MECHANIICS

SUPERVISION LEVEL IV
Supervising and Guiding Computer-Integrated
Manufacturing (CIM) Production Operations
MODULE CODE:IND MCS4 06 0217
NOMINAL DURATION:58Hrs

Academic Year: 2014/2021

Instructor: lt. kibru getahun
phone: 0912370975 1
 LO.1 Interpret the
design brief or scope of
production including
CIM system

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 Introduction to CIM
What is CIM ?
1. 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.
2. 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.
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1. 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.
2. 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 Assistance

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Data flow in CIM

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CIM Wheel

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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

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 Processes Involved
The various processes involved in a CIM are listed as
follows:
•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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 Advantages of CIM
1.Error Reduction
2.Speed
3.Flexibility
4.Integration
1. Error Reduction
Elimination of human error in many assignment and
reporting functions on factory floor operations drastically
reduces the error rate.

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 Advantages of CIM
2.Speed
CIM environments reduce the time it takes to
perform manufacturing fabrication and assembly,
allowing quicker flow of product to customers and
increased capacity.

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 Advantages of CIM
3. Flexibility
With CIM companies quickly react to market conditions
and then return to previous settings when market
conditions change.

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 Advantages of CIM
4. Integration
CIM offers a degree of integration that enables the
flexibility, speed and error reduction required to
compete and lead markets.
Integrating factory floor operations with
enterprise software enables employees to do
higher value functions for their companies.

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 Defining CIM
Technology, tool or method used to improve
entirely the design and manufacturing
process and increase productivity
Using computers to help people and machines
to communicate
Architecture for integration of multiple
technologies through computers, linking each
individual island of automation to a closed loop
business system

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integration of computer aided design, automatic
material handling, robotics, process
technologies, manufacturing planning & control,
computer aided quality control, computer aided
manufacturing
focuses on the computer as the center of control
of the entire factory, starting from the
computerization of the fabrication and assembly
processes to the information flow for production
control, quality, maintenance, material handling,
and inventory control in a totally integrated
system
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CIM
Computer – database
Integration – Network
Manufacturing – rapid development of new products
CIM; conceptual rather than physical
Objectives of CIM; managing enterprises

Elements of CIM
Information technology: Computer,
Communication, Control
Manufacturing technology: Manufacturing, Market,
Management
3Cs support 3Ms
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Elements of 3Cs
Computer: IT, OS, programming language,
database, artificial intelligence
Communication: communication
technology, MAP, TOP, LAN, WAN
Control: control technology, algorithm,
S/W for control

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Evolution of Computer Integrated Manufacturing
Computer Integrated Manufacturing (CIM) is
considered a natural evolution of the technology
of CAD/CAM which by itself evolved by the
integration of CAD and CAM.
The need to meet the design and manufacturing
requirements of aerospace industries after the
Second World War necessitated the development
these technologies. This prompted the US Air
Force to approach MIT to develop suitable control
systems, drives and programming techniques for
machine tools using electronic control.
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In the case of manufacture, CNC machines, DNC
systems, FMC, FMS etc provide tightly controlled
automation systems. Similarly computer control
has been implemented in several areas like
manufacturing resource planning, accounting,
sales, marketing and purchase.
Yet the full potential of computerization could not
be obtained unless all the segments of
manufacturing are integrated, permitting the
transfer of data across various functional modules.

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This realization led to the concept of computer
integrated 10 manufacturing. Thus the
implementation of CIM required the development
of whole lot of computer technologies related to
hardware and software.

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 Automation in Production System
Two categories of automation in the production
system:
1. Automation of manufacturing systems in the
factory.
2. Computerization of the manufacturing
support systems.
The two categories overlap because
manufacturing support systems are connected
to the factory manufacturing systems.
Computer-Integrated Manufacturing (CIM)

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Computer Integrated Manufacturing

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Automated Manufacturing Systems
Examples:
• Automated machine tools
• Transfer lines
• Automated assembly systems
• Industrial robots that perform processing or
assembly operations
• Automated material handling and storage
systems to integrate manufacturing operations
• Automatic inspection systems for quality control
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Automated Manufacturing Systems

Three basic types:

1. Fixed automation
2. Programmable automation
3. Flexible automation

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 Fixed Automation
A manufacturing system in which the sequence of
processing (or assembly) operations is fixed by
the equipment configuration.
Typical features:
• Suited to high production quantities.
• High initial investment for custom-engineered
equipment.
• High production rates.
• Relatively inflexible in accommodating product
variety.
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 Programmable Automation
A manufacturing system designed with the capability
to change the sequence of operations to
accommodate different product configurations.
Typical features:
• High investment in general purpose equipment.
• Lower production rates than fixed automation.
• Flexibility to deal with variations and changes in
product configuration.
• Most suitable for batch production.
• Physical setup and part program must be changed
between jobs (batches).
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 Flexible Automation
An extension of programmable automation in which
the system is capable of changing over from one job
to the next with no lost time between jobs.
Typical features:
• High investment for custom-engineered system.
• Continuous production of variable mixes of products.
• Medium production rates.
• Flexibility to deal with soft product variety.

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Product Variety and Production Quantity for Three
Automation Types

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 Computerized Manufacturing
Support Systems
Objectives of automating the manufacturing
support systems:
• To reduce the manual and clerical effort in
product design, manufacturing planning and
control, and the business functions.
• Integrates computer-aided design (CAD) and
computer-aided manufacturing (CAM) in
CAD/CAM.
• CIM includes CAD/CAM and the business
functions of the firm. 29
 CIM Hardware and CIM Software
CIM Hardware comprises the following:
i. 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.

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ii. Computers, controllers, CAD/CAM systems,
workstations / terminals, data entry terminals,
bar code readers, RFID tags, printers, plotters and
other peripheral devices, modems, cables,
connectors etc., CIM software comprises
computer programmes to carry out the following
functions:

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Management Information System
Sales
 Marketing
 Finance
Database Management
Modeling and Design
Analysis
Simulation
Communications
Monitoring
Production Control
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Manufacturing Area Control
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 33
 Nature and Role of the Elements of CIM
System
Nine major elements of a CIM system are in Fig
3 they are,
Marketing
Product Design
Planning
Purchase
Manufacturing Engineering
Factory Automation Hardware
Warehousing
Logistics and Supply Chain Management
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Finance
Information Management

Major elements of CIM systems

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1. Marketing: The need for a product is identified by the
marketing division. The specifications of the product,
the projection of manufacturing quantities and the
strategy for marketing the product are also decided
by the marketing department. Marketing also works
out the manufacturing costs to assess the economic
viability of the product.
2. Product Design: The design department of the company
establishes the initial database for production of a
proposed product. In a CIM system this is accomplished
through activities such as geometric modeling and
computer aided design while considering the product
requirements and concepts generated by the creativity
of the design engineer.
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3. Planning: The planning department takes the database
established by the design department and enriches it
with production data and information to produce a
plan for the production of the product. Planning
involves several subsystems dealing with materials,
facility, process, tools, manpower, capacity, scheduling,
outsourcing, assembly, inspection, logistics etc .
4. Purchase: The purchase departments is responsible
for placing the purchase orders and follow up, ensure
quality in the production process of the vendor,
receive the items, arrange for inspection and supply
the items to the stores or arrange timely delivery
depending on the production schedule for eventual
supply to manufacture and assembly.
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5. Manufacturing Engineering: Manufacturing Engineering
is the activity of carrying out the production of the
product, involving further enrichment of the database
with performance data and information about the
production equipment and processes. In CIM, this
requires activities like CNC programming, simulation
and computer aided scheduling of the production
activity. This should include online dynamic scheduling
and control based on the real time performance of the
equipment and processes to assure continuous
production activity. Often, the need to meet
fluctuating market demand requires the
manufacturing system flexible and agile.

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6. Factory Automation Hardware: Factory
automation equipment further enriches the
database with equipment and process data,
resident either in the operator or the
equipment to carry out the production
process. In CIM system this consists of
computer controlled process machinery such
as CNC machine tools, flexible manufacturing
systems (FMS), Computer controlled robots,
material handling systems, computer
controlled assembly systems, flexibly
automated inspection systems and so on.
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7. Warehousing: Warehousing is the function
involving storage and retrieval of raw
materials, components, finished goods as well
as shipment of items. In today's complex
outsourcing scenario and the need for just-in-
time supply of components and subsystems,
logistics and supply chain management
assume great importance.

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8. Finance: Finance deals with the resources pertaining
to money. Planning of investment, working capital,
and cash flow control, realization of receipts,
accounting and allocation of funds are the major
tasks of the finance departments.
9. Information Management: Information Management
is perhaps one of the crucial tasks in CIM. This
involves master production scheduling, database
management, communication, manufacturing
systems integration and management information
systems.

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Targets of CIM
Developing high quality products with low cost
Integration and control of product design and
manufacturing processes
Easy financial management
Increasing volume of sales

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Function of CIM
1. Order information and automatic scheduling
through computer
 dealing individual orders of various products
 control of due dates
 preparing production planning
2. Inventory control through JIT
- minimizing raw material, WIP, inventory
- utilizing bar code, RFID
3. Statistical quality control
- quality improvement

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4. Monitoring facility, process
 - data collection for facility operating
 - report for producing defective goods
 - records & analysis of failing facility
5. Data collection for MIS
 - WIP data
 - shipment data
 - direct & indirect labor data
 - production control data ; defective rate, operation
rate, failure rate, production rate
 - supplier record; quality, accomplishment
 - defective production data

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6. Managing MIS Data
- reducing indirect cost
- rapid decision making using database
7. Diagnosing failure
- minimizing down time
- details of failure (problems)
8. Managing Technical Data, Document
- managing S/W program
- tool life data
- quality data
- product history
- document update
9. Standard 45
POTANTIAL BENEFITS OF CIM
 Improved customer service
 Improved quality
 Shorter time to market with new products
 Shorter flow time
 Shorter vendor lead time
 Reduced inventory levels
 Improved schedule performance

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 POTANTIAL BENEFITS OF CIM
 Greater flexibility and responsiveness
 Improved competitiveness
 Lower total cost
 Shorter customer lead time
 Increase in manufacturing productivity
 Decrease in work-in process inventory

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CIM Hierarchy
1st Level: production facility
CNC, Robot, PLC
2nd Level: Work Cell
controlling 1st level activity, applying data from 1st
to process, production, quality control
3rd Level: Area level
managing several lines, production plan, facility
maintenance scheduling, assigning material, facility.
4th Level: Factory level
controlling function of whole factory, inter-factory
sales control, wages, finance, long term production
plan, marketing, customer services.
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Computer Integrated Manufacturing Activities

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 Computer Integrated Manufacturing Activities .1
CAD (Computer Aided Design)
The activity comprises computer support design, drafting,
and engineering calculations
CAPP (Computer Aided Process Planning)
This activity is concerned with the computer aided
generation of a technological plan to make the product.
The process plan describes the manufacturing processes
and sequences to make a part.
CAM (Computer Aided Manufacturing)
This activity defines the functions of a computer to control
the activities on the manufacturing floor, including direct
control of production equipment

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 CAQC (Computer Aided Quality Control)
This activity combines all ongoing quality control work of a
manufacturing system.
PP&C (Production, Planning and Control)
This function is the organizational activity of CIM. It is
concerned with manufacturing resources planning,
materials requirement planning, and scheduling
CIM Model

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CIM Model

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 Computerized manufacturing support
systems
Automation of the manufacturing support systems is
aimed at reducing the amount of manual effort in;
• product design
• manufacturing planning
• manufacturing control; and
• business functions
All modern manufacturing support systems are
implemented using computer systems
Computer technology is used to implement automation
of the manufacturing systems in the factory as well
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 Computerized manufacturing support systems
Computer Integrated Manufacturing (CIM) is the use of
computer systems to design the products, plan the
production, control the operations, and perform the
various business-related functions needed in a
manufacturing firm
True CIM involves integrating all of these functions in one
system that operates throughout the enterprise

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 Reasons for Automating
To increase labor productivity
To reduce labor cost
To reduce or eliminate routine manual tasks
To improve worker safety
To improve product quality
To reduce manufacturing lead time
To accomplish processes that can not be done
manually
To avoid the high cost of not automating

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 Manufacturing Systems
A manufacturing system is a collection of integrated
equipment and human resources, whose function is
to perform one or more processing and/or
assembly operations on a starting raw material,
part, or set of parts.
The integrated
equipment includes
production machines and
tools, material handling
and work positioning
devices, and computer
systems 56
 Components of a Manufacturing System
A manufacturing system consists of several
components usually include:
Production machines plus tools, fixtures and
other related hardware
Material handling system
Computer systems to coordinate and/or control
the above components
Human workers

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Production Machines
Manually operated machines are directed or
supervised by a human worker.
Example : conventional machine tools
Semi-automated machines perform a portion of
the work style under some form of program
control and a human worker tends to the machine
for the remainder of the cycle.
Example: CNC machines
Fully automated machines operate for extended
periods of time with ni human attention
Example: Injection molding plants
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 Material Handling System
1- Loading, positioning and unloading
These material handling functions occur at each
workstation
Loading involves moving work units into the production
machine or processing equipment from a source inside
the station
Positioning provides for the part to be in a known location
and orientation relative to work head or tooling that
performs the operation
Unloading Removes the work unit from the production
machine and either placed in a container at the
workstation of prepared for transport to the next
workstation in the processing sequence
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 Material Handling System
2- Work Transport between Stations
 Work transport means moving parts between
workstations in a multi-station system.
 The transport function can be accomplished
manually or by the most appropriate transport
equipment

Variable Routing, work units are Fixed Routing, the work units
transported through a variety of always flow through the
different station sequences same sequence of stations
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 Computer Control System
A computer is required to control the automated and semi-
automated equipment and to participate in the overall
coordination and management of the manufacturing
systems
Typical computer system functions include:
 Communicate instructions to workers
 Download part programs to CNC machines
 Control material handling systems
 Schedule production
 Quality control
 Operations management (directly by supervisory
computer or indirectly by preparing the necessary reports
for management personnel)
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 Human Resources
Direct labor
The directly add to the value of the work unit by
performing manual work on it or by controlling the
machines that perform the work
Indirect labor
The manage or support the system as computer
programmers, computer operators, part
programmers for CNC, maintenance and repair
personnel

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OBSTACLES TO CIM
 Cost
 Time
 Technical skills of support staff
 Management commitment
 Nature of business
 Integration of components from different suppliers
 Data Integrity
 Process Control
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 Manual Labor in Production Systems

Is there a place for manual labor in the modern

production system?
– Answer: YES
• Two aspects:
1. Manual labor in factory operations
2. Labor in manufacturing support systems

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 Manual Labor in Factory Operations
The long term trend is toward greater use of
automated systems to substitute for manual labor.
• When is manual labor justified?
– Some countries have very low labor rates and
automation cannot be justified.
– Task is technologically too difficult to automate
– Short product life cycle.
– Customized product requires human flexibility.
– To cope with ups and downs in demand.
– To reduce risk of new product failure.
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 Labor in Manufacturing Support Systems
• Product designers who bring creativity to the
design task.
• Manufacturing engineers who:
– Design the production equipment and tooling.
– And plan the production methods and routings.
• Equipment maintenance.
• Programming and computer operation.
• Engineering project work.
• Plant management.

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 Automation Principles and Strategies

1. The USA Principle

2. Ten Strategies for Automation and Process
Improvement
3. Automation Migration Strategy

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 U.S.A Principle
1. Understand the existing process:
– Input/output analysis
– Value chain analysis
– Charting techniques and mathematical modeling
2. Simplify the process:
– Reduce unnecessary steps and moves
3. Automate the process:
– Ten strategies for automation and production
systems
– Automation migration strategy
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Ten Strategies for Automation and Process Improvement
1. Specialization of operations
2. Combined operations
3. Simultaneous operations
4. Integration of operations
5. Increased flexibility
6. Improved material handling and storage
7. On-line inspection
8. Process control and optimization
9. Plant operations control
10.Computer-integrated manufacturing

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 Automation Migration Strategy
For Introduction of New Products
1. Phase 1 – Manual production:
– Single-station manned cells working
independently.
– Advantages: quick to set up, low-cost tooling.
2. Phase 2 – Automated production:
– Single-station automated cells operating
independently.
– As demand grows and automation can be
justified.
3. Phase 3 – Automated integrated production:
– Multi-station system with serial operations and
automated transfer of work units between
stations.
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Technological Categories of the Production
System

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 Manufacturing Operations
Sections:
1. Manufacturing Industries and Products
2. Manufacturing Operations
3. Production Facilities
4. Product/Production Relationships

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 Manufacturing:
Technological Definition
Application of physical and chemical processes to
alter the geometry, properties, and/or appearance
of a given starting material to make parts or
products.
• Manufacturing also includes the joining of multiple
parts to make assembled products.
• Accomplished by a combination of machinery,
tools, power, and manual labor.
• Almost always carried out as a sequence of
operations.
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 Manufacturing:
Technological Definition

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 Manufacturing: Economic Definition
Transformation of materials into items of greater
value by means of one or more processing and/or
assembly operations.
• Manufacturing adds value to the material
• Examples:
– Converting iron ore to steel adds value
– Transforming sand into glass adds value
– Refining petroleum into plastic adds value

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Manufacturing: Economic Definition

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 Classification of Industries
1. Primary industries – cultivate and exploit
natural resources
– Examples: agriculture, mining
2. Secondary industries – convert output of
primary industries into products
– Examples: manufacturing, power generation,
construction
3. Tertiary industries – service sector
– Examples: banking, education, government, legal
services, retail trade, transportation

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 Manufacturing Operations
• There are certain basic activities that must
be carried out in a factory to convert raw
materials into finished products
• For discrete products:
1. Processing and assembly operations
2. Material handling
3. Inspection and testing
4. Coordination and control

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Classification of manufacturing processes

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 Processing Operations
• Shaping operations
1. Solidification processes
2. Particulate processing
3. Deformation processes
4. Material removal processes
5. Additive manufacturing (a.k.a. rapid
prototyping)
• Property-enhancing operations (heat treatments)
• Surface processing operations
– Cleaning and surface treatments
– Coating and thin-film deposition 80
 Assembly Operations
• Joining processes
– Welding
– Brazing and soldering
– Adhesive bonding
• Mechanical assembly
– Threaded fasteners (e.g., bolts and nuts,
screws)
– Rivets
– Interference fits (e.g., press fitting, shrink fits)
– Other
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 Other Factory Operations

• Material handling and storage

• Inspection and testing
• Coordination and control

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 Material Handling and Storage
• Material transport:
– Vehicles, e.g., forklift trucks, AGVs, monorails
– Conveyors
– Hoists and cranes
• Storage systems
• Automatic identification and data capture: (AIDC)
– Bar codes
– RFID
– Other AIDC
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Time Spent by a Part in a Typical Metal Machining
Batch Factory

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 Inspection and Testing
Inspection – examination of the product and its
components to determine whether they
conform to design specifications:
– Inspection for variables – measuring
– Inspection for attributes – gaging
Testing – observing the product (or part, material,
subassembly) during actual operation or under
conditions that might occur during operation.

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 Coordination and Control
• Regulation of the individual processing and
assembly operations:
– Process control
– Quality control
• Management of plant level activities:
– Production planning and control
– Quality control

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 Production Facilities
• A manufacturing company attempts to organize its
facilities in the most efficient way to serve the
particular mission of the plant.
• Certain types of plants are recognized as the most
appropriate way to organize for a given type of
manufacturing.
• The most appropriate type depends on:
– Types of products made
– Production quantity
– Product variety
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 Production Quantity
Number of units of a given part or product
produced annually by the plant.
• Three quantity ranges:
1. Low production – 1 to 100 units
2. Medium production – 100 to 10,000 units
3. High production – 10,000 to millions of units

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 Product Variety
Refers to the number of different product or part
designs or types produced in the plant.
• Inverse relationship between production quantity
and product variety in factory operations.
• Product variety is more complicated than a
number:
– Hard product variety – products differ greatly
• Few common components in an assembly
– Soft product variety – small differences
between products
• Many common components in an assembly
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 Low Production Quantity
Job shop – makes low quantities of specialized and
customized products.
• Includes production of components for these
products.
• Products are typically complex (e.g., specialized
machinery, prototypes, space capsules).
• Equipment is general purpose.
• Plant layouts:
– Fixed position
– Process layout
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 Medium Production Quantities
1. Batch production – A batch of a given product is
produced, and then the facility is changed over to
produce another product
– Changeover takes time – setup time
– Typical layout – process layout
– Hard product variety
2. Cellular manufacturing – A mixture of products is
made without significant changeover time between
products
– Typical layout – cellular layout
– Soft product variety 91
 High Production
1. Quantity production – Equipment is
dedicated to the manufacture of one
product
– Standard machines tooled for high production
(e.g., stamping presses, molding machines)
– Typical layout – process layout
2. Flow line production – Multiple
workstations arranged in sequence
– Product requires multiple processing or
assembly steps
– Product layout is most common
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Learning Outcome 2:
Prepare production
process including
possible CIM system

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FLEXIBLE MANUFACTURING SYSTEMS
(FMS)
A flexible manufacturing system (FMS) is a highly
automated machine cell, consisting of a group or
processing workstations (usually CNC machine tools),
interconnected by an automated material handling
and storage system, and controlled by a distributed
computer system.

94
The reason the FMS is called flexible is that it is
capable of processing a variety of different part
styles simultaneously at the various workstations,
and the mix of part styles and quantities of
production can be adjusted in response to
changing demand Patterns.
The FMS is most suited for the mid-variety,
mid-volume production range
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 Flexible Manufacturing System
Computer
control
room
Tools

Conveyor

Machine
Machine

Pallet

Machine Machine

Machine Machine

Load Unload

Finished
Parts 96
goods
Classification of FMS
Flexible manufacturing systems can be
distinguished according to the number of
machines in the system. The following are typical
categories:
Single machine cell
Flexible manufacturing cell
Flexible manufacturing system

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Single Machine Cell (SMC)
A single machine cell consists of one CNC
machining center combined with a parts storage
system for unattended operation.
Completed parts are periodically unloaded from
the parts storage unit, and raw work parts are
loaded into it

98
Flexible Manufacturing Cell (FMC) A flexible
manufacturing cell consists of two or three
processing workstations (typically CNC machining
centers) plus a part handling system.
The part handling system is connected to a
load/unload station.

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Flexible Manufacturing System (FMS)
A flexible manufacturing system has four or
more processing workstations connected
mechanically by a common part handling system
and electronically by a distributed

100
 Basic components of FMS
Workstations or processing station
 Automated Material Handling and Storage systems
Computer Control System
1)Work station or processing station
 are typically computer numerical control(C.N.C) Machine
tool that performs different machining operation on families
of parts .
Flexible manufacturing system are being designed with
other type of processing equipment including inspection
station , assembly work and sheet metal process.
 The various types of workstation are:
Machining Center:-It is a Sophisticated CNC machine that
performs milling ,drilling, tapping and boring operation at
the same location with variety of tools. 101
Assembly Work Station :-Industrial Robots are
usually consider to be the most appropriate
automated assembly work station in the
F.M.S ,they can be programmed to perform
task with variation in sequences.
Inspection Station:-Inspection Station are
designed for inspecting the completed work ,
In F.M.S inspection can be happen either at
work station or by designing Special
Inspection Station for this purpose.

102
Industrial Robots assembling the Car:-

103
Load and Unload Station:-as identifies from the name
load and unload station are used for loading and
unloading of work parts in the F.M.S.
The various Feature of Load and Unload stations are:-

It act as a physical interface between the F.M.S and

rest of the Factory.
Raw work parts enter the system at load station, while
finished work parts exit at unload station

104
2. Automated Material Handling & Storage
System
The various Automated material handling system are
used to transport work parts and subassembly parts
between the processing station .
The other function of automatic material handling
and storage system are:-
 Random and Independent movement of work parts
between processing stations.
 Handling of variety of work part configuration
 Temporary storage
 Convenient access for Loading and unloading
station.
105
For automated material handling and storage of
work parts is done by A.G.V (Automated Guided
Vehicles),A.S.R.S & Conveyors .
Automated Guided Vehicle
Automated Guided Vehicles (AGVs) are
vehicles that are equipped with automatic
guidance systems and are capable of following
prescribed paths.
Unlike traditional robots, AGVs are not
manipulators, they are driverless vehicles that are
programmed to follow a guide path.
 In automated factories and facilities AGV’s
move pallets and containers. 106
Tow Type A.G.V:-

107
 Equipment of FMS

Primary equipment
Work centers:
Universal machining centers
Turning centers
 Grinding machines
Process centers
Coordinate measuring machines
Robotic work stations
Manual workstations

108
Secondary equipment
Support stations
Pallet/fixture load/unload stations
• Tool commissioning/setting area
Support equipment
• Robots
• Pallet/fixture/stillage stores
• Pallet buffer stations
• Tools stores
• Raw material stores
• Transport system (AGVs,RGVs,robots)
• Transport units(pallets/stillages)

109
Computer Control System
Function performed by FMS computer control:
1. Workstation control.
2. Distribution of control instructions to workstations.
3. Production control.
4. Traffic control. - Primary handling system
5. Shuttle control
6. Work piece monitoring.
7. Tool control. - concerned with managing two
aspects of the cutting tools: (a) tool location, (b)
tool life monitoring.
8. Performance monitoring and reporting -

110
111
Workstation control :
Fully automated FMSs use some form of
workstation control at each station, often in the
form of CNC control
Distribution of control instructions to workstations:
A central computer is required to handle the
processing occurring at disparate workstations; this
involves the dissemination of part programmers to
individual workstations, based upon an overall
schedule held by the central computer.

112
Production control:
Management of the mix and rate at which various
parts are launched into the system is important;
alongside data input of a number of essential
metrics, such as: daily desired production rates,
number of raw work parts available, work-in-
progress etc.
Traffic control:
Management of the primary handling system is
essential so that parts arrive at the right location at
the right time and in the right condition
113
Shuttle control:
Management of the secondary handling system is
also important, to ensure the correct delivery of
the work part to the station’s work head .
Work piece monitoring:
The computer must monitor the status of each
cart or pallet in the primary and secondary
handling systems, to ensure that we know the
location of every element in the system .

114
Tool control:
This is concerned with managing tool location
(keeping track of the different tools used at
different workstations, which can be a determinant
on where a part can be processed), and tool life
(keeping track on how much usage the tool has
gone through, so as to determine when it should be
replaced) .
Performance monitoring and reporting:
The computer must collect data on the various
operations on-going in the FMS and present
performance findings based on this data.
115
There are three levels of manufacturing flexibility.
1-Basic Flexibilities
Machine flexibility - the ease with which a
machine can process various operations
Material handling flexibility -a measure of
the ease with which different part types can be
transported and properly positioned at the various
machine tools in a system
Operation flexibility - a measure of the ease
with which alternative operation sequences can be
used for processing a part type
116
2-System flexibilities:
Volume flexibility
Expansion flexibility
Routing flexibility
Process flexibility
Product flexibility

3-Aggregate flexibilities
Program Flexibility
Production Flexibility
Market Flexibility

117
 FMS Layout Configurations
 In-line layout
 Loop layout
 Ladder layout
 Open field layout
 Robot-centered cell
In Line Layout
The machines and handling systems are arranged in a
straight line.
The parts progress from one workstation to the next in a
well defined sequence.
Work always moving in one direction and no back flow.
Secondary work handling system is provided at each
workstation to separate most of the parts from the
primary line. 118
119
120
Loop Layout
The workstations are organized in a loop that is
served by a parts handling system.
Parts usually flow in one direction around the
loop with the capability to stop and be transferred
to any station.
A secondary handling system is shown at each
workstation to permit parts to move without
obstruction around the loop.
The load and unload stations are typically located
at one end of the loop.

121
122
Ladder Layout
It consist of a loop with rungs between the
straight sections of the loop , on which
workstations are located.
 The rungs increase the number of possible
ways of getting from one machine to the next.
This reduces average travel distance and
minimize congestion in the handling system.
There by reducing transport time between the
stations.

123
124
Open field Layout
It consists of multiple loops and ladders and
may include sidings as well.
This layout type is generally appropriate for
processing a large family of parts.
The number of different machine types may be
limited , and parts are routed to different
workstations depending on which one become
available first.

125
126
Robot centered Layout
It uses one or more robots as the material
handling system.
Industrial robots can be equipped with grippers
that make them well suited for the handling of
rotational parts , and robot centered FMS layouts
are often used to process cylindrical or disk
shaped parts.

127
128
 Equipment used as primary handling system
Layout configuration Typical material handling system
In-line layout In-line transfer system
Conveyor system
Rail guided vehicle system

Loop layout Conveyor system

In-floor towline carts

Ladder layout Conveyor system

Automated guided vehicle system
Rail guided vehicle

Open field layout Automated guided vehicle system

In floor towline carts

Robot-centered layout Industrial robot

129
Flexibility in FMS
In manufacturing flexibility means-
 The Capability of Producing Different parts without
major retooling.
 A measure of how fast the company converts its
process From making an old line of product to
produce a new product.
 The ability to change a production schedule ,to
modify a part or to handle multiple parts.
So a flexible manufacturing system is a
manufacturing system in which there is some amount
of flexibility that allows the system to react in the case
of changes whether predicted or unpredicted. 130
To be flexible, a manufacturing system must
posses the following capabilities:
Identification of the different production
units to perform the correct operation.
Quick changeover of operating instructions.
Quick changeover of physical setups of
fixtures, tools and other working units.

131
Application of FMS
Metal-cutting machining
Metal forming
Assembly
Joining-welding (arc , spot), glueing
Surface treatment
Inspection
Testing

132
133
 Automation Defined
Automation is the technology by which a process or
procedure is accomplished without human
assistance.
• Basic elements of an automated system:
1. Power - to accomplish the process and operate
the automated system
2. Program of instructions – to direct the process
3. Control system – to actuate the instructions

134
 Power to Accomplish the
Automated Process
• Power for the process
– To drive the process itself
– To load and unload the work unit
– Transport between operations
• Power for automation
– Controller unit
– Power to actuate the control signals
– Data acquisition and information processing

135
 Program of Instructions
Set of commands that specify the sequence of steps
in the work cycle and the details of each step.
• Example: NC part program.
• During each step, there are one or more activities
involving changes in one or more process
parameters.
– Examples:
• Temperature setting of a furnace
• Axis position in a positioning system
• Motor on or off
136
 Decision-Making in a
Programmed Work Cycle
• Following are examples of automated work cycles in
which decision making is required:
– Operator interaction:
• Automated teller machine
– Different part or product styles processed by the
system:
• Robot welding cycle for two-door vs. four door
car models
– Variations in the starting work units:
• Additional machining pass for oversized sand
casting
137
CNC TECHNOLOGY and CNC PROGRAMMING
THE OBJECTIVE:
to be competitive through increasing productivity
and total quality assurance PROFIT increases as
COST decreases and as PRODUCTIVITY
increases.
The metal cutting operations (also called
machining) is one of the most important
manufacturing processes in industry today (as it
was yesterday).

138
machining is the removal of materials in forms of chips
from the work piece by shearing with a sharp tool.
The main function of a machine tool is to control the work
piece-cutting tool positional relationship in such a way as
to achieve a desired geometric shape of the wor kpiece
with sufficient dimensional accuracy.
Machine tool provides:
work holding
tool holding
relative motion between tool and work piece
primary motion
secondary motion

139
 machine control unit
position transducers

work holding device

tool holding device

140
CLASSIFICATION OF THE CHIP REMOVING METHODS
ACCORDING TO THE RELATIVE MOTION

141
 CLASSIFICATION OF MACHINE TOOLS

THOSE USING THOSE USING THOSE USING

SINGLE POINT MULTIPOINT ABRASIVE
TOOLS TOOLS TOOLS

lathes drilling m/c’s grinding m/c’s

shapers milling m/c’s honing m/c’s
planers broaching m/c’s etc.
boring m/c’s hobbing m/c’s
etc. etc.

142
NUMERICALLY CONTROLLED MACHINE TOOLS:
An NC machine tool is functionally the same as a
conventional machine tool. The technological
capabilities NC machine tools in terms of
machining are no different from those of
conventional ones. The difference is in the way
in which the various machine functions and slide
movements are controlled.

143
 The functions and motions such as;
turning the spindle on and off
setting cutting speeds
setting feed rate
turning coolant on and off
moving tool with respect to work piece are
performed by Machine Control Unit (MCU) in NC
machine tools.

144
What Is Numerical Control?
An automated manufacturing process in which a
machine tool is controlled;
In an ordered sequence
Along a predetermined path
To require dimensions
At a specific feed and speed rate
Done through a group of alphanumeric
instructions

145
Objectives of Numerical Control
Increased production
Reduced labor costs
Make production more economical
Make production jobs easier
Do production jobs that are impossible without
numeric control
Increased accuracy on duplicate parts

146
Advantages of Numerical Control
Reduces time for delivery of part Reduces
scrap rate of material
Reduces tooling costs
Reduces layout time
Increases machine and tool life
Reduces storage problems
Less setup time
Reduces actual machining time
Allows rapid design changes in part
Less jigs and fixtures are needed

147
Limitations of Numerical Control
High initial investment
Machine tools cost $30,000 - $1,500,000
High maintenance requirements
Maintenance personnel must have both
mechanical and electronics expertise
Not cost-effective for low-level production on
simple parts
As geometric complexity or volume
increases CNC becomes more economical

148
 Types of Numerical Control
Numerical Control (NC):- Data is sent to the
machine tool by means of punch cards or
tapes. The reader at the machine performs no
calculations or interpolations
Direct Numerical Control (DNC):- Is a method
where a single computer controls many
numerical control machine tools. These
machine tools may or may not be of a similar
nature

149
Computer Numerical control (CNC):- The idea of
computer numerical control is to position a
computer right at the machine tool. Most, if not
all machine tools that are numerical the controlled
are CNC machine tools.
Distributive numerical control:- Because CNC
machine tools have the ability to run multiple
programs without being attached to a centralized
computer this enables a centralized computer to
perform many different tasks
Line balancing
Scheduling
Monitoring
Quality
150
DEFINITION
In CNC (Computer Numerical Control), the
instructions are stored as a program in a micro-
computer attached to the machine. The computer
will also handle much of the control logic of the
machine, making it more adaptable than earlier
hard-wired controllers.
CNC APPLICATIONS
Machining
2.5D / 3D
Turning ~ Lathes, Turning Centre
Milling ~ Machining Centres
Forming
2D ,Plasma and Laser Cutting , Blanking, nibbling
and punching
3D , Rapid Prototyping 151
 CNC MILLING CNC TURNING

CNC LASER CUTTING CNC PLASMA CUTTING

152
 SAMPLE PRODUCTS OF CNC MANUFACTURING
Different Products
Engine Block

CNC MOLD MAKING

ELECTRONIC INDUSTRY
153
 AEROSPACE INDUSTRY
Aircraft Turbine Machined by
5-Axis CNC Milling Machine

154
ADVANTAGES of CNC
Productivity
Machine utilization is increased because more time is
spent cutting and less time is taken by positioning.
Reduced setup time increases utilization too.
Quality
Parts are more accurate.
Parts are more repeatable.
Less waste due to scrap.
Reduced inventory
Reduced setup time permits smaller economic batch
quantities.
Lower lead time allows lower stock levels.
Lower stock levels reduce interest charges and working
capital requirements. 155
Machining Complex shapes
Slide movements under computer control.
Computer controller can calculate steps.
First NC machine built 1951 at MIT for aircraft
skin milling.
Management Control
CNC leads to CAD
Process planning
Production planning

156
DRAWBACKS of CNC
High capital cost
Machine tools cost $30,000 - $1,500,000
Retraining and recruitment of staff
New support facilities
High maintenance requirements
Not cost-effective for low-level production on
simple parts
As geometric complexity or volume increases
CNC becomes more economical
Maintenance personnel must have both
mechanical and electronics expertise

157
CNC SYSTEM ELEMENTS
A typical CNC system consists of the
following six elements
Part program
Program input device
Machine control unit
Drive system
Machine tool
Feedback system

158
NC SYSTEM ELEMENTS

159
OPERATIONAL FEATURES of CNC MACHINES

160
PART PROGRAM
A part program is a series of coded instructions required to
produce a part. It controls the movement of the machine
tool and the on/off control of auxiliary functions such as
spindle rotation and coolant. The coded instructions are
composed of letters, numbers and symbols and are
arranged in a format of functional blocks as in the
following example
N10 G01 X5.0 Y2.5 F15.0
| | | | |
| | | | Feed rate (15 in/min)
| | | Y-coordinate (2.5")
| | X-coordinate (5.0")
| Linear interpolation mode
Sequence number
161
PROGRAM INPUT DEVICE
The program input device is the mechanism for part
programs to be entered into the CNC control. The
most commonly used program input devices are
keyboards, punched tape reader, diskette drivers,
throgh RS 232 serial ports and networks.

162
MACHINE CONTROL UNIT
The machine control unit (MCU) is the heart of a CNC
system. It is used to perform the following functions:
Read coded instructions
Decode coded instructions
Implement interpolations (linear, circular, and helical)
to generate axis motion commands
Feed axis motion commands to the amplifier circuits
for driving the axis mechanisms
Receive the feedback signals of position and speed for
each drive axis
Implement auxiliary control functions such as coolant
or spindle on/off, and tool change

163
 TYPES of CNC CONTROL SYSTEMS
Open-loop control
Closed-loop control
OPEN-LOOP CONTROL SYSTEM
 In open-loop control system step motors are used
 Step motors are driven by electric pulses
 Every pulse rotates the motor spindle through a certain
amount
 By counting the pulses, the amount of motion can be
controlled
 No feedback signal for error correction
 Lower positioning accuracy

164
Operates without verifying that the actual position
achieved in the move is the desired position

165
CLOSED-LOOP CONTROL SYSTEMS
In closed-loop control systems DC or AC motors are used
Position transducers are used to generate position feedback
signals for error correction
Better accuracy can be achieved
More expensive
Suitable for large size machine tools

Uses feedback measurements to confirm that the final

position of the worktable is the location specified in the
program 166
CNC PROGRAMMING
Offline programming linked to CAD programs.
Conversational programming by the operator.
MDI ~ Manual Data Input.
Manual Control using jog buttons or `electronic
hand wheel'.
Word-Address Coding using standard G-codes
and M-codes.

167
Basics of NC Part Programming
During secondary motion, either the tool moves
relative to the work piece or the work piece
moves relative to the tool. In NC programming, it
is always assumed that the tool moves relative to
the work piece no matter what the real situation
is.
The position of the tool is described by using a
Cartesian coordinate system. If (0,0,0) position
can be described by the operator, then it is called
floating zero.

168
In defining the motion of the tool from one
point to another, either absolute positioning
mode or
incremental positioning mode can be used.
1. Absolute positioning. In this mode, the
desired target position of the tool for a
particular move is given relative to the origin
point of the program.
2. Incremental positioning. In this mode, the
next target position for the tool is given relative
to the current tool position.
169
Structure of an NC Part Program:
Commands are input into the controller in units called
blocks or statements.
Block Format:
1. Fixed sequential format
2. Tab sequential format
3. Word address format

170
1. Fixed sequential format
0050 00 +0025400 +0012500 +0000000 0000 00
0060 01 +0025400 +0012500 -0010000 0500 08
0070 00 +0025400 +0012500 +0000000 0000
2. Tab sequential format
0050 TAB 00 TAB +0025400 TAB +0012500 TAB +0000000
TAB TAB
0060 TAB 01 TAB TAB TAB -0010000 TAB 0500 TAB 08
0070 TAB 00 TAB TAB TAB -0000000 TAB 0000 TAB 09
3. Word address format
N50 G00 X25400 Y125 Z0 F0
N60 G01 Z-10000 F500 M08
N70 G00 Z0 M09
171
Modal commands: Commands issued in the NC
program that will stay in effect until it is changed
by some other command, like, feed rate selection,
coolant selection, etc.
Nonmodal commands: Commands that are
effective only when issued and whose effects are
lost for subsequent commands, like, a dwell
command which instructs the tool to remain in a
given configuration for a given amount of time.

172
INFORMATION NEEDED by a CNC
1. Preparatory Information: units, incremental or
absolute positioning
2. Coordinates: X,Y,Z, RX,RY,RZ
3. Machining Parameters: Feed rate and spindle speed
4. Coolant Control: On/Off, Flood, Mist
5. Tool Control: Tool and tool parameters
6. Cycle Functions: Type of action required
7. Miscellaneous Control: Spindle on/off, direction of
rotation, stops for part movement
This information is conveyed to the machine through a
set
of instructions arranged in a desired sequence –
Program.

173
BLOCK FORMAT
Sample Block
N135 G01 X1.0 Y1.0 Z0.125 F5
Restrictions on CNC blocks
Each may contain only one tool move
Each may contain any number of non-tool move G-codes
Each may contain only one feed rate
Each may contain only one specified tool or spindle
speed
The block numbers should be sequential
Both the program start flag and the program number
must be independent of all other commands (on
separate lines)
The data within a block should follow the sequence
shown in the above sample block

174
G & M Codes
•G-codes: Preparatory Functions involve actual
tool moves.
•M-codes: Miscellaneous
Functions – involve actions
necessary for machining (i.e.
spindle on/off, coolant on/off).

175
 G Codes
G40 Cutter compensation –
cancel
G00 Rapid traverse G41 Cutter compensation –
G01 Linear interpolation left
G02 Circular interpolation, CW G42 Cutter compensation-
G03 Circular interpolation, CCW right
G04 Dwell G70 Inch format
G08 Acceleration G71 Metric format
G09 Deceleration G74 Full-circle
G17 X-Y Plane programming off
G18 Z-X Plane G75 Full-circle
G19 Y-Z Plane programming on
G20 Inch Units (G70) G80 Fixed-cycle cancel
G21 Metric Units (G71) G81-G89 Fixed cycles
G90 Absolute dimensions
G91 Incremental
dimensions
176
 Modal G-Codes
Most G-codes set the machine in a “mode” which stays in
effect until it is changed or cancelled by another G-code.
These commands are called “modal”.
G00 Rapid Transverse G43 Tool length compensation
G01 Linear Interpolation (plus)
G02 Circular Interpolation, CW G44 Tool length compensation
G03 Circular Interpolation, (minus)
CCW G49 Tool length compensation
G17 XY Plane cancel
G18 XZ Plane G80 Cancel canned cycles
G19 YZ Plane G81 Drilling cycle
G20/G70 Inch units G82 Counter boring cycle
G21/G71 Metric Units G83 Deep hole drilling cycle
G40 Cutter compensation cancel G90 Absolute positioning
G41 Cutter compensation left G91 Incremental positioning
G42 Cutter compensation right
G43 Tool length compensation
(plus)
177
 M Codes
M00 Program stop
M01 Optional program stop
M02 Program end
M03 Spindle on clockwise
M04 Spindle on counterclockwise
M05 Spindle stop
M06 Tool change
M08 Coolant on
M09 Coolant off
M10 Clamps on
M11 Clamps off
M30 Program stop, reset to start

178
N Codes
Gives an identifying number for each block of information.
It is generally good practice to increment each block
number by 5 or 10 to allow additional blocks to be inserted
if future changes are required.
X,Y, and Z Codes
X, Y, and Z codes are used to specify the coordinate axis.
Number following the code defines the coordinate at
the end of the move relative to an incremental or
absolute reference point.

179
I,J, and K Codes
I, J, and K codes are used to specify the coordinate
axis when defining the center of a circle.
Number following the code defines the respective
coordinate for the center of the circle.
F,S, and T Codes
F-code: used to specify the feed rate
S-code: used to specify the spindle speed
T-code: used to specify the tool identification
number associated with the tool to be used in
subsequent operations.

180
Three Main parts of a CNC program
Part 1- Program Petup
N5 G90 G21 (Absolute units, metric)

N10 M06 T2 (Stop for tool change, use

tool # 2)
N15 M03 S1200 (Turn the spindle on CW to
1200 rpm)

181
Three Main parts of a CNC program
Part 2- Chip Removal
N20 G00 X1 Y1 (Rapid to X1,Y1 from origin
point)
N25 Z0.125 (Rapid down to Z0.125)
N30 G01 Z-0.125 F100 (Feed down to Z-
0.125 at 100 mm/min)
N35 G01 X2 Y2 (Feed diagonally to X2,Y2)
N40 G00 Z1 (Rapid up to Z1)
N45 X0 Y0 (Rapid to X0,Y0)
Part 3- System Shutdown
N50 M05 (Turn the spindle off)
N55 M00 (Pprogram stop)
182
 Advanced Automation Functions

1. Safety monitoring
2. Maintenance and repair diagnostics
3. Error detection and recovery

183
 Safety Monitoring
Use of sensors to track the system's operation and
identify conditions that are unsafe or potentially
unsafe
• Reasons for safety monitoring
– To protect workers and equipment
• Possible responses to hazards:
– Complete stoppage of the system
– Sound an alarm
– Reduce operating speed of process
– Take corrective action to recover from the safety
violation 184
 Maintenance and Repair Diagnostics
• Status monitoring:
– Monitors and records status of key sensors
and parameters during system operation
• Failure diagnostics:
– Invoked when a malfunction occurs
– Purpose: analyze recorded values so the
cause of the malfunction can be identified
• Recommendation of repair procedure:
– Provides recommended procedure for the
repair crew to effect repairs

185
 Error Detection and Recovery
1. Error detection – functions:
– Use the system’s available sensors to determine
when a deviation or malfunction has occurred
– Correctly interpret the sensor signal
– Classify the error
2. Error recovery – possible strategies:
– Make adjustments at end of work cycle
– Make adjustments during current work cycle
– Stop the process to invoke corrective action
– Stop the process and call for help
186
 Learning Outcome 3:
Perform supervision of
conventional and /or CIM
supported production

187
Group Technology & Cellular Manufacturing
Group Technology – Similar Parts are identified
and grouped together to take advantage of their
similarities in Design and Manufacturing
It has been implemented in order to arrange
production equipment into machine groups,
or cells, in order to facilitate work flow and
part handling.

188
Part Families – Similar design or
manufacturing characteristics/Attributes
Cellular Manufacturing – Grouping
equipment into machine cells where each
cell specializes in the production of a part
family

189
 Families
The word ‘Family’ is used as a name for any list of
similar parts. The families used with group layout
are lists of parts which are similar because they
are all made on the same group of machines. This
type of family is called a ‘Production Family’.
However, not all parts which are similar in shape
will appear in the same family.

190
The other important features that is
important choosing the families;
Manufacturing tolerances
Required quantities
Materials
Special features, which will require the
use of different machines

191
Groups
A group is a list of machines, selected for layout
together in one place, because it contains all
necessary facilities to complete the processing of a
given family of parts.
A family of parts can only be defined by relating it
to a particular group of machines, and a group by
relating it to a family.
Groups vary greatly in type and size, widely in the
number of machines and different machines types.

192
Group technology begun by grouping parts into
families, based on their attributes.
There are four methods that can be used to form
part families:
Manual visual inspection
Production flow analysis
Classification and coding
Clustering methods
Bond energy method
Rank order clustering
Graph theoretical approach
Neural
193
1) Manual visual inspection
Involves arranging a set of parts into groups
known as part families by visually inspecting
the physical characteristics of the parts.

194
Features of Manual visual inspection
• incorrect results
• human error
• different judgment by different people
• inexpensive
• least sophisticated
• good for small companies having smaller
number of parts

195
2) Production flow analysis:
Parts that go through common operations are
grouped into part families.
The machines used to perform these
common operations may be grouped as a cell,
consequently this technique can be used in
facility layout (factory layout)

196
3) Coding methods:
are employed in classifying parts into part
families
Coding refers to the process of assigning
symbols to the parts
The symbols represent design attributes of
parts or manufacturing features of part families

197
SELECTION OF CLASSIFICATION AND CODING
SYSTEMS
For the purpose of selecting or developing your
own code, it is important to understand the
attributes of classification and coding systems.
Some of the important classification and coding
system attributes include:
1. Flexibility for various applications such as part
family formation, process planning, costing, and
purchasing

198
2. Accuracy, to provide correct information
on parts
3. Expandability, to accommodate
information on more part attributes
deemed important later on
4. Ease of learning
5. Ease of retrieval
6. Reliability and availability of software
7. Suitability for specific applications

199
BENEFITS OF GROUP TECHNOLOGY
Group technology is a management strategy to help
eliminate waste caused by duplication of effort.
It affects all areas of a company, including:
•engineering
•equipment specification
•facilities planning
•process planning
•production control
•quality control
•tool design
•purchasing
•service

200
BENEFITS OF GROUP TECHNOLOGY
Some of the well-known tangible and intangible
benefits of implementing GT :
1.Engineering design
• Reduction in new parts design
• Reduction in the number of drawings through
standardization
• Reduction of drafting effort in new shop
drawings
• Reduction of number of similar parts, easy
retrieval of similar functional parts, and
identification of substitute parts
201
2. Layout planning
Reduction in production floor space required
Reduced material-handling effort

3. Specification of equipment, tools, jigs, and

fixtures
Standardization of equipment
Implementation of cellular manufacturing systems
Significant reduction in up-front costs incurred in
the release of new parts for manufacture

202
4. Manufacturing: process planning
Reduction in setup time and production time
Alternative routing leading to improved part
routing
Reduction in number of machining
operations and numerical control (NC)
programming time

203
5. Manufacturing: production control
•Reduced work-in-process inventory
•Easy identification of bottlenecks
•Improved material flow and reduced warehousing
costs
•Faster response to schedule changes
•Improved usage of jigs, fixtures, pallets, tools,
material handling, and manufacturing equipment

204
6. Manufacturing: quality control
•Reduction in number of defects leading to
reduced inspection effort
•Reduced scrap generation
•Better output quality
•Increased accountability of operators and
supervisors responsible for quality production,
making it easier to implement total quality control
concepts.

205
7. Purchasing
•Coding of purchased part leading to
standardized rules for purchasing
•Economies in purchasing possible because of
accurate knowledge of raw material
requirements
•Reduced number of part and raw materials
•Simplified vendor evaluation procedures
leading to just-in-time purchasing

206
8. Customer service
Accurate and faster cost estimates
Efficient spare parts management, leading
to better customer service
CELLULAR MANUFACTURING
Cellular manufacturing is an application of group
technology in manufacturing in which all or a
portion of a firm’s manufacturing system has
been converted into cells.

207
A manufacturing cell is a cluster of machines or
processes located in close proximity and
dedicated to the manufacture of a family of parts.

The parts are similar in their processing

requirements, such as operations, tolerances, and
machine tool capacities

208
The primary objectives in implementing a
cellular manufacturing system are to reduce:
•setup times (by using part family tooling and
sequencing)
•flow times (by reducing setup and move
times and wait time for moves and using
smaller batch sizes)
•reduce inventories
•market response times

209
In addition, cells represent sociological units
that have more tendency to teamwork. This
means that motivation for process
improvements often arises naturally in
manufacturing cells.
Manufacturing cells are natural
candidates for just-in-time (JIT)
implementation.

210
Functional and cellular layouts of an electronics
plant:

211
4) Rank Order Clustering
Step 1 – Read the series of 1’s and 0’s from left to
right as a binary number. Rank the rows in
decreasing order.
Step 2 – Reorder the matrix with the new ranking
Step 3 – In each column, read the series of 1’s and
0’s from top to bottom as a binary number. Rank
the columns in decreasing order of these values.
Step 4 – Reorder the columns in decreasing order.

212
First Iteration – Rank Order Clustering

213
Second Iteration – Rank Order Cluster

214
Solution of Example

215
Cell Design
Design of cellular manufacturing system
is a complex exercise with broad
implications for an organization.
The cell design process involves
issues related to both system structure
and system operation

216
Structural issues include:
• Selection of part families and
grouping of parts into families
• Selection of machine and process
populations and grouping of these into
cells
• Selection of tools, fixtures, and pallets
• Selection of material-handling
equipment
• Choice of equipment layout
217
Issues related to procedures include:
•Detailed design of jobs
•Organization of supervisory and support
personnel around the cellular structure
•Formulation of maintenance and inspection
policies

218
•Design of procedures for production
planning, scheduling, control, and acquisition
of related software and hardware
•Modification of cost control and reward
systems
•Outline of procedures for interfacing with
the remaining manufacturing system (in
terms of work flow and information, whether
computer controlled or not)

219
Evaluation of Cell Design Decisions
The evaluation of design decisions can be
categorized as related to either
the system structure
or
the system operation.

220
Typical considerations related to the system
structure include:
•Equipment and tooling investment (low)
•Equipment relocation cost (low)
•Material-handling costs (low)
•Floor space requirements (low)
•Extent to which parts are completed in a cell
(high)
•Flexibility (high)

221
Evaluations of cell system design are
incomplete unless they relate to the operation
of the system.
A few typical performance variables related to
system operation are:
•Equipment utilization (high)
•Work-in-process inventory (low)
•Queue lengths at each workstation (short)
•Job throughput time (short)
•Job lateness (low)

222
A major problem throughout the cell design
process is the necessity of trading off against
each other objectives related to structural
parameters and performance variables.
For example, higher machine utilization can
be achieved if several cells route their parts
through the same machine. The drawbacks
are increased queuing and control
problems.

223
System cost and performance are affected by
every decision related to system structure
and system operation.
It is necessary to evaluate each important
design parameter and relate its performance
to pre-established criteria.
For example, structural variables such as
number of machines must be balanced
against operational variables such as machine
utilization and throughput time using
analytical and simulation approaches. 224
 Computer Aided Process Planning (CAPP)
• CAPP- system offers the potential for reducing the
routine clerical work of manufacturing engineers
- At the same time, it provides the opportunity to
generate production routings, which are:-
- Rational
- Consistent, and
- optimal
• Two alternative approaches to CAPP
1) Retrieval, and
2) Generative CAPP system 225
 1) Retrieval type CAPP
• Use parts classification and group
technology as a foundation
• For each part family, a standard process
plan is established
• The standard process plan is stored in
computer files and,
• Permits efficient retrieval of the
appropriate Process plan.

226
User Enters part Part family Part family
code number Search matrix file

Standard Machine Machine

routing retrieve routing file

Standard operation Operation

Retrieve/edit sequence file

Process Other
plan Process plan formatter Application
Programs

Information flow in a retrieval type computer aided process planning

system 227
 2) Generative Process Planning System
• Involves the use of the computer to create
an individual process plan from scratch,
automatically and with out human
assistance.
• The computer would employ a set of
algorithms to progress through the various
technical and logical decisions toward a
final plan for manufacturing

228
 Benefits of CAPP
• Process rationalization- the routings is more
likely to be consistent, logical and optimal
• Increased Productivity of process planners
- with CAPP, there is reduced clerical effort,
fewer errors are made
• Reduced turn around time
• Improved Legibility- Computer Prepared
document is neater and easier to read than
manually written.
229
Agile and Lean Manufacturing

230
 Lean Manufacturing

What Is Lean Manufacturing?

231
 What Is Lean Manufacturing?
An overall strategy to improve a
production process that focuses on:
– Eliminating wastes
– Enhancing quality
– Reducing production time and cost
– Promoting a “lean culture” in the
company

232
Definition of Lean Manufacturing
Lean manufacturing is a management
philosophy focusing on reduction of the 7
wastes
Over-production, Waiting time,
Transportation, Processing, Inventory,
Motion and Scrap
in manufactured products. By eliminating
waste (muda), quality is improved,
production time is reduced and cost is
reduced.
233
 5 principles of lean Manufacturing
• Specify value :
Specify value from the standpoint
of the end customer by product family.
• Identify the value stream :
Identify all the steps in the value
stream for each product family,
eliminating whenever possible those
steps that do not create value.
234
• Create flow :
Make the value-creating steps occur
in tight sequence so the product will
flow smoothly toward the customer.
• Let the customer pull product through
the value stream:
Make only what the customer has
ordered.

235
Muda, Muri, and Mura

• Muda – wasteful or
unproductive activity
• Mura - unevenness
• Muri – overburden,
unreasonableness

236
 “Seven plus One” Types of Waste
1. Overproduction
• Producing more than the internal or
external customer needs
• Producing sooner than the internal or
external customer needs
Why is it waste? Overproduction results in
obsolescence, handling damage and
undetected defects. It requires extra
handling, extra space, extra interest charges,
extra machinery and extra labour.
237
Causes? Lack of communication,
inappropriate reward system, focus on
keeping busy rather than meeting customer
needs
2. Delays (waiting time)
• People waiting for: Machinery, Tooling,
Raw Materials, Maintenance, etc.
• Machinery waiting for: Maintenance,
People, Materials, Tooling etc.
Causes? Inconsistent work methods, long
changeover times
238
3. Transportation
• Moving materials or people over long
distances can double or triple handling
Causes? Poor layout, lack of co-ordination
of processes, poor housekeeping, poor
workplace organization, multiple storage
locations

239
4. Processes
• Unnecessary or inefficient processing e.g.
removing burrs caused by dull tools
Causes? Inappropriate tooling or
equipment, poor tooling maintenance,
failure to combine operations

240
5. Inventories
• Inventory hides problems and causes extra
handling, extra paperwork, extra space and
extra cost
Causes? Long changeover times, unreliable
equipment, unbalanced flow, incapable
suppliers, inaccurate forecasting, large batch
sizes

241
6. Motions
• Any motion of people or machines
which does not add value to the product
or service
Causes? Lack of workplace organization,
poor layout, inconsistent work methods,
poor machine design

242
7. Defective products
• Scrap, rework, customer returns, customer
dissatisfaction
Causes? Incapable processes, insufficient
training, lack of standardized procedures
7 + 1. Defective Design
• Designs which do not meet customers
needs, unnecessary extra features
Causes? Lack of customer input in design,
over-design

243
Seven types of Waste

244
 Pull Production
• Minimum Inventory
• Supplying the right part, at the right time, in the
right amount
• Each sub-process draws its needs from the
preceding sub-processes, and ultimately from
an outside supplier.
• When a preceding process does not receive a
request or withdrawal it does not make more
parts.

245
 Lean Manufacturing Pros
• Minimizes the overhead fixed cost; reduces operational
cost
• Implementing manufacturing techniques and strategies
reduce manufacturing time
• Targets to eliminate most of the wastes that were
mentioned on the previous slides
• Use of energy will be significantly reduced
• Tries to eliminate wasted space since it is very
important for the company to run smoothly
246
 Lean Manufacturing Cons
• Support of employees and upper
management throughout the overall org
chart is necessary to make the lean
techniques implement in the company and
make them successful.
• Proper leaders should be trained to direct
teams about lean manufacturing and how it
works.

247
•Leaders should be employee friendly since
there can be personality clashes and it is
difficult to get people to follow and take
orders from co-workers.
•Training is an on-going process and it is a
long time process to completely adopt “lean
manufacturing” for the overall company.

248
 Agile Manufacturing

• Manufacturing industry is on the verge of

a major paradigm shift. This shift will
take us away from mass production, way
beyond lean manufacturing, into a world
of Agile Manufacturing

249
 What is Agile Manufacturing?
• Agile manufacturing is a method for
manufacturing which combine our
organization, people and technology into
an integrated and coordinated whole.

250
 Why do we need to be agile
• Global Competition is intensifying.
• Mass markets are fragmenting into niche
markets.
• Cooperation among companies is becoming
necessary, including companies who are in
direct competition with each other.

251
 Why do we need to be agile cont:
• Customers are expecting:
1.Low volume products
2.High quality products
3.Custom products
• Very short product life-cycles,
development time, and production lead
times are required.
• Customers want to treated and individuals
252
 Keys to agility and flexibility
• To determine customer needs quickly and
continuously reposition the company against
it’s competitors.
• To design things quickly based on those
individual needs.
• To put them into full scale, quality ,
production quickly.
• To respond to changing volumes and mix
quickly.
• To respond to a crisis quickly. (1)
253
Learning Outcome 4:
Assure quality
production process

254
Q&A: ISO 9001 And ISO 14001 Standard
Revisions
Developed through global consensus,
International Organization for Standardization
standards help to break down barriers to
international trade. It just so happens that
the revision cycle has fallen on some of the
world’s most popular standards, with both
ISO 9001 (quality) and ISO 14001
(environmental) among those currently being
revised.
255
An ISO 9001 Quality Management
System (QMS) will help you streamline your
processes, reduce errors, free up valuable
management time and improve internal
communications. Companies adopting this
approach benefit from increased employee
morale, improved customer retention and
healthier revenues.

256
In short, through certification to ISO 9001
you demonstrate that your organisation is
customer-focused and committed to
delivering high quality services.

257
Here are the top benefits of using the ISO
9001 framework:
Increased efficiency: by following industry
best-practice and focusing on quality you
can reduce costs.
Increased revenue: through the reputation
of ISO 9001 you can win more tenders and
contracts, and by being more efficient you
will also retain more customers and
experience more repeat custom.

258
Higher levels of customer
satisfaction: by understanding your
customers’ needs and reducing errors
you increase customer confidence in your
ability to deliver products and services.

259
Improved supplier relationships: because
ISO 9001 certification ensures best-practice
processes are in place which can
contribute to more efficient supply chains,
certification increases their confidence in
your processes.
Improved employee morale: by improving
internal communications you ensure
everyone works to one agenda.
260
The ISO 9001 standard uses which covers
four key areas:
Management Responsibility – the areas
within the QMS that your management
team need to focus on, be involved with and
be accountable for
Resource Management – how resources
such as people, infrastructure and facilities
must be assigned to ensure the best
possible performance
261
Product Realization – details on how your
business will operate in order to provide a
high quality service or product
Measurement, Analysis and Improvement –
how you can determine if your Management
System is working as expected, facilitating the
continual improvement of your system

262
ISO 14001 Certification
Environmental Management Helping you
protect the environment, meet your legal
obligations and strengthen your brand.
ISO 14001 sets the standard for Environmental
Management Systems.

263
If you want to reduce waste management
costs and demonstrate your commitment
to protecting the environment, you need
ISO 14001 certification.
Implementing this global standard will also
help your organization comply with
increasingly stringent environmental laws
and regulations, as well as building trust
with customers and other stakeholders.

264
ISO 14001 is the International Standard for
Environmental Management Systems
(EMS). It was designed by the International
Organization for Standardization (ISO) to
help businesses and other organizations to
reduce their environmental impact.

265
Any business, of any size, in any sector, can
implement the ISO 14001 framework and
apply for certification of their environmental
management plan. This makes ISO 14001
one of the most popular standards in the
world.

266
Here are the top benefits of using the ISO
14001 framework:
1.Identify cost savings, particularly in your
resource, waste and energy management
2.Improve efficiency and reduce
environmental impact across your product
life cycle

267
3.Improve your corporate image and
credibility, so helping you win new
customers
4. Quantify, monitor and control the
ongoing environmental impact of your
operations
5. Ensure your organization understands
and complies with environmental
legislation, so reducing the likelihood of
fines and prosecutions
268
The ISO 14001 standard uses cover four key
areas:
Environmental impact – the processes your
business must follow to run a successful
Environmental Management System and
reduce its environmental impact. Unlike the
other sections, not all areas will be
applicable to your business
Management Responsibility – the areas
where your management team need to focus
on, be involved with and be accountable for
269
Resource Management – how resources such
as people, infrastructure and facilities must be
assigned to ensure the best possible
performance
Measurement, Analysis and Improvement –
the final clauses within the ISO 14001
standard cover how you can determine if your
Management System is working as expected,
facilitating the continual improvement of your
system
270
 How does ISO 9001 compare to ISO 14001?
ISO 9001 is a Quality Management System (QMS)
which gives organizations a systematic approach
for meeting customer objectives and providing
consistent quality.
ISO 14001 is an Environmental Management
System (EMS) which gives organizations a
systematic approach for measuring and improving
their environmental impact.
ISO 9001 and ISO 14001 share a similar Plan-Do-
Check-Act structure and have many similarities,
but they do not directly align clause for clause.
271
ISO 14001 and ISO 9001 similarities are
highlighted in red in the comparison chart
(below):
•Documented Systems (manual and
procedures) on how you plan to achieve
improvement
•Control Documents and Records, etc.
•Training
•Internal Auditing
•Corrective/Preventive action
•management review
272
THANK YOU FOR TOUR
ATTENTION
GOD BLESS ETHIOPIA
273