CIM Introduction - Lecture notes 1 PDF

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NARENDRA A. PATEL M. Tech. CAD/CAM U V PATEL COLLEGE OF ENGINEERING GANPAT UNIVERSITY

Computer Integrated Manufacturing

Computer Integrated Manufacturing

Introduction to Computer Integrated Manufacturing

Definition of CIM Computer and Automated Systems Association of the Society of Manufacturing Engineers define CIM as under: “CIM is the integration of total manufacturing enterprise through the use of integrated systems and data communications coupled with new managerial philosophies that improve organizational and personnel efficiency.” “Computer Integrated Manufacturing is a technology in which computer aided design, planning, manufacturing and control are integrated by using computer system to communicate data for achieving goal of manufacturing firm.”

CIM I We know the fundamental components of information and communication technology like computer-, communication- and data-base-systems. Furthermore they know the principles that support the product development process (Virtual Product Development, Virtual Prototyping). In this particular process IVth generation of computer is used and is called as CIM I. LSI and VLSI technology is used for CIM-I

CIM II The main focus is on flexible automated processes of manufacturing that are characterized by the operation of NC-machines and industrial robots. Typical systems of the flexible automation are Flexible Manufacturing Cells, Flexible Production Systems and Flexible Production Lines. The students know the basic design of these systems as well as their programming, control and monitoring. Generally parallel processing is done in CIM-II.

Role of CAD/CAM in CIM

Evolution of CIM with Time Scale

Objectives of CIM Improve efficiency of the system as imagined in definition by making optimum use of computers in following control functions: • • • • • • • •

Machine control DNC & VNC control Production control Traffic control of work piece transport system Shuttle control of AGVs, pallet carriers, robots etc. Work handling system monitoring Tool control System performance monitoring and reporting

Major Elements of CIM

Various Activities of CIM

Objectives of CIM •

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The manufacturing engineers are required to achieve the following objectives to be competitive in a global contest. • Reduction in inventory • Lower the cost of the product • Reduce waste • Improve quality Increase flexibility in manufacturing to achieve immediate and rapid response to : • product changes • production changes • process change • equipment change • change of personnel

Why Use CIM? •

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Responsiveness to Rapid Changes in Market Demand and Product Modification. Better Use of Materials, Machinery, Personnel, Reduction in Inventory. Better Control of Production and Management of the Total Manufacturing Operation. The Manufacture of High-Quality Products at Low Cost.

CIM Wheel

Strengths of CIM Wheel •

This CIM Wheel represent different resources required for the complete implementation of the CIM.

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The second rim from out side define the main CIM implementation required three main function involvement (i) Manufacturing Planning and control, (ii) Product Process and (iii) Factory Automation.

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The outer rim shows the management and resource requirement of the CIM Implementation.

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It can also helpful to find out the island required for the complete CIM

Weakness of CIM Wheel •

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The main and major weakness of the CIM wheel is it doesn’t shows the way of integration. It also doesn’t represent the complete connection of the different island. We can not clarify in which sequence we have to plan for implementation of the CIM. The CIM is a computer Integrated Manufacturing so it is need not to use the conventional words for preparing the CIM Wheel. The existing CIM wheel is not being time constrained or not giving particular process constituents or weight age for the same.

CASA CIM Wheel

CIM Enterprise Wheel

CIM Wheel

Positive Changes in CIM Wheel There are positive changes in CASA/SME wheel are like: • In second inner rim instead of communication data and common data we can use other word like hardware management and software management that will emphasis on the other than data we can communicate the signal also through the compatible hardware and software systems. • In third inner rim it is newly added in comparison of old wheel, it will represent that which work is pre planned or virtual or actual in CIM implementation. • Then in next rim there is no use to use conventional word of the different island of the CIM because the CIM is already Computer Integrated manufacturing so we can not go for conventional methods that’s why it will better to use the actual name of the island. • In outer rim instead of using the area of CIM it is better to use major participant to collaborate with the successful CIM implementation.

Major Applications of CIM • • • • • • • • •

Computer Numerical Control Adaptive Control Industrial Robots Automated Handling of Materials Automated and Robotic Assembly Systems Computer-Aided Process Planning Just-in-time Production Group Technology Artificial Intelligence

Computer Numerical Control • • •

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Use Control Microcomputer as an Integral Part Can be Repeated at a Remote Site by the Programmer May Incorporate Information From Drafting Software

Advantages of CNC: • • •

Increased Flexibility Greater Accuracy More Versatility

Adaptive Control • • •

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Research Began in Early 1950s A Logical Extension of CNC Operator Parameter Adjust Themselves to Fit in New Circumstances It Is a Feedback System Basically

Basic Function of AC • •

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Determine Operating Conditions of Process Configure the Process Control in Response to the Operating Conditions Continue to Monitor the Process

Industrial Robots •

The Word ‘Robot’ was Converted from the Czech Work ‘Robota’ Which Means ‘Worker’

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Research Began in Early 1960s

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A Mechanism Including Several Degrees of Freedom

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Having One or Several Arms

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Controlled by A Memorizing Device

Major Applications of Industrial Robots •

Material Handling

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Spot Welding Utilizes Automobile and Truck bodies

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De-burring, Grinding and Polishing

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Applying Adhesives and Sealants

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Spray Painting

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Automated assembly

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Inspection and gaging

Automated Handling of Materials •

Manual Handling is Very Costly

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Working Process and Environment Could Be Danger to Human Being

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Automated Handling Can Minimized the Risk of Getting Injured

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More Efficient and Accurate

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Reduction in Cost

Automated & Robotic Assembly •

Cost of Manual Assembly is Very High

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Automated & Robotic Assembly Reduce the Cost of Production

Computer-Aided Process Planning (CAPP) •

Tradition Process Planning Is Very Time Consuming and Not Efficient

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CAPP Is Especially Good For Small Volume, High Variety Parts Production

Cost Savings of CAPP •

Reduction in process planning effort

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Saving in direct labor

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Saving in material

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Saving in scrap

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Saving in tooling

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Reduction in work-in-process

Benefits of CAPP •

Reduced Process Planning and Production Lead-Time

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Greater Process Plans Consistency

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Improved Cost Estimating Procedures F Calculation Errors

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More Complete and Detailed Process Plans

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Improved production utilization.

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Improved Ability to Introduce New Manufacturing Technology

scheduling

and

capacity

Just-In-Time Production •

First Implemented in Japan

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Eliminate Sources of Manufacturing Waste

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Receive Supplies Just-In-Time

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Produce Parts Just-In-Time

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Produce Subassemblies Just-In-Time

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Produce and Deliver Finished Products Just-In-Time to Be Sold

Advantage of JIT •

Low Inventory Carrying Costs

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Fast Detection of Defects

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Reduced Inspection and Rework of Parts

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High-Quality Parts Produced at Low Cost

Group Technology •

First Developed In Europe in Early 1900s

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Parts Can Be Grouped and Produced By Classifying into Families

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Seek Advantage of ‘Design and Processing Similarities’

Artificial Intelligence •

To Simulate Human Behaviors on Computers

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AI Can Exhibit Learning, Reasoning, Problem Solving, Understand Language

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Capable of Modeling, Simulating Production Facilities

Implementation of CIM The following steps are suggested for implementing CIM : • Define objectives • Define strategic planning horizon • Prepare the organization for change over • Identify the needs and fix the priorities and determine the level of integration. • Estimate costs, schedule plans, document system requirements and prepare purchase specifications • Procure hardware, software and training services. • Install equipment and train employee. • Analyze the results and improve the working

Benefits of CIM • • • • • • • • • • • • •

Improved customer service Improved quality Shorter time to market with new products Shorter flow time Shorter vendor lead times Reduced inventory levels Improved schedule performance Lower total cost Greater long-term profitability Shorter custom lead times Increase in manufacturing productivity Decrease in work in process inventory. Reduced direct and indirect labor

Benefits of CIM • • • • • • • • • • • • •

Reduced manufacturing lead time Lower in-process inventory Scheduling flexibility Higher profit Reduced scrap and rework Shortened new product development time Fewer missed delivery dates Deceased warranty cost Higher employee moral Safe working environment Improved customer image Increased job security Increased machine utilization...