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M.S.Ramaiah School of Advanced Studies

Computer Integrated Manufacturing

AMT 2508

Shanmuga Raja

(BVB0912004)

Module leader : Prof. Ramdas Chandrashekar

Sandeep .N


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Introduction

Computer Integrated Manufacturing (CIM) is an approach to

control entire manufacturing process using computers through theprinciple of networking.

The integration allows possibilities such as,

Data sharing across different functions of the plant. Closed loop controlled process based on real time sensing.

Using a common database for information interchange.

Encompassing product virtualization, realization, control and

maintenance. Mass customization.

Relieves human intervention to larger extent, improvising

quality, cost and delivery.


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Elements and Resources of CIM

Computer aided techniques

CAD (computer-aided design) CAE (computer-aided engineering)

CAM (computer-aided manufacturing) CAPP (computer-aided process planning) CAQ (computer-aided quality assurance) PPC (production planning and control) ERP (enterprise resource planning) A business system integrated by a common

database.

Devices and Equipment

CNC, Computer numerical controlled machine tools DNC, Direct numerical control machine tools

PLCs, Programmable logic controllers Robotics Computers Controllers Networks Interfacing

Monitoring equipmentTechnology

FMS, (flexible manufacturing system) ASRS, automated storage and retrieval system AGV, automated guided vehicle Robotic

Automated conveyance systems

Other

Lean manufacturing Quality program


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Group technology

Group technology is a technique involved in, grouping similar

parts with design and manufacturing characteristics and create acell based on rationalization of overall attributes.

The benefits of GT are,

Reduces Work In Process (WIP) by optimization of part flow.

Provides reliable work-piece statistics.

Facilitates accurate estimation of machine tool requirements

and logical machine loadings.

Provides for better machine tool utilization and better use of

tools, fixtures and people.

Limitations.

Problem in part identification among large group.

Re-arrangement of machines in appropriate cells.


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Group technology

The technique used to form Part families are,

Visual Inspection

Coding and Classification

Production Flow Analysis

Cost effective, suitable for less

part count.

Experienced personnel are

required to identify

MonocodePolycode Polycode

Systematic classification

through Monocode, Polycode

or Hybrid code

Time consuming process

Algorithms are used for

classification and cell

formation.

Flexibility is an issue.


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CAPP - Variant

Variant or Retrieval CAPP uses similarities between the stored

part, followed with necessary amendment on the feature attributes

so as to adapt the new part configuration.

Variant CAPP is basically,

GT based

Computer aids for editing

Parameters selection

Pros:

Easier to create and cost effective. Have a structured standard sequencing.

Cons:

Manual editing is not consistent Knowledge and experience of planner

limits the plan effectiveness.


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CAPP - Generative

Generative CAPP, is a planning technique based from first

principle. It relies mainly on an expert system to deduce the part

attributes and uses decision logic to advocate the sequence.

Generative CAPP is basically,

Some kind of decision logic

Decision tree/table

Artificial Intelligence

Objective-Oriented

Still experience based

Pros:

No need to rely on GT because ofdecision logic.

No need to maintain & update database.

Cons:

Creating the logic is too cumbersome. High Investment.


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Material Planning in CIM

Aggregate

Production Plan

(APP)

Master

Production

Schedule (MPS)


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Production

Activity Control

(PAC)

MaterialRequirement

Planning (MRP)

Material Planning in CIM


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Flexible Manufacturing System

FMS, is an automated reprogrammable manufacturing system

offering solution to wide variety of products.

Elements of FMS:

Computer controlled

Production Machines

(CNC / DNC).

Support systems (APC,

ATC).

Material handling

systems (RGV, AGV).

Automated Storage &

Retrieval system (ASRS). Buffer storage.


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FMS Layout

In-Line layout

Loop layout

Rectangular layout


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FMA Layout

Ladder layout Open field layout Robot centered layout


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Production MonitoringShop floor production activity is monitored for,

Real time date

To check output parameters for controlled process.

To warn the concerned in uncertain event.

To provide diagnostic information.

Cell performance data

To analyze cell utilization. To assess the part flow time.

To check the inventory level.

Direct Digital Controller

(DDC)Programmable Logic Controller

(PLC)

Distributed Control System

(DCS)


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Sensors in automation

Sensors are devices which detects the presence or absence of

conditions and forwards the signal for monitoring or manipulation.

Non contact sensors are preferred because it eliminates any

alignment issue, faster sensing and longer life. Some of its types

are,

Inductive sensor (Electromagnetic field)

Capacitive sensor (Electrostatic field)

core coilOscillator Magnetic Field

Without Object With Object


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Sensors in automation

Ultrasonic sensor (Sound waves)

Photoelectric sensor (Light energy)

Transmitter Receiver

Without Object

With Object

S

E

S

E

Without Object

With Object

Mirror

S

E

S

E

Without Object

With Object

ObjectDiffuse SensorTransmitter +Receiver

Transmitter

Receiver

Thru beam type Retro-reflective type Diffused type


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Industrial Robots

Cartesian Robot

Polar Robot Jointed Arm

Robot

Selective Compliant

Articulated Robot Arm

(SCARA)

Cylindrical Robot


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Industrial Robots

End effector

Grippers

Tools

Robot Programming is done by, Walk through.

Lead through.

Simulation and offline programming.


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Material handling

1. Containers and Unitizing Equipment

Containers

Unitizers

2. Material Transport Equipment

Conveyors

Industrial Vehicles

AGV, RGV

Monorails, Hoists, and Cranes

Material handling system can be categorized as,


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Material handling

3. Storage and Retrieval Equipment

Unit Load Storage and Retrieval

Unit Load Storage Equipment Unit Load Retrieval Equipment

Small Load Storage and Retrieval

4. Automatic Data Collection and

Communication Equipment

Automatic Identification and Recognition

Automatic Paperless Communication


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References

21

Prof. Ramdas Chandrashekar (2013) Module notes: Computer Integrated

Manufacturing, Bangalore: MSRSAS

Prof. Anatoly Sachenko (n.d,) Lecture 6. Computer Integrated Manufacturing Systems

[online] available from

[13 Mar 2013]

Dr. R. A. Wysk (2011) ISE789 -- Manufacturing Systems, [online] available from [13 Mar

2013]

Tom Foster (n.d,) Flexible Manufacturing System, [online] available from

[14 Mar 2013]Mikell P. Groover (2008) Automation, Production Systems, and Computer-Integrated

Manufacturing, [online] available from [14 Mar 2013]


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References

22

Festo (2007) Basics of Automation Technology, [online] available from

[14 Mar 2013]

Nuigalway (2007) Industrial Robot, [online] available from

[14 Mar 2013]

Dr. MuzafferKapanolu (2003) Material Handling, [online] available from

[14 Mar 2013]


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M.S.Ramaiah School of Advanced Studies 23

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