ME6703

COMPUTER INTEGRATED
MANUFACTURING
SYSTEMS
Unit - I
Introduction
Prepared by:
K. Chellamuthu. M.E.,
AP / Department of Mechanical Engineering,
K. Ramakrishnan College of Engineering.
 Syllabus
Brief introduction to CAD and CAM -
Manufacturing Planning, Manufacturing
Control - Introduction to CAD/CAM -
Concurrent Engineering - CIM concepts -
Computerized elements of CIM system -
Types of Production - Manufacturing
models and Metrics - Mathematical models
of Production Performance - Simple
problems - Manufacturing Control - Simple
Problems - Basic Elements of an Automated
System - Levels of Automation - Lean
 CAD - Definition

CAD - Computer Aided Design

“ The design activity that involves the

effective use of computer technology to
create, modify, analyze and document
an engineering design ”
 Introduction - CAD
•Earlier designs were made manually.
•Designing, editing and finally arriving at a
complete design was so time consuming.
•If the design fails during prototyping or 1st
run / pre-production / trial run, the designer
has to start from scratch.
•Analyses were done only when the prototype
is completed.
•Time and cost of designing were really very
high.
 Why CAD?
I t not only makes the operations

Faster, Better & Easier

to control, but the operations were more

Accurate, Precise & Efficient

in terms of

Time, Cost & Quality.

 ROLE OF COMPUTERS IN A
MANUFACTURING ORGANISATION
P
R Enterprise
Manufacturing Support
O Level MI
System
D S
U
Quality Control
C
System
T
Factory F
I
Level Manufacturing A
O
System C
N
I
L
S Automation & Control Material Handling I
Y Technologies Technologies T
S I
T E
E Manufacturing Processes and Assembly Operations S
M
 Drawbacks - Manual Design
•Earlier designs were made manually.
•Designing, editing and finally arriving at a
complete design was so time consuming.
•If the design fails during prototyping or 1st run /
pre-production / trial run, the designer has to start
from scratch.
•Analysis were done only when the prototype is
completed.
•Time and cost of designing were really very high.
 CAD - Features
• Geometric Modeling features - Easy design
using basic entities
• Editing or Manipulation features - Easy
transformations of basic entities
• Display Control features - Various views,
Animation, etc.
• Drafting features - Use of various drawing tools
• Programming facilities - Using of programs to
draw, present, animate, etc.
• Analysis features - Optimization/ dynamic
testing
• Connecting features - Networking & Portability
 CAD - Applications
Increased Design
Productivity

Increased Availability of Geometric Forms in Design

Improved Quality of
the Design
Improved Design
Documentation
Creation of a Manufacturing
Data Base
Design
Standardization
 CAD - Design Process
Recognition of Need

Problem Definition
CAD
Synthesis Geometric Modelling

Analysis & Optimization Engineering Analysis

Design Review &

Evaluation Evaluation

Presentation Automated Drafting

 CAM - Definition

CAM - Computer Aided Manufacturing

“ The manufacturing activity that
involves the effective use of
computer technology to fabricate, mass
produce, control quality and create
manufacturing data base”
CAM - Components

CAM - Computer Aided

Manufacturing
The main elements are:

Manufacturing Planning
&
Manufacturing Control
 Manufacturing / Production
Planning
Manufacturing Planning
Computer technology can be incorporated in
the planning for the manufacturing in the
following forms.

• Computer Aided Process Planning

• Computer Assisted NC Part Programming
• Computerized Machinability Data System
•Development of Work Standards
• Cost Estimation
• Production & Inventory Planning
• Computer Aided Line Balancing
 Manufacturing / Production
Planning
Computer Aided Process Planning
Process plan is a detailed worksheet of the
conversion of raw material into FG.
Computer helps to design the process in
easier selection of processes from the related
database than manual planning.
 Manufacturing / Production
Planning
Computer Assisted NC Part
Programming

NC and CNC machines can be

incorporated for accurate mass pro ad the
programming can be computerized.
 Manufacturing / Production
Planning
Computerized Machinability Data System
Computerized manufacturing database
helps in easy selection of process and the
parameters.
Development of Work Standards
Digitized process planning and database
helps in creation of working instructions
 Manufacturing / Production
Planning
Cost Estimation
This program estimates the overall fabrication
cost o the product easily.
Production & Inventory Planning
Computerized materials stocks & production
quantity management portrays the current and
correct status of the inventory in the warehouse
and the production floor aiding in better planning .
 Manufacturing / Production
Planning

Computer Aided Line Balancing

It helps in assigning equal workloads to
all work stations for a smooth production
flow without blockages.
 Manufacturing / Production
Control
Manufacturing Control
Computer technology can be
incorporated in the control for the
manufacturing in the following forms.
• Process Monitoring & Control
• Quality Control
• Shop Floor Control
• Inventory Control
• Just In Time (JIT) Production
Systems
 Manufacturing / Production
Control
Process Monitoring & Control
Monitors the process in real time and
corrections are made then and there.

Quality Control
To maintain the quality of the product
at the highest possibility.
 Manufacturing Control
Shop Floor Control (SFC)
The control of the actual production
flow though computer technology.
Inventory Control
The control of the purchase, storage
and issue of raw materials, components,
tools, etc. and also handling of the WIP,
 Manufacturing Control

JIT Production Systems

The Japanese concept of maintaining
Zero wastages and holding nil stock to
improve the productive efficiency.
 Introduction to CAD/CAM
Automation of manufacturing support
system is aimed at reducing the amount f
manual and clerical effort in product,
manufacturing planning and control and
the related business functions.
CAD/CAM denotes the integration to
the individual CAD and CAM systems
 Concurrent Engineering

Product Prototype Performanc Mass Quality Marketin

Design Making e Testing Productio Control g & Sales
n

Traditional Engineering

Marketin Performanc
g & Sales e Testing

Product Mass
Design Productio
n
Prototype Quality
Making Control

Concurrent Engineering
 CIM
Computer Integrated Manufacturing is the
process of integration and control of all the
departments’ functions in an organization
using a centralized computer.

CIM = CAD + CAM + Other Business

Functions
 EVOLUTION of CIM
Computer Integrated Manufacturing (CIM) is considered a
natural evolution of the technology of CAD/CAM which
by itself evolved by the integration of CAD and CAM.
Massachusetts Institute of Technology (MIT, USA) is
credited with pioneering the development in both CAD
and CAM.
The need to meet the design and manufacturing
requirements of aerospace industries after the Second
World War necessitated the development of these
technologies to develop sophisticated aircraft and
satellite launch vehicles.
This prompted the US Air Force to approach MIT to
develop suitable control systems, drives and
 OBJECTIVE OF CIM
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
 OBJECTIVE OF CIM
• Increase flexibility in manufacturing to
achieve immediate and rapid response to:
• Product changes
• Production changes
• Process change
• Equipment change
• Change of personnel
CIM technology is an enabling technology to
meet the above challenges to the
manufacturing.
CIM WHEEL
 Concept of CIM

The concept is that all of the firm’s

operation related to production are
incorporated in an integrated computer
system to assist, augment and automate
the operations.
Scope of CIM
CIM ELEMENTS
9 MAJOR ELEMENTS OF
CIM
Mktg
Produc
Info . t
Mgmt. Design
Finan Plannin
ce g

Logisti
cs &
CIM Purchas
e
SCM
Ware Mfg.
housing Process Engg.
Automatio
n
 Production Types

Continuous and Batch Production

1. Job Shop
2. Batch Production
3. Mass Production
4. Continuous Production
 MANUFACTURING MODELS
Mathematical Models of Production
Performance

• Production Rate
• Production Capacity
• Utilization & Availability
• Manufacturing Lead Time
• Work in Progress
 MATHEMATICAL MODELS
Production Rate
Work units completed per hour or the time taken
for completion of a unit.
This cycle time includes: Tc = To + Th + Tth
i) actual processing / operation time (To)
ii) work handling time (Tt)
iii) tool handling time (Tth)
For batch production: Tb = Tsu + Q*Tc
i) batch setup time (Tb)
ii) quantity per batch(Q)
iii) cycle time for the individual parts (Tc)
 MATHEMATICAL MODELS
Production Rate
For Mass Prouction:
Tc = Tr + max. To
(Rp Rc = 60 / Tc)
i) transfer time between stations (Tr)
ii) operation time of individual station (T o)
iii) cycle time for the individual parts (T c)
 MATHEMATICAL MODELS
Production Capacity
The max. rate of output a production facility
(or production line, work center or group of
work centers) is able to produce under a given set
of assumed operating conditions in terms of
shifts, days, weeks, months or year.
PC = n . S . Hs . Rp
n = no. of machines / work centers
S = No. of shifts per day/week/month
Hs= No. of hours per shift
& Rp= Rate of production (units/hour)
 MATHEMATICAL MODELS
Utilization & Availability
Utilization is the measure of output of a
production facility to its capacity.
Utilization, U = Q / PC
Availability is the measure of reliability of the
machine.
Availability, A = (MTBF – MTTR)/ MTBF
where MTBF – Mean Time Between Failure/
Breakdowns
& MTTR – Mean Time To Repair
Quantity Produced, Q = A . U . PC
 MATHEMATICAL MODELS
Problem
A production machine operates 80 Hrs/week
(2 shifts & 5 days) @ full capacity. Its
production rate is 20 Units/hr. during
a certain week, the machine produced 1000
parts and was idle the remaining time.
a. Determine the production capacity of the
machine
b. What was the utilization rate of the
machine during the week under consideration?
Solution MATHEMATICAL MODELS
a. Production Capacity, PC
= No. of Operating hours X Production rate
= 80 hrs/wk X 20 units/wk
= 1600 units/wk
b. Utilization, U = Q / PC
= 1000 / 1600
= 0.625 = 62.5 %
or b. Hours req. to produce 1000 units, H =
1000 / Pr = 1000 / 20 = 50 hrs.
U = Hours used / Max capacity
= 50 / 80 = 62.5 %
 MATHEMATICAL MODELS
Problem
Consider the same problem, but if the
availability of the machines is 90 % ad the
utilization of the machines is 80%, compute the
expected plant output.
Solution
Quantity or Output , Q = A . U . PC
= 0.90 x 0.80 x 1600
= 1152 units/week
 MATHEMATICAL MODELS
Manufacturing Lead Time
MLT is defined as the total time required to
process a given part or product through the
plant facilities including all lost time due to
delays, storage/retrieval, reliability, repairs,
etc.

MLT =  (Ts + To + Tno)

 MATHEMATICAL MODELS
Problem
A certain part is produced in a batch size of
of 100 units. The batch must be routed through
five operations to complete the processing of
the parts. Average setup time 3 hrs./operation
and average operation time is 6 mins. Average
non-operation time due to handling, delays,
inspection, etc. is 7 hrs. for each operation.
Determine how many days it will take to
complete the batch, assuming the plant runs
one 8 hr – shift /day.
 MATHEMATICAL MODELS

Solution
MLT =  (Ts + To + Tno)
= 5 (3 + 100 X (6/60) + 7)
= 100 hrs
= 100/8
= 12.5 days
 MATHEMATICAL MODELS
Work-in-Progress
WIP is the quantity of parts currently located
in the factory that are either are being
processed (semi finished goods).
It is a company’s investment but yet to be
converted into revenue.

WIP =A.U.(PC).(MLT) / (SW . HSH)

 MATHEMATICAL MODELS
Fixed & Variable Costs
TC =FC + (VC . Q)
TC – Total cost of the product / part
FC – Fixed Cost which remains constant
irrespective of any level (quantity) of
production. E.g. Facility, Equipment, Insurance,
Lighting, etc.
VC – Variable Cost is one that varies with the
level of production. E.g., Raw material, Direct
Labour, Consumables, etc.
 MATHEMATICAL MODELS
Break Even os t
al C
Point Tot
Manufacturing Cost

o s t
i ab le C
Va r

Fixed
Cost

No. of Units
Produced
 MATHEMATICAL MODELS
Direct Labour, Material & Overhead
Direct Labour Cost
The sum of wages/benefits paid to the workers
who operate the equipment and perform the
processing /assembly tasks.

Material Cost
The cost of all raw materials/consumables used
to fabricate the product.
 MATHEMATICAL MODELS
Direct Labour, Material & Overhead

Overhead Cost
All the other expenses associated with running
the manufacturing firm.

i) Factory Overhead &

ii) Corporate Overhead
 MATHEMATICAL MODELS
Factory Overhead Expenses
Factory
Plant Supervision Applicable Taxes
Depreciation
Equipment
Line Foreman Insurance
Depreciation
Heat / Air
Maintenance Crew Fringe Benefits
Conditioning
Custodial Services Lighting Material Handling
Powder for Shipping &
Security Personnel
Machinery Receiving
Tool Crib
Payroll Services Clerical Support
Attendant
 MATHEMATICAL MODELS
Corporate Overhead Expenses

Corporate
Engineering Applicable Taxes
Executives

Sales & Research &

Office Space
Marketing Development
Accounting Other Support
Security Personnel
Department Personnel
Finance Heat & Air
Insurance
Department Conditioning

Legal Counsel Fringe Benefits Lighting

 MATHEMATICAL MODELS
Factory Overhead Rate

FOHR = FOHC / DLC

Corporate Overhead Rate

COHR = COHC / DLC

where DLC is Annual Direct Labour Cost

 MATHEMATICAL MODELS
Cost of Equipment Usage
Normally cost of labour is divided into two
components
i) Cost of Worker & ii) Cost of Equipment
Moreover the cost of operation will vary according the
usage rate as old machines need more maintenance and
work slower than newer or new technology.
Also care should be taken while deriving at this
overhead as it may be:
Single Worker / Single Machine or Single Worker
Multiple Machines or Multiple Worker Multiple
Machine or Multiple Worker On Multiple Machines.
 AUTOMATION
Automation is defined as the technology
by which a process or procedure is
accomplished without human assistance.
It is implemented by using a program of
instructions combined with a control system
that executes the system.
 Why Automation is Preferred?
• To increase the productivity
• To reduce labour cost
• To mitigate the effects of labour shortages
• To reduce or eliminate routine manual / clerical
tasks
• To improve worker safety
• To improve product quality
• To reduce manufacturing lead time
• To accomplish processes that cannot be done
manually
• To avoid high cost of non-automation
10 Strategies for Automation
& Process Improvement
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 & Optimization
9. Plant Operations Control
10. Computer Integrated Manufacturing (CIM)
 Basic Automated System
P Enterprise Level
r M
o Manufacturing Support Systems I
d S
u
Quality Control Systems
C Factory Level F
t a
I Manufacturing Systems c
o I
n
l
S Automation & Control Material Handling
y Technologies Technologies
I
S T
t I
e Manufacturing Processes & Assembly Operations E
m s
 Elements of Automated System

Power

Program of
Control
Instruction Process
System
s
Elements of Automated System

Power to an automated system may be in

any of the following forms viz., Thermal,
Electrical, Mechanical, Optical, etc.

Control System consists of Controller,

Actuator, Feedback/Forward Sensors, etc.
 Levels of Automation
Level Description Example
Corporate Information
5 Enterprise Level
System (MIS)

4 Plant Level Production System

3 Cell / System Level Manufacturing System

2 Machine Level Individual Machines

Sensors, Actuators &

1 Device Level
H/Ws
 Levels of Automation
Level 1 – Device Level
• The lowest level of automation
• Consists of sensors, actuators, other H/W
components comprised of the machines.
Level 2 – Machine Level
• Device levels are assembled into individual
machines.
Level 3 – Cell / System Level
• Consists of group of automated machines in
a cluster
• This work centres may include automated
material handling equipments also.
 Levels of Automation
Level 4 – Plant Level
• It is the manufacturing or shop floor control.
• This receives the instructions from the
corporate level and executes them.

Level 5 – Enterprise Level

• It is the highest level of automation.
• Concerned with all necessary functions of
the organization including marketing, sales,
accounting, design, research, aggregate and
master production planning.
 Lean Production
Lean manufacturing means operating the factory
with minimum resources, yet maximizing the
work introduced by Toyota Motor Company,
Japan in 1980s.
It aims at achieving highest quality with least
resources or man, material, machines, time,
cost, etc.
So it literally aims at eliminating non-value added
activities and achieving high efficiency
effectively.
The activities can be categorized as:
Value Added, Auxiliary and Wasteful
 Principles of Lean Production
Lean production is based on four principles
1. Minimize Waste
2. Perfect First Time Quality
3. Flexible Production Lines
4. Continuous Improvement
 Concept of Lean Production
Lean production is based on the following concept
1. Value Creation And Waste Reduction
2. Pull Production
3. Continuous Flow
4. Continuous Improvement
5. Worker Improvement
6. Standardization of Work
 Lean vs. Mass Production
S. No. Characteristics Mass Production Lean Production

01. Buffers Available Min. waste

02. Delivery Just-in-Case Just-in-Time

03. Inventory Just-in-Case Minimum

Acceptable Quality Perfect First Time

04. Quality
Level (AQL) Quality
Taylorism (To do
05. Working Methodology Worker Teams
as instructed)
Worker
06. Production Max. Efficiency
Involvement
Flexible
Inflexible
07. Flexibility Production
Production System
System

08. Improvement Corrective Continuous

 Lean Production Techniques

• Just in Time Delivery of parts

• Worker Involvement
• Continuous Improvement
• Reduced Setup times
• Stopping the process when something goes
wrong
• Error prevention
• Total Productive Maintenance
Lean Production - Structure
Customer
Focus
JIT Automatio
Production n

Elimination of Waste
 Lean Production - Elements
Just in Time Delivery of Parts

• Pull system of production

• Control using Kanbans
• Setup time reduction for smaller batches
• Production levelling
• On-time deliveries
• Zero defects
• Flexible workforce
 Lean Production - Elements
Worker Involvement

• Continuous Improvement (Kaizen)

• Quality Circles
• Visual Management
• 5S System
• Standardized Work Procedures
• Participation in Total Productive Maintenance
(TPM) by workers
 Lean Production - Elements
Automation

• Stopping the process if error/defect occurs

• Prevention of Over-production
• Error prevention
• Mistake Proofing
• TPM for reliable equipment
 Lean Production - Muda
Taiichi Ohno, then Vice President of Toyota
Motor Company, classified activities in a
factory as below.
Value Added
Actual Works
to the Product

Manufacturi Supports
Auxiliary Works
ng Activities Actual Work

Wastes
Muda
(No value added)

Muda means activities that are neither value

adding nor supporting the value adding
Lean Production – 7 Muda (Wastes)

1. Production of defective parts

2. Over production
3. Excessive inventories
4. Unnecessary processing steps
5. Unnecessary movement of people
6. Unnecessary handling of materials
7. Idle workers/machines, etc.
 JIT
Aims to minimize inventory especially WIPs.
It is, again, a Japanese concept from Toyota and
now been adopted worldwide.
JIT can be applied through:
• `Pull system of production
• Control using Kanbans
• Setup time reduction for smaller batches
• Production levelling
• On-time deliveries
• Zero defects
• Flexible workforce
 JIT
So, JIT is simply described as the manufacturing
which produces only the required quantity of
input the next work station or process needs
just before the commencement of the next
process.
i.e., Starting the production only upon receipt of
order rather than mass producing and stocking
for later demands.
 JIT
Aims @
• Zero Wastages
• Continuous Improvement
• Demand driven production

The 6 – 0s & 1 – 1of JIT is:

Zeroes One
1. Zero Mistakes Batch / Lot Size
2. Zero Inventory of 1
3. Zero Setup Time
4. Zero Breakdown
5. Zero Handling
6. Zero Non-productive Time
Thank
You!