) production of defective parts,
(2) production of more than till: number of
items needed,
(3) unnecessary inventories,
(4) unnecessary processing steps,
(5) unnecessary movement of people,
(6) unnecessary transport of materials, and
(7) workers waiting.

Perfect First-Time
Quality
In mass production, quality control

is defined in
terms of an acceptable quality level. This means
that a certain level of fraction defects is sufficient,
even satisfactory.
In lean production, by contrast, perfect quality is
required. The just-in-time delivery discipline used in
lean production necessitates a zero defects level
in parts quality, because if the part delivered to the
downstream workstation is defective, production
stops. A single defect draws attention to the quality
problem, forcing corrective action and a permanent
solution. Workers inspect their own production,
minimizing the delivery of defects to the
downstream production station

Flexible Production
Systems

Lean production makes use of worker teams to

organize the tasks to be accomplished and
worker involvement to solve technical problems.
In mass production, the goal is to maximize
efficiency. This is achieved using long
production runs of identical parts. Long
production
runs
tolerate
long
setup
changeovers.
In lean production, procedures are designed to
speed the changeover. Reduced setup times
allow for smaller batch sizes, thus providing
the production system with greater flexibility.

Continuous Improvement
Kaizen
by
the
Japanese,
continuous
improvement means constantly searching for
and implementing ways to reduce cost, improve
quality, and increase productivity.
Beyond factory operations and involves
design improvements.
Cost
reduction,
quality
improvement,
productivity improvement, setup time reduction,
cycle time reduction, manufacturing lead time
and work-in-process inventory reduction, and
improvement of product design to increase
performance and customer appeal.

JUST-IN-TIME PRODUCTION SYSTEMS

Just-in-time (JIT) production systems were
developed in Japan to minimize inventories,
especially WIP.
Just at the time when that component is
needed.
Certain requisites must be in place for a JIT
production system to operate successfully.
They are,
1. a pull system of production control,
2. small batch sizes and reduced setup times,
and
3. stable and reliable production operations.

Pull System of Production Control

One way to implement a pull system
is to use Kanbans.
The word Kanban (pronounced
kahn-bahn) means "card" in Japanese.
Use of cards that authorize
(1)parts production and
(2)parts delivery in the plant.
Two types of kanbans
(3)Production kanbans (P-Kanban) and
(4)Transport kanbans (T-Kanban).

Small Batch Sizes and Reduced

Setup Times
To minimize WIP inventories in
manufacturing, batch size and setup
time must be minimized.
Average inventory level is equal to
one half the batch size. To reduce
average inventory level, batch size must
be reduced. And to reduce batch size,
setup cost must be reduced. This means
reducing setup times. Reduced setup
times permit smaller batches and lower
WIP levels.

Setup time reductions

Separate the work elements that comprise the
setup procedure into two categories:
(1) internal elements, those that must be done
during the machine stoppage, and
(2) external elements, those that can be done
while the previous job is still running.
()Design the setup tooling [e.g., die, fixture,
mold) and plan the setup method to permit as
much of the changeover procedure as possible
to consist of external work elements.
()Use time and motion study to reduce the
internal work elements to the fewest possible.

Eliminate or minimize adjustments in the

setup.
Adjustments are time consuming.
Use quick-acting clamping devices instead of
bolts and nuts.
Develop permanent solutions for problems that
cause delays in the setup.
Schedule batches of similar part styles in
sequence to minimize the magnitude of
changes required in the setup.
Use
group
technology
and
cellular
manufacturing it possible so that similar part
styles are produced on the same equipment.
Design modular fixtures consisting of a base
unit plus insert tooling that can be quickly
changed for each new part style

Stable and Reliable Production

Operations
1.
2.
3.
4.
5.

Stable production schedules

On-time delivery
Defect-free components (Jidoka)
Reliable production equipment
A workforce that is capable,
committed, and cooperative
6. A dependable supplier base.