MFGE 404

Computer Integrated Manufacturing CIM

ATILIM UNIVERSITY
Manufacturing Engineering Department

Lecture 1 - Introduction

Fall 2005/2006
Dr. Saleh AMAITIK
Production Systems
Production system is the collection of people, Equipment, and
procedures organized to accomplish the manufacturing
operations of a company.
Production Systems
Production systems can be divided into two levels:

1. Facilities
The facilities of the production system consists of
• the factory
• the equipment in the factory, and
• the way the equipment is organized.

2. Manufacturing support systems

Set of procedures used by the company to:
• manage production
• solve the technical and logistics problems
encountered in
• ordering material
• moving work through the factory
• ensuring that products meet quality standards.
Production Systems

In modern manufacturing operations, portions of the

production system are automated and/or computerized.
- Production System Facilities
Facilities in the production system are:

• The factory
• Production machines and tooling
• Material handling equipment
• Computer systems that control the manufacturing
operations

Facilities also include the plant layout, which is the

way the equipment is physically arranged in the
factory.

The equipment is usually organized into logical

groupings, and we refer to these equipment
arrangements and the workers who operate them as the
manufacturing systems in the factory
Various Types of Plant Layouts

1- Fixed – position layout

Workers and processing equipment are brought to the
product, rather than moving the product to the equipment
Various Types of Plant Layouts

2- Process layout
In which the equipment is arranged according to function
or type. The lathes are in one department, milling
machines are in another department and so on.
Various Types of Plant Layouts
3- Cellular layout
Each cell is designed to produce a limited variety of part
configurations; that is the cell specializes in the production
of a given set of similar parts or products, according to the
principles of Group Technology.
Various Types of Plant Layouts
4- Product layout
Multiple workstations arranged in sequence, and the parts
or assemblies are moved through the sequence to complete
the product.

The collection of stations is designed specifically for the

product to maximize efficiency.
Production quantity and product variety

Production quantity: refers to the number of units of a

given part or product produced annually by the plant.

Production quantity can be classified into three ranges

1- Low Production (Job Shop)

Quantities in the range of 1 to 100 units per year

2- Medium Production (Batch Production)

Quantities in the range of 100 to 10000 units per yea

3- High Production (Mass Production)

Quantities are 10000 to millions of units per year

Product Variety: refers to the different product designs or

types that are produced in a plant. (Different products have
different shapes and sizes and styles)
Relationship between product variety and production
quantity in discrete product manufacturing

When product variety is high, production quantity tends to be low; and

vice versa.
Types of facilities and layouts used for different
levels of production quantities and product
variety
II- Manufacturing Support Systems

To operate the production facilities efficiently, a company must organize

itself to

• Design the processes and equipment

• Plan and control the production orders; and
• Satisfy product quality requirements

This accomplished by manufacturing support systems (people and procedures)

Most of manufacturing support systems do not

directly contact the product, but they plan and
control its progress through the factory.
II- Manufacturing Support Systems
Manufacturing support involves a cycle of information-processing activities
II- Manufacturing Support Systems

1- Business Functions

Included in business functions are

• Sales and marketing

• Sales forecasting
• Order entry
• Cost accounting
• Customer billing
II- Manufacturing Support Systems

2- Product Design

Included are

• Research and development

• Design engineering
• Drafting and modeling
II- Manufacturing Support Systems

3- Manufacturing Planning

The information-processing activities

included in manufacturing planning are:

• Process planning
• Scheduling
• Material requirement planning
II- Manufacturing Support Systems

4- Manufacturing Control

Information included in manufacturing control

function are

• Shop control
• Inventory control
• Quality control
 Automation in Production Systems

Automation can be defined as a technology concerned with

the application of mechanical, electronic and computer-
based systems to operate and control production

The automated elements of the production system can be separated into two
categories:
• Automation of the manufacturing systems in the factory
• Computerization of the manufacturing support systems
utomated Manufacturing Systems
Examples of automated manufacturing system included:

• Automated machine tools that process parts

• Transfer lines that perform a series of machining operations
• Automated assembly systems
• Industrial robots to perform processing or assembly
• Automatic material handling and storage systems
• Automatic inspection systems for quality control

omated manufacturing systems can be classified into three basic types:

ixed automation
Programmable automation
lexible automation
utomated Manufacturing Systems

1- Fixed Automation

Fixed automation is a system in which the sequence of

processing (or assembly) operations is fixed by the
equipment configuration. Each of the operations in the
sequence is usually simple.

Examples:
• machining transfer lines
• automated assembly machines
utomated Manufacturing Systems

2- Programmable Automation

In programmable automation, the production equipment is

designed with the capability to change the sequence of
operations to accommodate different product configurations.
The operation sequence is controlled by a program

Examples:
• Numerically controlled machines (NC)
• Industrial robots
utomated Manufacturing Systems

3- Flexible Automation

Flexible automation is an extension of programmable

automation. A flexible automated system is capable of
producing a variety of parts with virtually no time lost
for changeovers from one part style to the next.

Example
• Flexible manufacturing systems
Three types of automation relative to production
quantity and product variety
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
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
easons 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
Automation Migration Strategy
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
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
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
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 workhead 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
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 Fixed Routing, the work

are transported through a units always flow through
variety of different station the same sequence of
sequences. stations
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)
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
Classification of Manufacturing Systems

Factors that define and distinguish the different types of

manufacturing systems are:

1. Types of operations performed

2. Number of workstations and system layout
3. Level of automation
4. Part or product variety
lassification of Manufacturing Systems
lassification of Manufacturing Systems
lassification of Manufacturing Systems

M=The manning level of a workstation is defined as the portion of

time a worker is in attendance at the station
lassification of Manufacturing Systems
lassification of Manufacturing Systems
lassification of Manufacturing Systems
lassification of Manufacturing Systems
lassification of Manufacturing Systems
lassification of Manufacturing Systems
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

• 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
Computer Integrated Manufacturing Activities
Computer Integrated Manufacturing Activities
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

QC (Computer Aided Quality Control)

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
CIM Model
CIM Model