Computer Integrated Manufacturing (CIM)

Course code :- MaEng 4143

Lecturer:- Elias G/kiros (M.Sc. in Manufacturing &
Materials engineering)
ECTS :- 5
Pre-requisites:- Computer Aided Manufacturing (CAM)
(MaEng3142)
Contact office:- B-07 R-204
Chapter -1 : Outlines
Introduction
 Manufacturing Definition and Development
 Mechanization and Automation
 Automation and computerization in a PS
 Conceptual model of automation and CIM
 Benefits of CIM
1.1. Automation In Production Systems, Automation Principles And
Strategies.
1.2. Basic  elements of  an automated system, advanced  automation ,
functions, levels of automations.
1.3.
Flow lines & transfer mechanisms, fundamentals of transfer lines.
Conti…
1.4. Production Concepts And Mathematical
Models
 Manufacturing lead time
 Production rate
Components of operation time;
 Capacity, Utilization and Availability
Work-in-process ; WIP ratio, tip ratio.
Problems using mathematical model equations.
 Introduction
 Manufacturing Definition and Development
 Manufacturing Definition:
Manufacturing is defined two ways: technologic and economic
A. Technologically, manufacturing is application of physical and
chemical processes to alter the geometry, properties, and/or
appearance of a starting material to make parts or products.
– It is carried out as a sequence of operations to bring the
material closer to the desired final state.
– The processes involve a combination of machinery, tools,
power, and labor i.e manufacturing system

4
B. Economically, it is the transformation of materials into items
of greater value.
– iron ore into steel,
– sand into glass,
– petroleum into plastic,
– molded plastic into complex geometry of chair.

5
Conti…
 Manufacturing System
• Manufacturing as a system goes beyond the
conversion of raw material and processes.
• It considered as a system, due the integration of
people, equipment, policies and procedures to
accomplish organizational objectives
• The holistic approach for manufacturing system
incorporates design, planning and conversion.

6
Conti…
 Manufacturing Development
• Manufacturing process has developed immensely to
increase production, capacity, productivity and
quality to get higher profit.
• Focusing on role of people and type of tool used
manufacturing have five stages of development:
1. Manual – people using hand tools
2. Mechanized – machine directly controlled by people
3. Automated/mechanically driven – machine controlled by
mechanical device
4. Automated/program driven – machine controlled by
programmed computers
5. Computer integrated manufacturing – machine controlled
by a hierarchy of computers.
 Mechanization and Automation:
• Mechanization - precursor to automation
• It is the transfer of skills and manual activities to
machine operations.
– Mechanization may be defined as the use of energy
of a non-living system to carry out process
operations
• Automation is process of following predetermined
sequence of operations with little or no human labor,
– In its full sense, it is achieved through the use of a
variety of devices, sensors, actuators, techniques
and equipment.
– Automation includes feedback for controlling an
automated system.
 Automation and computerization in a PS
Automated Production System elements have two
categories, which somehow overlap
1. Automation of mnfg systems operate on physical
product such as processing, assembly, inspection, or
handling.
– The factory floor are themselves often connected to mnfg
support at plant and enterprise level,
2. Computerization of mnfg support systems is aimed at
reducing manual and clerical effort in design, planning
and control and business functions, which are currently
computerized.
– The term CIM is used to indicate this extensive use of
computers in production systems.
 Conceptual model of automation and CIM
• The physical production activities (in direct contact
with the product) can be distinguished from info -
processing activities (design and planning, in office
environment).
• Raw materials flow into one end of the factory and
finished products flow out of the other end.
• The activities take place in the factory (tube).
• The information-processing activities (support
functions) form a ring that surrounds the factory,
providing the data and knowledge required to
successfully produce the product.
Conceptual model of automation and CIM…

Fig. Model of manufacturing showing factory operations and the

information processing activities.
 Benefits of CIM
Compared with conventional systems, CIM system gives
the following benefits:
• Reduction of design cost by 15 – 30%
• Reduction of the in-shop time by 30-60%
• Increase of productivity by 40 – 70%
• Better product quality; scrap reduction by 20 – 50%
• Improved product design; i.e. calculating many design
variants,
• CIM reduces the human component (slow, expensive
and error-prone) of manufacturing
1.1.(A). Automation In Production Systems
 The automated elements of the production system
can be separated into two categories: (1) automation
of the manufacturing systems in the factory and (2)
computerization of the manufacturing support
systems.
 In modern production systems, the two categories
overlap to some extent. because the automated
manufacturing systems operating on the factory
floor are themselves often implemented by
computer systems and connected to the
computerized manufacturing support systems and
management information system operating at the
plant and enterprise levels.
Conti…
 The term computer-integrated manufacturing is used to
indicate this extensive use of computers in production
systems.

Opportunities of automation and

computerization in a production system
 Basic types of automated mnfg systems:
(1)Fixed automation; the sequence of processing/
assembly operations is fixed by the equipment
configuration. Each operation in the sequence is
simple; for example, feeding a spindle. It is the
integration and coordination of many such operations
into one piece of equipment
Typical features of fixed automation are:
• It uses mechanical, electrical, pneumatic and hydraulic systems
• High initial investment for custom-engineered equipment
• High production rates
• Relatively inflexible in accommodating variety
The economic justification is found in very large
quantities at high rates where cost can be spread over
large number of units.
(2) Programmable automation: is designed with
capability to change the sequence of operations to
accommodate different product configurations. The
sequence is controlled by a program (instructions that
can be read and interpreted by the system).
Some features include:
• High investment in general purpose equipment
• Lower production rates than fixed automation
• Flexibility to deal with variations and changes
• Most suitable for batch in low- and medium-volume.
• Process includes: setup, reprogramming and production
for each new batch, . E. g; NC machine tools, robots,.
(3) Flexible automation. is an extension of
programmable automation, capable of producing a
variety of parts (soft variety) with virtually no time
lost for changeovers b/n part style (reprogramming
and altering the physical setup)..
The features of flexible automation are:
• High investment for custom-engineered system
• Continuous production of variable mixtures
• Medium production rates
• Flexibility to deal with product design variations

E. g FMS
 Fig. Relative positions of automation types for
production volumes and product varieties

For low quantities and new product introductions, manual is

competitive with programmable automation,
 Reasons for Automating
1. To increase labor productivity by increasing production rate
2. To reduce ever-increasing labor cost in the industrialized societies
by substituting machines for human labor
3. To mitigate effects of labor shortages in advanced nations,
4. To reduce or eliminate routine manual and clerical tasks that are,
boring, fatiguing, and possibly risky.
5. To improve worker safety by transferring worker from the process
to a supervisory role.
6. To improve product quality with greater uniformity and
conformity to quality specifications.
7. To reduce manufacturing lead time b/n customer order and
product delivery, providing a competitive advantage.
8. To accomplish processes that cannot be done manually for
precision, miniaturization, or complexity for manual work.
9. To avoid the high cost of not automating: competitive advantage
gained in automating a manufacturing plant.
 1.1.(b). Automation Principles And Strategies
The preceding discussion leads us to conclude that
automation is not always the right answer for a given
production situation. A certain caution and respect must be
observed in applying automation technologies.
I. The USA Principle,

II. The Ten Strategies for Automation and

Production Systems
 Conti…
I. USA Principle
USA stands for;
1. Understand the existing process
2. Simplify the process
3. Automate the process.
1. Understand the Existing Process.
The obvious purpose of the first step in the
USA approach is to comprehend the current process in
all of its details. What are the inputs and outputs? What
exactly happens to the work unit between input and
output? What is the function of the process? How does
it add value to the product?
 Conti…
2. Simplify the Process.
Once the existing process is understood, then the search
can begin for ways to simplify. This often involves a
checklist of Questions about the existing process. What
is the purpose of this step or this transport? Is this step
necessary? Can this step be eliminated? Is the most
appropriate technology being used in this step? How
can this step be simplified? Are there. unnecessary steps
in the process that might be eliminated without
detracting from function?
 Conti…
3. Automate the Process.

Once the process has been reduced to its simplest form,

then automation can be considered. The possible forms
of automation include those listed in the ten strategies
discussed in the following section.
 Conti…
II. Ten Strategies for Automation and Production
Systems.
We refer to them as strategies for automation and
production systems because some of them are
applicable whether the process is a candidate for
automation or just for simplification.
1. Specialization of operations,
The first strategy involves the use of special-purpose
equipment designed to perform one operation with the
greatest possible efficiency. This is analogous to the
concept of labor specialization, which is employed to
improve labor productivity.
 Conti…
2. Combined operations.
The strategy of combined operations involves reducing
the number of distinct production machines or work-
stations through which the part must be routed. This is
accomplished by performing more than one operation at
a given machine, thereby reducing the number of
separate machines needed. Since each machine typically
involves a setup, setup time can usually be saved as a
consequence of this strategy.
 Conti…
3.Simultaneousoperations. In effect, two or more
processing (or assembly) operations are being
performed simultaneously on the same work part. thus
reducing total processing time.
4. Integration of operations. Another strategy is to link
several work stations together into a single integrated
mechanism, using automated work handling devices to
transfer parts between stations. In effect, this reduces
the number of separate machines through which the
product must be scheduled. the system.
 Conti…
5. Increased flexibility. This strategy attempts to achieve
maximum utilization of equipment for job shop and
medium-volume situations by using the same equipment
for a variety of parts or products
6. Improved material handling and storage. A great
opportunity for reducing nonproductive time exists in
the use of automated material handling and storage
systems.
7. On-line inspection, Incorporating inspection into the
manufacturing process permits corrections to the
process as the product is being made. This reduces scrap
and brings the overall quality of the product closer to
the nominal specifications.
 Conti…
8, Process control and optimization. By this strategy, the
individual process times can be reduced and product
quality improved.
9. Plant operations control. this strategy is concerned with control
at the plant level. It attempts to manage and coordinate the
aggregate operations in the plant more efficiently.
10. Computer-integrated manufacturing (CIM). we have the
integration of factory operations with engineering design and
the business functions of the firm, ClM involves extensive use of
computer applications, computer data bases, and computer
networking throughout the enterprise.
1.2.Basic  elements of  an automated system, advan
ced  automation functions, levels of automations.
An automated system consists of three basic
elements
(1) Power: to accomplish the process
and operate the system. E.g. Electrical power
(2) Program of instructions: to direct the process.
E.g. Work Cycle Programs in furnace.
(3) Control system: to actuate the instructions.
either closed loop or open loop.
Conti…

Closed loop control system

Elements of an automated system: (1) power, (2) program of

instructions, and (3) control systems.
Conti…
 Advanced  automation functions
In addition to executing work cycle programs,
automation can enhancing the performance and
safety of the equipment. Advanced automation
functions include the following:
(1)safety monitoring,
(2)maintenance
and repair diagnostics, and
(3)error detection and recovery.
Conti…
 Levels of Automations
There are five possible levels of automation in a
production plant.
1. Device level
2. Machine level
3. Cell or system level
4. Plant level.
5. Enterprise level
Conti…
1.3.Flow lines & transfer mechanisms, fundamentals
 of transfer lines.
 An automated flow line consists of several
machines or workstations which are linked
together by work handling devices that transfer
parts between the stations.
Configurations of automated flow line
1) In-line type
Conti…
2) Segmented In-Line Type

L-shaped configuration

U-shaped configuration
Conti…

Rectangular-shaped configuration
Conti…
3.Rotary type

Rotary configuration
Conti…
 Methods of Work part Transport
The general methods of transporting work pieces on flow
lines can be classified into the following three categories:
1.Continuous transfer
2. Intermittent or synchronous transfer
3. Asynchronous or power-and-free transfer
Transport system for a given application depends on:
 The types of operation to be performed
 The number of stations on the line
 The weight and size of the work parts
 Whether manual stations are included on the line
 Production rate requirements
 Balancing the various process times on the line
Conti…
1.Continuous transfer: work parts are moved continuously at
Constant speed. This requires the work heads to move during
processing in order to maintain continuous registration with the work
part.
2. Intermittent or synchronous transfer: Work pieces are
transported with an intermittent or discontinuous motion. The
workstations are fixed in position and the parts are moved between
stations and then registered at the proper locations for processing.
3. Asynchronous or power-and-free transfer: also referred to as
a "power-and-free system,“ allows each work part to move to the next
station when processing at the current station has been completed.
Each part moves independently of other parts. Hence, some parts are
being processed on the line at the same time that others are being
transported between stations.
Conti…
 Transfer Mechanisms
There are various types of transfer mechanisms used to move parts
between stations. These mechanisms can be grouped into two types:
those used to provide linear travel for in-line machines, and those used
to provide rotary motion for dial indexing machines.
 Linear transfer mechanisms:

Walking beam systems

Conti…
 Linear transfer mechanisms:

Powered roller conveyor system

Chain drive conveyor

Conti…
 Rotary transfer mechanisms:
Rack and pinion
1.4. Production Concepts And Mathematical
Models
A number of production concepts are quantitative,
or require a quantitative approach to measure them.
Manufacturing lead time:
Let us divide the activities in production into two main
categories, operations and non operation elements.
An operation on a product (or work part) takes place when
it is at the production machine. The non operation
elements are the handling, storage, inspections, and other
sources of delay.
Conti…
To –operational time
T no- non operation time
nm- separate machines or operations through which the
product must be routed in order to be
completely processed.
Q- batch production situation, there are units of the
product in the batch.
Conti…

Problem .1

A certain part is produced in a batch size of 50 units

and requires a sequence of eight operations in the
plant. The average setup time is 3 h, and the average
operation time per machine is 6 min. The average non
operation time due to handling, delays, inspections,
and so on, is 7 h. compute how many days it will take
to produce a batch, assuming that the plant operates
on a 7-h shift per day?
Conti…
Production rate;
The production rate for an individual manufacturing
process or assembly operation is usually expressed as an
hourly rate (e.g., units of product per hour). The rate will
be symbolized as Rp.

Where TP is given by;

Components of operation time;
The operation time (To) is the time an individual
work part spends on a machine, but not all of this
time is productive.
Operation time for a machining operation is
composed of three elements: the actual machining
time Tm, the work piece handling time Th, and any
tool handling time per work piece Tth.
Hence,
Capacity, Utilization and Availability
Capacity;
The term capacity, or plant capacity, is used to define the
maximum rate of output that a plant is able to produce
under a given set of assumed operating conditions.
W-represent the number of work centers
Rp - production rate
H- hours per shift for work center operations
Sw -number of shifts per week.

PC= W x Sw x Rp x H
Problem 2

The turret lathe section has six machines, all devoted to

production of the same pad . The section operates 10 shifts
per week. The number of hours per shift averages 6.4
because of operator delays and machine breakdowns. The
average productionrateis17units/h. Determine the
production capacity of the turret lathe section?
Utilization;
Utilization refers to the amount of output of a production
facility relative to its capacity. Let say U represent
utilization,

Problem 4
A production machine is operated 65 h/week at full
capacity. Its production rate is 20 units/hr. During a certain
week, the machine produced 1000 good parts and was idle
the remaining time.
(a) Determine the production capacity of the machine?
(b) What was the utilization of the machine during the
week under consideration?
Availability
The availability is sometimes used as a measure of-
reliability for equipment. Availability is defined using two
other reliability terms, the mean time between failures
(MTBF) and the mean time to repair (MTTR). The MTBF
indicates the average length of time between breakdowns
of the piece of equipment. The MTTR indicates the
average time required to service the equipment and place it
back into operation when a breakdown does occur:
Work-in-process
Work - in-process (WIP) ; is the amount of product
currently located in the factory that is either being
processed or is between processing operations. WIP is
inventory that is in
the state of being transformed from raw material to
finished product. A rough measure of work-in-process
can be obtained from the equation
The TIP ratio measures the time that the
product spends in the plant relative to its actual
processing time. It is computed as the total
manufacturing lead time for a pan divided by
the sum of the individual operation times for the
part.