UME1702: Computer Integrated

Manufacturing System

Unit 1 - Introduction to CIM

Session 2
 Session Meta Data

Author K.S.VIJAY SEKAR

Reviewer

Version Number 1.2

Release Date 03.07.2018

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 Revision History

Revision Date Details Version

no.
12 April 2018 1. New SSN template applied 1.2

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 Session Objectives
• Introduction to CIM Concepts

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 Session Outcomes
• At the end of this session, participants will be able to
– Know the basic concept of CIM
– Know the elements of CIM system
– Know the types of production systems
– Know what are the manufacturing models

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 Agenda

• CIM concepts
• Computerized elements of CIM system
• Types of production

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 Definition of CIM
• CIM is the integration of total manufacturing
enterprise through the use of integrated system
and data communication mixed with new
managerial philosophies which results in the
improvement of personnel or organizational
efficiencies.

(by CASA – Computer and Automation System

Association of Society of Mechanical Engineers).

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 Introduction to CIM
 CIM is the use of computers to integrate the manufacturing activities.
 These activities encompass all functions necessary to translate customer needs into a final
product.
 CIM starts with the development of a product concept.
 Includes product design and specification.
 Extends through production into delivery and after-sales activities.
 Integration of these activities requires that accurate information be available when needed
in the specified format.
 Data may come directly from the originating source or through an intermediate database.
 CIM systems have emerged as a result of the developments in manufacturing and computer
technology.

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 Introduction to CIM

 CIM is the manufacturing approach of using computers to control the

entire production process.
 Benefits:
 Individual processes exchange information with each other and
initiate actions.
 Main advantage is the ability to create automated manufacturing
processes.
 Manufacturing can be faster and less error-prone.
 Typically, CIM relies on closed-loop control processes based on real-time
input from sensors.
 It is also known as flexible design and manufacturing.
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 CIM - Functions

www.unc.edu

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 Challenges to development of CIM system:
1. Integration of components from different suppliers: When different machines,
such as CNC, conveyors and robots, are using different communications protocols.
In the case of AGVs, even differing lengths of time for charging the batteries may
cause problems.
2. Data integrity: The higher the degree of automation, the more critical is the
integrity of the data used to control the machines. CIM system requires extra
human labor in ensuring that there are proper safeguards for the data signals that
are used to control the machines.
3. Process control: Computers may be used to assist the human operators, but there
must always be a competent engineer on hand to handle unforeseen
circumstances.

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 CIM Wheel

www.manufacturing-oper
ations-management.com

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 Agenda

• CIM concepts
• Computerized elements of CIM system
• Types of production

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 Elements of CIM

www.manufacturing-o
perations-managemen
t.com
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 Elements of CIM
• Computerized integration of all aspects of design, planning, manufacturing,
distribution and management.
• Includes all engineering functions of CAD/CAM and also business functions.
• Product and process design, production planning and control and
production processes replaced by CAD/CAM, CAPP and automated
material handling system and computerized business systems.
• Completely automated factory with no human interface and factory of the
future.
• To transform ideas into a high quality products in the minimum cost and
minimum time.
• CIM technologies tied together using a network and integrated databases.

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 CIM Hardware
1. Manufacturing equipments
Workstations
Cells
DNC
FMS
Work, tool handling & storage devices
Sensors
SFC data collection devices
2. Computer related hardware
Computers, controllers, printers, plotters, Modems, Cables, Connectors,
Workstation terminals
CAD/CAM systems
3. Office equipment
4. Communication hardware
Remote batch terminals, Front end processors,
Transmitters, Acoustic couplers
Multiplexers, Concentrators

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 Benefits of CIM
• Creates truly interactive system
• Accurate data transferability
• Faster responses to data changes
• Increased flexibility towards new products
• Improved quality and accuracy
• Control of data flow
• Reduction of lead time
• Streamlined manufacturing flow form order to delivery
• Easier training and re-training facilities

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 Agenda

• CIM concepts
• Computerized elements of CIM system
• Types of production

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 What is a Production System?

• Production System are those activities of

an organization where
– resources flowing within a defined system
– are combined and transformed
– in a controlled manner
– to add value
– in accordance to the policies
communicated by the management

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 Production Choices

 Make-to-stock
• Number of units of each product are kept on hand at all times
• Quick delivery to customers upon receipt of an order
• When delivery response time is a key competitive factor
• Limited number of products manufactured repeatedly
• An idea what customers will want
• Allows to schedule production in advance
 Make-to-order
• Only produce items after they have been ordered
• Production system must respond quickly
• Products have high degree of customization
• Shelf life of products is short
 Assemble-to-order
• Customers have influence on the design
• They can select various options from predesigned subassemblies
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 Types of Production processes

Youtube
.com

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 Job Shop production
• 1. High variety of products and low volume.
• 2. Use of general purpose machines and facilities.
• 3. Highly skilled operators who can take up each job as a challenge because of
uniqueness.
• 4. Large inventory of materials, tools, parts.
• 5. Detailed planning is essential for sequencing the requirements of each product,
capacities for each work centre and order priorities.
• Advantages
• 1. Because of general purpose machines and facilities variety of products can be
produced.
• 2. Operators will become more skilled and competent, as each job gives them
learning opportunities.
• 3. Full potential of operators can be utilized.
• 4. Opportunity exists for Creative methods and innovative ideas.
• Limitations
• 1. Higher cost due to frequent set up changes.
• 2. Higher level of inventory at all levels and hence higher inventory cost.
• 3. Production planning is complicated.
22 • 4. Larger space requirements. v 1.2
 Batch production
• 1. Shorter production runs.
• 2. Plant and machinery are flexible.
• 3. Plant and machinery set up is used for the production of item in a batch and
change of set up is required for processing the next batch.
• 4. Manufacturing lead-time and cost are lower as compared to job order production.
• Advantages
• 1. Better utilization of plant and machinery.
• 2. Promotes functional specialization.
• 3. Cost per unit is lower as compared to job order production.
• 4. Lower investment in plant and machinery.
• 5. Flexibility to accommodate and process number of products.
• 6. Job satisfaction exists for operators.
• Limitations
• 1. Material handling is complex because of irregular and longer flows.
• 2. Production planning and control is complex.
• 3. Work in process inventory is higher compared to continuous production.
• 4. Higher set up costs due to frequent changes in set up.

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 Mass Production
• 1. Standardization of product and process sequence.
• 2. Dedicated special purpose machines having higher production capacities and
output rates. 3. Large volume of products.
• 4. Shorter cycle time of production. 5. Lower in process inventory.
• 6. Perfectly balanced production lines.
• 7. Flow of materials, components and parts is continuous and without any back
tracking. 8. Production planning and control is easy.
• 9. Material handling can be completely automatic.
• Advantages
• 1. Higher rate of production with reduced cycle time.
• 2. Higher capacity utilization due to line balancing.
• 3. Less skilled operators are required.
• 4. Low process inventory.
• 5. Manufacturing cost per unit is low.
• Limitations
• 1. Breakdown of one machine will stop an entire production line.
• 2. Line layout needs major change with the changes in the product design.
• 3. High investment in production facilities.
24 • 4. The cycle time is determined byv 1.2
the slowest operation.
 Continuous Production

• 1. Dedicated plant and equipment with zero flexibility.

• 2. Material handling is fully automated.
• 3. Process follows a predetermined sequence of operations.
• 4. Component materials cannot be readily identified with final product.
• 5. Planning and scheduling is a routine action.
• Advantages
• 1. Standardization of product and process sequence.
• 2. Higher rate of production with reduced cycle time.
• 3. Higher capacity utilization due to line balancing.
• 4. Manpower is not required for material handling as it is completely automatic.
• 5. Person with limited skills can be used on the production line.
• 6. Unit cost is lower due to high volume of production.
• Limitations
• 1. Flexibility to accommodate and process number of products does not exist.
• 2. Very high investment for setting flow lines.
• 3. Product differentiation is limited.

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 Products, Processes, and Layouts
PRODUCTS PROCESSES LAYOUTS

Make-to-stock Continuous high volume,

standardized process industries Product Layout
commodities repetitive mfg low variety

Assemble-to-order Hybrid, FMS, low volume,

Cellular Layout
modular CAM, CIM medium variety

Make-to-order low volume,

Job-Shop(Intermittent) Process Layout
custom
high variety

low volume,
Engineer-to-order Special Project Fixed Position
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low variety26
 Information Flow for Various Production Systems

Order Entry

Raw I I I
Material

a. Materials Requirements Planning (MRP)

Raw
Material

b. Just-In-Time (KANBAN)

Material Flow
Processor I Infinite Capacity Finite Capacity
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Inventory Buffer Inventory Buffer 27 Information Flow
 KANBAN control

• Kanban control uses the levels of buffer inventories in

the system to regulate production. When a buffer
reaches its preset maximum level, the upstream
machine is told to stop producing that part type. This is
often implemented by circulating cards, the kanbans,
between a machine and the downstream buffer.
• The machine must have a card before it can start an
operation. It can then pick raw materials out of its
upstream (or input) buffer, perform the operation, attach
the card to the finished part, and put it in the downstream
(or output) buffer.

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 KANBAN control

• Kanban control ensures that parts are

not made except in response to a
demand.
• The analogy is to a supermarket:
Only the goods that have been sold
are restocked on the shelves.

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 Information Flow for Various Production Systems
Limit on
Total
Inventory
Raw I I
Material

c. Constant Work-In-Process (CONWIP)

Raw
Material

d. Hybrid CONWIP-KANBAN

Material Flow
Processor I Infinite Capacity Finite Capacity
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Inventory Buffer Inventory Buffer 30 Information Flow
 CONWIP Control
• CONWIP stands for Constant Work-In-Process.
• a control strategy that limits the total number of
parts allowed into the system at the same time.
• Once the parts are released, they are processed
as quickly as possible until they fill up the last
buffer as finished goods.
• Once the consumer removes a part from the
finished goods inventory, the first machine in the
chain is authorized to load another part.

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 CONWIP Control
• Like KANBAN, the CONWIP system only
responds to actual demands, so it is still a ``pull''
type system.
• But unlike kanban, the buffers for all
downstream machines are empty, except
finished goods, which is full.
• This occurs because any part released to the
system will move to finished goods. New parts
will not be released if the finished goods buffer is
full.

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 Summary
• At the end of this session, participants have Learnt

CIM concepts
Computerized elements of CIM system
Types of production

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 References
• CIM TEXT BOOK:
• 1. Mikell.P.Groover “Automation, Production Systems and Computer Integrated Manufacturing”,
Prentice Hall of India, 2008.
• 2. Radhakrishnan P, Subramanyan S.and Raju V., “CAD/CAM/CIM”, 2nd Edition, New Age
International (P) Ltd, New Delhi, 2000.
• REFERENCES:
• 1. Kant Vajpayee S, “Principles of Computer Integrated Manufacturing”, Prentice Hall India, 2003.
• 2. Gideon Halevi and Roland Weill, “Principles of Process Planning – A Logical Approach”
Chapman & Hall, London, 1995.
• 3. Rao. P, N Tewari &T.K. Kundra, “Computer Aided Manufacturing”, Tata McGraw Hill Publishing
Company, 2000.

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