Advanced Computer

Integrated Manufacturing

Dr. Ramesh B T
Department of Robotics and Automation
SIT- Pune
Course Outcomes

 C01: To Understand the importance of automation & its role in

industrial revolutions with various principles of modern factory
 CO2: To study and describe the different aspects FMSs in CIM.
 CO3: To Apply the knowledge of data driven models in manufacturing
technology.
 CO4: To evaluate the concepts and trends of CIM through the available
literature in the domain.
Module-1 Manufacturing Automation:
Automated Manufacturing Systems, Computerized Manufacturing Support Systems, Reasons for
Automation, Automation Strategies-The USA Principle, Ten Strategies for Automation and
Process Improvement, Automation Migration Strategy, Industrial Revolutions.

Module-2 Introduction to Modern Factory:

Overview of Automated Flow lines, Manual Assembly Lines, Automated Assembly Systems,
Automatic Material Handling and Storage systems, Automated Inspection systems, Cellular
Manufacturing Systems, Computer Aided Process Planning.

Module-3 Flexible Manufacturing Systems & CIM:

Flexibility, Types Of FMS-A Dedicated FMS, A Random Order FMS, FMS Components-
workstations, Material Handling And Storage Systems, Computer Control System, Human
Recourses, FMS Applications And Benefits Computer Integrated Manufacturing. The Scope Of
CAD/CAM And CIM, Computerized Elements Of A CIM System, Components Of CIM, Database
For CIM, Planning, Scheduling And Analysis Of CIM Systems.
Module-4 Data Driven Models for Manufacturing Systems:
Introduction to Data Driven Models, Model based Manufacturing, Data driven manufacturing,
data collection in manufacturing processes, Typical Applications, Challenges, and opportunities
data driven manufacturing, Future trends.

Module-5 Latest Trends in Computer Integrated Manufacturing:

Case Studies - Process Industries, Manufacturing Industries & Food Industries; Current and
future trends by review of Technical papers in the related journals.

Pedagogy:
1.Classroom / Online Lectures (including flipped classroom)
2.Group Discussions
3.Filed visits/seminars
4.Case-studies
 Course Code: 701480104
Number of Credits: 03

Suggested Assessment/ Evaluation Methods

A. Continuous Assessment:
1. Presentations
2. Case-studies
3. Class Test/Unit Test
4. Field Visit Report
 
B. End Semester Examination:
1. ESE Exam
Definition of CIM
Computer-integrated manufacturing (CIM) refers to the use of computer-
controlled machineries and automation systems in manufacturing products.

CIM as a computer system in which the peripherals are robots, machine tools and other processing
equipment.
In straightforward terms, CIM is the technique of using computers to control an entire
production process. It’s commonly used by factories to automate functions such as analysis,
cost accounting, design, distribution, inventory control, planning and purchasing.

The challenge before the manufacturing engineers

Manufacturing engineers are required to achieve the
following objectives to be competitive in a global context.

• 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
CIM is recognized as Islands of Automation
 CIM HARDWARE AND CIM SOFTWARE

CIM Hardware

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.
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

•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)
CIM software comprises computer programs to carry out the following functions:
• Management Information System
• Sales
• Marketing
• Finance
• Database Management
• Modeling and Design
• Analysis
• Simulation
• Communications
• Monitoring
• Production Control
• 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
NATURE AND ROLE OF THE ELEMENTS OF CIM SYSTEM
CIM Wheel
Conceptual model of manufacturing
 Historical Development of Manufacturing

3500 BC Use of Wheel and axle for

transportation
500 BC Lathe used for wood turning
1569 Screw-cutting lathe developed -- Jacques
Besson
1769 James Watt invented the steam engine --
later used to provide power to industry
1774 Precylinder-boring mill developed -- John
Wilkinson
1790 Samuel Slater opens the first successful
textile mill in the United States
1793 Eli Whitney builds the first cotton gin
1798 Eli Whitney invents a milling machine to
produce standardized parts in muskets 11/29/2022
 Historical Development of Manufacturing

1801 J.M. Jacquard invented a silk-loom-- punched cards controlled the

machine
1851 Issac Singer patented his sewing machine
1900 High-speed steel cutting tools developed
1903 Oxyacetylene welding torch developed
1903 First fully automated machine-made bottles produced
1907 Paint spray gun developed
1913 Ford Motor Co. opens first moving assembly line
1914 Centrifugal casting of cast iron pipe -- re-usable molds are used
1920 Ford introduces continuous casting of cast iron for engine blocks

https://youtu.be/mcwIMsh_g3o
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 Historical Development of Manufacturing

1921 Jigs and fixtures used in the jig-boring machine to make rifles and
revolvers -- Enfield, England
1930 First automatic factory -- Made chassis frames for cars: one every six
seconds
1952 First commercial NC machine
1962 First industrial robot
1963 Electro-coating methods for painting car bodies is developed
1964 Technique for fast-breaking electric motors developed -- machine
tools can now be stopped quickly
1985 First products manufactured in space went on sale -- tiny plastic beads,
perfectly round and uniform in size

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The Production System

Manufacturing
support systems

Manufacturing facilities:
factory, equipment

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 AUTOMATION DEFINED
Automation is a technology concerned with the application of mechanical, electronic, and
computer-based systems to operate and control production. This technology includes:
Automatic machine tools to process parts
Automatic assembly machines
Industrial robots
Automatic material handling and storage systems
Automatic inspection systems for quality control
Feedback control and computer process control
Computer systems for planning, data collection, and decision making to support
manufacturing activities
TYPES OF AUTOMATION
 Fixed Automation (transfer lines)
 Hard automation, automation for mass production
 Produces large numbers of nearly identical parts
 High initial investment for custom engineered equipment
 Product design must be stable over its life
 Advantages: equipment fine tuned to application - decreased cycle time, infrequent setups,
automated material handling - fast and efficient movement of parts, very little WIP
 Disadvantage: inflexible

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Programmable Automation (NC, CNC, robots)
 Sequence controlled by a program
 High investment in general purpose equipment
 Lower production rates
 Flexibility to deal with variation
 Suitable for batch production
 Smaller volumes (than fixed) of many different parts
 More flexible than fixed automation
 Major disadvantage: setup prior to each new part
 Large batch size (due to setups)
 Speed sacrificed for flexibility

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 Flexible Automation (FMS)
 Extension of programmable automation
 No time lost for change over
 High investment in custom-engineered systems
 Production of product mix
 Flexibility to deal with design variations
 Low to medium quantities
 Compromise between fixed and programmable automation in speed and
flexibility
 Advantage: programming and setup performed off-line
 More expensive - size and tool change capabilities
 Small batch sizes are justified - reduced WIP and lead time
 Typical parts are expensive, large and require some complex machining 11/29/2022
 Example Industries
 Aerospace
 Typically, complex, three-dimensional shapes, exotic materials, medium-volume to
low-volume production quantities
 Military and space technology filters down to industrial applications
 Pioneered work in NC machining, CAD/CAM, composites and flexible
manufacturing system applications
 Goals: energy efficiency, high strength-to-weight ratio

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 Example Industries
 Automotive
 Relatively large production quantities, multiple options: automated
assembly is difficult
 Traditionally, primary processes were metalworking: machining of
power train parts, forming and bending sheet metal; assembly by
spot welding and mechanical fasteners; finishing by spray painting
and plating
 New materials: plastics, fiberglass
 Increasing automation: robots for spot welding and spray painting
 Improved quality with production groups that assemble large
portions of the automobile

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 Example Industries
 Chemical
 Chemical processes for man-made fibers and plastics, oil distillation and
pharmaceutical industries
 Continuous flow of product and byproducts; some batch processing
 reasonably easy to automate

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 Example Industries
 Food
 Large volume industry
 Standard products and operations, therefore reasonably easy to automate
 Many products use continuous processes; discrete processes includes packaging

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 Example Industries
 Semiconductor
 Large volume industry
 Emphasis on design and production of low-cost integrated circuits
 Smaller size and more stringent requirements for cleanliness
 Process requirements have forced automation

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 Reasons for Automating

 Increase production rate

eliminate portions of process that directly increase production time:
machine processing time, handling time, setup times (SMED)
 Remove humans from hazardous environments
exposure to chemicals, fumes, temperature or radiation
robotic applications: L/UL furnaces, spray painting, welding
 Remove humans from processes that require extremely clean
environments: e.g., semiconductors, drugs
 Reduce number of defective products
 Reduce direct labor
one worker monitors a larger number of machines
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 Reasons for Automating
 Reduce work-in-process
parts being processed, part waiting to be processed
large WIP: longer time to fill orders, more storage space, value of
unfinished goods that could be invested elsewhere
reduced WIP: better control and scheduling
 Reduce manufacturing lead time
processing time, setup time, waiting time
setup time: flexible automation, common fixtures and tooling
processing time: combining or eliminating operations, increase
speed (work measurement principles)
 Increase quality
repeatable operations through every cycle - tighter control limits,
easier detection when process is out of control
status of manufacturing operations
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 Reasons for Automating
 Increase productivity
 Reduce labor cost
 Address labor shortages
 Reduce or eliminate routine manual and clerical tasks
 Health and Safety
 May be the only option
 Stay up-to-date (avoid cost of catching up)

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TYPES OF PRODUCTION
 FUNCTIONS IN MANUFACTURING

the functions are:

 1. Processing
 2. Assembly
 3. Material handling and storage
 4. Inspection and test 5. Control
 ORGANIZATION-AMD INFORMATION
PROCESSING IN MANUFACTURING
 1. Business functions
 2. Product design
 3. Manufacturing planning
 4. Manufacturing control
Plant Layout

 Fixed Position layout

 Process Layout
 Product flow layout
 PRODUCTION CONCEPTS AND
MATHEMATICAL MODELS
Manufacturing lead time

To = Time per operation at a given machine or workstation.

Tno = Non operation time associated with the same machine.
nm = Number of separate machines or operations through which
the product must be routed in order to be completely processed.
Q = Units of the product in the batch (for batch production)
Tsu = Setup time

i = 1,2, . .n
 Components of the operation time
The components of the operation time To, The operation time is the time an individual
workpart spends on a machine, but not all of this time is productive.

the actual machining time (Tm ),

the workpiece handling time (Th ),
any tool handling time per workpiece (Tth)

Capacity
The term capacity, or plant capacity, is used to define the maximum rate of output that a plant is able
to produce under a given set of assumed operating conditions.

Let Dw be the demand rate for the week in terms of number of units required. Replacing PC and rearranging,
 Utilization and Availability

Utilization (U) refers to the amount of output of a production facility relative to its capacity. It can be
expressed by

Availability is defined using two other reliability terms, the mean time between failures (MTBF) and
the mean time to repair (MTTR).

Work-in-process (WIP) is the amount of product currently located in the factory that is either being
processed or is between processing operations.
Problems
 AUTOMATION PRINCIPLES AND STRATEGIES

USA Principle:
1. Understand the existing process
2. Simplify the process
3. Automate the process

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 AUTOMATION PRINCIPLES AND STRATEGIES

Ten Strategies for Automation

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 (CIM).

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 AUTOMATION PRINCIPLES AND STRATEGIES

Automation Migration Strategy

Phase 1: Manual production using single station manned cells operating
independently.
Phase 2: Automated production using single station automated cells
operating independently.
Phase 3: Automated integrated production using a multi-station automated
system with serial operations and automated transfer of work units between
stations.

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https://youtu.be/ltVgDeClaiE

https://youtu.be/ltVgDeClaiE

https://youtu.be/A-2U-EAMGhw

https://youtu.be/K-FvYZv785U

https://www.youtube.com/watch?v=T6kaU2sgPqo

https://youtu.be/4aaPZ80Yo4s
 PRINCIPLE OF 4.0 INDUSTRIAL
REVOLUTION

Presented by: Assoc. Prof. Dr. Shadi M. S. Hilles

 The 4th Industrial Revolution is leading
Internet of Things
the Intelligent Information Society the Digital
Transformation, its advance Technologies. Cloud Computing
Big data
By using 5G wireless network which Artificial
is 70 times faster than 4G wireless. Intelligence
WHAT ARE THE MAIN PILLARS OF INDUSTRY
4.0?
Technology
Autonomous o Robotics deals with the design, construction, operation
Robots
Cloud
and its Replacing humans on assembly line.
Computing Simulation o 3D Printing is any of various processes in which material is
joined or solidified under computer control to create a
three- dimensional object, the manufacturing customized
Big data System
components
analytics
Industry integration
o Big Data – Collecting performance parameters, used to
refer to data sets that are too large or complex for
Augmented
4.0 Industrial traditional data- processing application, aanalytics –
Internet of
reality
Things Understanding collected data
Adaptive
Cyber People
Manufactor Security
ies o Increased efficiency – Reduction in labor per unit
o Skill Development – Up-skilling, Re-skilling,
Continuous learning & Mindset change
o Only to handle disruptions – Monitoring and
corrective actions
Process
o Constant communication – Data exchange between components
o Decentralized decision making any process where the decision-making authority is
distributed throughout a larger group
o Standardization – Ease of customization
o Smart Transport System - Automated transportation of raw material for final
 Social changes due to industry revolutions

 Technology including machine learning, deep learning and big data makes machine
think like human.
 Changes in recognition of human identity and job topography are commonplace.

 New products , VR/AR, smart car, telemedicine, virtual labs virtualize general daily
lives and social and economic activities.
 Human experience and cognitive domain become blurred
 New service in various fields of industry can be created

 Proliferation of digital network and mobile devices expand a range of human-

human, human-thing and thing-thing interaction (IoE: Internet of Everything)
 Hyper-connection causes new group behavior pattern
CONVENTIONAL INDUSTRIAL
PRODUCTION AND THE INDUSTRY
4.0
 Advanced Manufacturing Systems
 Sensors
- Traceability
- Predictability

 3D Printing
- Scrap Elimination
- Customization

 Cloud Computing
- Big Data
Robotics
Source: ECPE European Center for Power Electronics - Autonomy - Cyber Security
e.V., Nuremberg, Germany - Productivity
THREE CLUSTERS MERGING IN
CYBER- PHYSICAL SYSTEMS DRIVEN
BY AI AND ROBOTS:
• Physical, Digital (techno sphere),
• Biological (natural world)

Physical:
• Autonomous technology from DARPA, Google,
Tesla, Toyota, 3D printing, Advanced Robotics, New
Materials such as polymers, nanomaterials like
quantum, new batteries and dot tech

Biological: Digital:
• Genetic analysis. Mobile,Smart sensors, devices:
• Synthetic human genome cell line. heterogeneous Smart network,
• CRISPR for designer plants, animals, Stochastic computing Arduino,
humans, embryo experimentation Augmented reality
network,
and virtual
• DARPA example: brain Brain reality.
implants, Mind control of objects, EU
interfaces,
Brain project, US Brain initiative
 WHAT ARE THE BENEFITS OF
MOVING ON TO INDUSTRY 4.0?
Moving to Industry 4.0 include improved
• Increase flexibility
productivity and efficiency, better
• Productivity
flexibility and agility, and increased
• Efficiency
profitability. Industry 4.0 also improves
• Quality
the
• Reduced time to market
customer experience.
• More R&D and activities
This includes technologies that improve
• Development of new skills
automation, machine-to-machine
communication, manufacturing oversite,
and decision making.
Benefits

Shorter Work with

Parallel Time existing Fail Fast Low
Frames infrastructure & Learn cost
 INTERNET OF THINGS IoT

Internet of Things, integrated into the manufacturing, processing and

logistics The IoT is a term coined by Kevin Ashton back in 1999 and the
term quickly gained popularity as a way to refer to physical devices that are
able to connect and exchange data.
IoT will consist of about 30 billion objects by 2020” and that “the
global market value of IoT will reach $7.1 trillion” by the same year.
INTERNET OF EVERYTHIN IoE
IoE is the network of devices, vehicles, and home appliances that contain electronics,
software, actuators, and connectivity which allows these things to connect, interact
and exchange data. IoE is considered a superset of IoT. Cisco, first coined the term
the Internet of Everything, process , people, data, and things together to make
networked connections more relevant and valuable.
CYBER SECURITY AND
CYBER ATTACKS
Cyber attacks can exploit vulnerabilitiesof
the
infrastructures such as the energy, critical
and communications sectors and
transportation undermine military
seriously mission success,

Cyber attacks on government agencies, defense and

high tech companies, or economic crimes with
losses of more than a million dollars.
Cyber security is a discipline that
requires national effort, and it is not
something that the citizens and private
companies can expect to outsource to the
military.

CYBERCRIME IN NUMBERS: 3.9 Million cyber crimes reported in 12 months (2016)

 INNOVATIVE ICT MAKES THE DIFFERENCE

Laser-based manufacturing Cyber-physical systems for

process (chain) optimisation

Robotics Modelling, Simulation, Analytics

5/16
 BEING DEVELOPED OR NEW ON
THE MARKET
Artificial intelligence
Robotics

Virtual reality
3D printing
Self
driving
cars

Google Smart hand watch

 EXPECTATIONS FOR INDUSTRY 4.0
BY REGION ROBOTS WORKING IN
AMAZON
Robotics
45000

40000
35000

30000
25000

20000
15000

10000
5000
0
Global Communications, PwC United
2 2014 2015 2016
 THE IMPACT OF THE FOURTH INDUSTRIAL
REVOLUTION CROSS- COUNTRY
Country/Region Continent Start Year End Year Duration

United States (US) North America 2011 N/A N/A

Germany Europe 2012 2020 9
France Europe 2013 2020 8
United Kingdom (UK) Europe 2013 2050 38
Europe Europe 2014 2020 7
South Korea Asia 2014 2020 7
India Asia 2014 N/A N/A
Netherlands Europe 2014 N/A N/A
Sweden Europe 2015 2020 6
China Asia 2016 2025 10
Spain Europe 2015 N/A N/A
Malaysia Asia 2016 2020 5
Taiwan Asia 2016 2024 9
Japan Asia 2016 2020 5
Mexico North America 2016 2030 15
Canada North America 2016 2030 15
Singapore Asia 2016 2020 5
Italy Europe 2017 2020 4

Pontifícia Universidade Católica do Paraná, Curitiba, PR, Brazil,

2018
 ARTIFICIAL INTELLIGENCE AS THE
FUTURE OF ECONOMIC GROWTH

The top five countries for industrial robotics by sales and

Thank you