MM Unit 4

Computer Integrated Manufacturing
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CIM
DATABASE
MANUFACTURING TYPES
MATERIAL HANDLING
FMS
MANUFACTURING STRATERGY
INDUSTRY 4.0
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Computer Integrated Manufacturing
Definitions of CIM
CIM – The linking of CAD and CAM.
CIM – Methodology involving a consistent system based approach to

running a manufacturing business, partly as the integration of information
and the integration of business and manufacturing activities.
CIM concept starts with integration of various aspects of production

(design, planning, manufacturing, warehousing, material handling and
quality control, sales, marketing and financial management).
CIM is thus essentially a means of organising and controlling the

manufacture of components and assemblies as logically and flexibly as
possible and of mastering and coordinating the corresponding flow of
data and information.
CIM aims at optimizing the use of equipment, decreasing lead time and
stocks and ensuring high product quality and low unit costs.
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 CIM encompasses the entire range of product development and
manufacturing activities with all the functions being carried out with the
help of dedicated software packages.
 The data required for various functions are passed from one
application software to another in a seamless manner.
 For example, the product data is created during design has to be

transferred from the modeling software to manufacturing software
without any loss of data.
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Challenges before the Manufacturing Engineers
CIM has several software tools to address the above needs

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Integrated Manufacturing
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Objectives of CIM
 Develop the quality product at a competitive price.
 Integrate and control the design and manufacturing processes.
 Manage all the finances in the system.
 Increase sales by controlling product demand.
 To strengthen the relationship between the supplier and the

customer.
 Plan production and deliveries more efficiently
 Shorter delivery time.
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Architecture of CIM
 The architecture of CIM provides the structure of computer hardware

and software with appropriate interfaces for computer system in
manufacturing system to integrate information and business process.
 Communication is the critical aspect of the CIM architecture to integrate.
 In CIM environment, local area network (LAN) is needed on the shop

floor for data communication.
 The CIM system becomes highly reliable and flexible with the use of
LAN.
 The major way of connecting the CIM system together is to use the
international standards given by ISO.
 The architecture of the CIM provides a consistent base to enterprise’s

product, processes, and business data.
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Architecture of CIM
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CIM HARDWARE AND CIM SOFTWARE
CIM Hardware
Manufacturing equipments
 CNC machines or computerized work centres.
 Robotic work cells.
 DNC/FMS systems.
 Work handling and tool handling devices.
 Storage devices.
 Sensors.
 Shop floor data collection devices.
 Inspection machines.
Computers and controllers

 CAD/CAM systems,
 Workstations / terminals,
 Data entry terminals, bar code readers, RFID tags,
 Printers, plotters and other peripheral devices,
 Modems, cables, connectors etc.,
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CIM software comprises computer programmes 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
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MAJOR ELEMENTS OF CIM SYSTEM
Nine major elements of a CIM system are
1. Marketing
2. Product Design
3. Planning
4. Purchase
5. Manufacturing Engineering
6. Factory Automation Hardware
7. Warehousing
8. Finance
9. Information Management
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1. Marketing:
 The need for a product is identified by the marketing division.
 The specifications of the product, the projection of manufacturing

quantities and the strategy for marketing the product are also decided by the
marketing department.
 Marketing also works out the manufacturing costs to assess the economic
viability of the product.
2. Product Design:
 The design department of the company establishes the initial database for
production of a proposed product.
 It is accomplished through geometric modeling and computer aided design

while considering the product requirements and concepts generated by the
creativity of the design engineer.
 Complex designs are usually carried out by several teams working

simultaneously, located often in different parts of the world.
 The design process creates the database required to manufacture the part. 13
3. Planning:
 The planning department takes the database established by the

design department and enriches it with production data and
information to produce a plan for the production of the product.
 Planning involves several subsystems dealing with materials, facility,

process, tools, manpower, capacity, scheduling, outsourcing,
assembly, inspection, logistics etc.
 In a CIM system, this planning process should be constrained by the

production costs and by the production equipment and process
capability, in order to generate an optimized plan.
4. Purchase:
 The purchase departments is responsible for placing the purchase

orders and follow up, ensure quality in the production process of the
vendor, receive the items, arrange for inspection and supply the
items to the stores. 14
5. Manufacturing Engineering:
 Manufacturing Engineering is the activity of carrying out the production

of the product, involving further enrichment of the database with
performance data and information about the production equipment and
processes.
 In CIM, this requires activities like CNC programming, simulation and

computer aided scheduling of the production activity.
 It includes online dynamic scheduling and control based on the real time
performance of the equipment and processes to assure continuous
production activity.
 Often, the need to meet fluctuating market demand requires the

manufacturing system flexible and agile.
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6. Factory Automation Hardware:
Factory automation equipment further enriches the database with

equipment and process data, resident either in the operator or the
equipment to carry out the production process.
 It consists of computer controlled process machinery such as CNC

machine tools, FMS, Computer controlled robots, material handling
systems, computer controlled assembly systems, flexibly automated
inspection systems.
7. Warehousing:
 Warehousing is the function involving storage and retrieval of raw

materials, components, finished goods as well as shipment of items.
 In today’s complex outsourcing scenario and the need for just-in-time

supply of components and subsystems, logistics and supply chain
management assume great importance.
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8. Finance:
 Finance deals with the resources pertaining to money.
 Planning of investment, working capital, and cash flow control,

realization of receipts, accounting and allocation of funds are the major
tasks of the finance departments.
9. Information Management:
 Information Management is perhaps one of the crucial tasks in CIM.
 This involves master production scheduling, database management,

communication, manufacturing systems integration and management
information systems.
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Levels of Integration Against Evolution of CIM
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Costs Associated with CIM Implementation
Initial costs
 Application engineering
 Equipment procurement
 Site preparation
 Actual installation
 Operation costs.
Other costs
 Machine tools, Robots, Material handling systems,
 Computer hardware and software, interface accessories,
 Terminals, spare parts and special tools.
 Training programs for CIM system operators.
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Benefits of CIM
 Quick release of new products.
 Shorter delivery time.
 More realistic inventories.
 Shorter production time.
 Reduced lead times.
 Improved product quality.
 Increases responsiveness and competitiveness.
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Application areas of CIM
 Marketing : Customer need data base through CIM.
 Engineering Design: Speed of designing product is faster due to

enormous database.
 Research and Development: CIM adapt quickly to market changes and

provide guidelines to future product development.
 Manufacturing Operations: The resources and information available

through CIM allows more realistic scheduling of manufacturing
operations, resulting in shorter production times.
 Finance Planning: The CIM offers better product cost tracking, more
accurate financial projections and improved cash flow for business
management activities and developing enterprise directives and financial
plans.
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CIM DATA BASE
In a CIM environment the total integration of operations is achieved by a
common database linking various designs, manufacturing and other related
activities.
The information required for manufacturing is complex covering a wide range of

disciplines
i. Product Data: Data about parts to be manufactured. It includes text and

geometry data.
ii. Manufacturing Data: The information as to how the parts are to be

manufactured is available in production data.
iii. Operational Data: Closely related to manufacturing data but describes the
things specific to production, such as lot size, schedule, assembly sequence,
qualification scheme etc.
iv. Resource Data: This is closely related to operational data but describes the
resources involved in operations, such as materials, machines, human
resources and money. 22
CIM Data Base
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DATABASE REQUIREMENTS OF CIM
A major challenge facing the implementation of CIM is to establish the type of
data needed to bridge the mechanical design and manufacturing functions.
1. Designing assemblies and performing tolerance analysis.
2. Preparing production drawings of assemblies, individual parts, tooling.
3. Creating analytical models of parts for structural, kinematical and thermal

analysis (FEM etc).
4. Calculating weights, volumes, centres of gravity and other mass properties

and costs of manufacturing (cost estimation).
5. Classifying existing parts according to shape, function, and the process

(Group technology and coding).
6. Preparing part lists and bill of materials (BOM).
7. Preparing process plans for individual part manufacture and assembly

(Variant or Generative).
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8. Programming CNC machines for processing complete parts (CAM).
9. Designing work cells and programming the movement of components

in those cells using work handling devices like robots, conveyors,
AGV’s/ RGV’s, etc. (Cellular manufacture).
10. Controlling engineering changes and maintaining associatively

between design manufacturing (PDM, concurrent associatively etc).
11. Preparing programs to handle components or manipulate production

equipment (like welding torches or robots).
12. Preparing inspection programs including programs for CNC co-

ordinate measuring machines [CNC CMM’s].
13. The exchange of graphic information has been advanced with

increasing acceptance of Initial Graphics Exchange Specification
(IGES).
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OBJECTIVES OF DATABASE
Reduce or eliminate redundant data.
 Integrate existing data.
Provide security.
Share data among users.
Incorporate changes quickly and effectively.
Exercise effective control over data.
Simplify the method of using data.
Reduce the cost of storage and retrieval of data.
Improve accuracy and integrity of data.
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ISSUES OF CONCERN IN DATABASE
Some issues to be considered while implementing a database.
• High investment in hardware and software.
• Need to use larger and faster hardware.
• Necessity to have highly trained manpower.
• Crash of the database server.
• Need to ensure integrity and reliability of data.
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DATABASE MANAGEMENT
It consists of a collection of interrelated data and a set of programs to access
that data.
Database management involves:
• Organize a database.
• Add new data to the database.
• Sort the data in some meaningful order.
• Search the database for types of information.
• Print the data into formatted reports.
• Edit the data.
• Delete the data. 28

DATABASE ADMINISTRATOR
The person responsible for managing the database is often referred to as

database administrator.
His functions includes:
• Creating the primary database structure.
• Backing up and restoring data in case of crash.
• Modifying the structure.
• Transfer data to external files.
• Allocate and control user access rights.
• Monitoring performance.
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Problems of traditional file systems that can be overcome by DBMS
i. Data dependence.
ii. Rigidity.
iii. Static nature.
iv. Lack of integration.
v. Data duplication.
vi. Inconsistency.
vii. Difficulty in sharing information.
viii. Inefficiency.
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DATABASE MODELS
There are three ways in which data can be organized:
 Hierarchical
 Network
 Relational
HIERARCHICAL DATABASE
 The nodes in level 2 are the children

of node at level 1.
 The nodes at level 2 in turn become

parents of nodes in level 3 and so on.
A Typical Hierarchical File Structure

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 In a hierarchical model, data files are arranged in a tree like structure which
facilitates searches along branch lines; records are subordinated to other
records at a higher level.
 Starting at the root of the tree, each file has a one-to-many relationship to its
branches.
 A parent file can have several children. A good example of such an
organization might be a parts list, in which each product is composed of
assemblies which are in turn composed of sub assemblies and/or component
parts.
 Examples of hierarchical database management systems are IMS and
SYSTEM 2000.
Parts of a Lathe Assembly
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NETWORK DATABASE
 The network database is a combination of several hierarchies in which
child files can have more than one parent file, thereby establishing a
many-to- many relationship among data.
 Examples of network database languages are TOTAL and IDMS.
 Access to data is processed by associated application programs.
 A limitation of both hierarchical and network systems is the restriction they

place on data access.
 They both require that the rules of data access be defined when the data
structure is defined.
 The access rules are difficult to modify after the database has been
implemented.
 They are suited for batch operations that are highly structured and repetitive
involving high transaction rates.
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RELATIONAL DATABASE MANAGEMENT SYSTEMS (RDBMS)
 Data is organized in the form of a table for a large variety of manufacturing
applications.
 There is a correspondence between the concept of a table and the mathematical

concept of a relation.
 In a RDBMS (Relational Database Management System) an entity is an object

that is distinguishable from other objects.
 An entity set is a set of entities of the same type and is represented by a set of
attributes.
 For each attribute there is a set of permitted values for domains. An entity
relationship model (E-R Model) is based on the perception of the real world
which consists of a set of entities and relationships among them.
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 The relational database eliminates the need to follow predefined access
paths to reach target data, and makes data access more flexible.
 The database user gains quicker access to information since the

database provides direct access to all data.
 The access is independent of the way it is stored.
 The RDBMS is also flexible.
 Hence relational database facilitates unanticipated queries and makes it

well suited to the manufacturing environment.
 Several vendors now offer RDBMS, suitable for CIM applications.
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Features of RDBMS include:
 Unanticipated queries. This is typical in a manufacturing environment.
 Relational database is dynamic.
 The relationships change and are extended frequently in a manufacturing

database.
 Suitable where, enterprise information has to be available to a large

number of users for decision making.
 Desirable where application specifications, development and maintenance

costs are to be kept at the minimum level.
 Compatible with distributed databases.
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Rules for Relational Databases
In order for a relational database to function, a number of basic
rules need to be followed:
 Each table has a unique name.
 Each table contains multiple rows.
 Each row in a table is unique.
 Every table has a key to uniquely identify the rows.
 Each column in a table has a unique attribute name.
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Some of the important features of RDBMS are given below:
i. Guaranteed logical accessibility.
ii. Dynamic on-line catalogue.
iii. Comprehensive data sublanguage.
iv. Views that could be modified depending on need.
v. High-level insert updates and delete.
vi. Physical data independence.
vii. Logical data independence.
viii.Integrity independence.
ix. Distribution independence.

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Manufacturing Systems
 A manufacturing system can be defined as a combination of people,

machinery and equipment which is constrained by material and
information flow.
 Manufacturing systems can be classified into

 Discrete part manufacturing –
Product undergoes a finite number of production or assembly
operations.
 Continuous process manufacturing –
Product undergoes continuous changes such as chemical
reactions which transform raw materials into final products.
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Types of Manufacturing Systems
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 Transfer line :
 Oldest type of manufacturing systems. Efficient for mass
production (large volumes at high output rate).
 Suitable for manufacturing identical parts.
 They are inflexible and cannot tolerate variations in part
design.
 Any change in part design requires the line to shutdown
and be retooled.
 Special Manufacturing System:

 This system is suitable to produce a very limited number of
different parts and a medium production rate per part.
 Only limited changes in the system are possible.
 Flexible Manufacturing System:

 A mid volume and mid variety production range is covered.
 Most of the system activities and coordination are done
automatically under computer control.
 Work parts are automatically loaded at central locations on to the
handling system and are routed to the proper machine tools. 41
 Manufacturing cell :
 This is the most flexible CIM system.
 Lowest production rate.
 It contains many stand-alone machine tools and robots.
Stand-alone and NC machines:

Highly flexible.
Production rates are too slow due to tool setting up time and
tool
changes.
Highly programmable and can deal with product changeovers
and
part design changes.
Appropriate for job shop and small batch manufacturing.
Flexibility and automation are desired characteristics of

manufacturing
systems.
These systems must be carefully designed to handle the expected
production volume. 42
Manufacturing systems classification scheme is defined by four factors:
(1) Type of processing or assembly operations performed

(2) Number of stations and layout
(3) Automation level
(4) Flexibility to deal with part or product variety
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1. Types of Operations Performed
(i) Processing operations on individual work units
(ii) Assembly operations to combine individual parts into assembled entities.
Additional parameters of the product that play a role in determining the

design of the manufacturing system include:
Type of material processed
Size and weight of the part or product
Part geometry
For example: Machined parts can be classified according to part geometry as

rotational or non-rotational.
Rotational parts arc cylindrical or disk-shaped and require turning and related
rotational operations.
Non rotational (also called prismatic) parts are rectangular or cube-like and
require milling and related machining operations to shape them.
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2. Number of Workstations and System layout
 It exerts a strong influence on the performance of the manufacturing

system in terms of production capacity, productivity, cost per unit, and
maintainability.
 Let us denote the number of workstations in the system by the symbol n.
 The number of workstations in the manufacturing system is a convenient

measure of its size.
 As the number of stations is increased, the amount of work that can be

accomplished by the system increases.
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Type I Single station
This is the simplest case, consisting of one workstation (n=1), usually

including a production machine that can be manually operated, semi-
automated, or fully automated.
Type II Multiple stations with variable routing
This manufacturing system consists of two or more stations (n > 1) that are
designed and arranged to accommodate the processing or assembly of
different part or product styles.
Type III Multiple stations with fixed routing
This system has two or more workstations (n > 1), which are laid out as a
production line.
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3. Level of Automation
The workstations (machines) in a manufacturing system can be manually operated,
semi-automated, or automated.
Manning Level. Closely correlated with the level of automation is the proportion of
time that direct labour must be in attendance at each station.
The manning level of a workstation, symbolized Ml is the proportion of time that

a worker is in attendance at the station.
If Ml = 1 for station i, it means that one worker must be at the station

continuously.
If one worker tends four automatic machines, then Ml = 0.25 for each of the four
machines, assuming each machine requires the same amount of attention.
On portions of an automobile final assembly line, there are stations where multiple
workers perform assembly tasks on the car, in which case Ml = 2 or 3 or more.
In general, high values of Ml (Ml >=1) indicate manual operations at the

workstation, while low values (Ml < 1) denote some form of automation. 47
Automation in the Classification Scheme.
There are two possible automation levels for single stations and three
possible levels for multi-station systems.
The two levels for single stations (type I) are:

M = manned station
A = fully automated
 The manned station is identified by the fact

that one or more workers must be at the station every cycle.
 This means that any machine at the station is manually operated or semi-
automatic and that manning is equal to or greater than one (M >=1).
 However, in some cases, one worker may be able to attend

more than one machine, if the semi-automatic cycle is long relative to the
service required each cycle of the worker (thus, M < I).
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Fully automated station requires less than full-time attention of a worker
(M < 1). For multi-station systems (types II and III), the levels M and A are
applicable, and a third level is possible:
H = hybrid, in which some stations are manned and others are fully
automated.
Listing the alternatives, we have the following
Type I M Single-station manned cell.

The basic case is one machine and one worker (n = 1,w = l).
The machine is manually operated or semi-automated, and the
worker must be in continuous attendance at the machine.
Type I A Single station automated cell.

This is a fully automated machine capable of unattended operation (M < 1)
for extended periods of time (longer than one
machine cycle).
A worker must periodically load and unload the machine or
otherwise service it.
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Type II M Multi-station manual system with variable routing.
This has multiple stations that are manually operated or semi-

automated.
The layout and work transport system allow for various routes to be
followed by the parts or products made by the system.
Work transport between stations is either manual or mechanized.
Type II A Multi-station automated system with variable routing.
The stations are fully automated (n > 1, wi = 0, M < 1). Work transport is
also fully automated.
Type II H Multi-station hybrid system with variable routing.
It contains both manned and automated stations. Work transport is manual,

automated, or a mixture (hybrid).
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Type III M Multi-station manual system with fixed routing.
It consists of two or more stations (n > 1), with one or more workers at
each station (wi >= 1). The operations are sequential, thus necessitating a
fixed routing, usually laid out as a production line.
Work transport between stations is either manual or mechanized.
Type III A Multi-station automated system with fixed routing.
This system consists of two or more automated stations (n > 1, wi = 0, M

< 1) arranged as a production line or similar configuration.
Work transport is fully automated.
Type III H Multi-station hybrid system with ftxed routing.
This system includes both manned and automated stations(n > 1,wi >= 1
for some stations, wi= 0 for other stations, M > 0). Work transport is
manual, automated, or a mixture (hybrid).
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(a) single station manned cell. (b) single station automated cell, (c) multi-station
manual system with variable routing, (d) multi-station automated system with variable
routing, (e) multi-station hybrid system with variable routing, (f) multi-station manual
system with serial operations, (g) multi-station automated system with serial
operations, and (h) multi-station hybrid system with serial operations. 52
4. Part or Product Variety
The degree to which it is capable of dealing with variations in the parts or
products it produces.
• Variations in type and/or color of plastic of molded parts in injection
molding.
• Variations in electronic components placed on a standard size printed circuit

board.
• Variations in geometry of machined parts.
• Variations in parts and options in an assembled product on a final assembly

line.
Three Types of Manufacturing System According to Their Capacity to Deal
with Product Variety
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Single model case
All parts or products made by the manufacturing system are identical.
There are no variations.
Batch model case

 Different parts or products are made by the system, but they are made
in batches because a changeover in physical setup and/or equipment
programming is required between models.
 Changeover of the manufacturing system is required because the

differences in part or product style are significant enough that the
system cannot cope unless changes in tooling and programming are
made.
 It is a case of hard product variety. The time needed to accomplish the

changeover requires the system to be operated in a batch mode, in
which a batch of one product style is followed by a batch of another,
and so on.
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The plot shows production quantity as a function of time, with interruptions
between batches for changeover (setup).
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Mixed model case
Different parts or products are made by the manufacturing system, but the
system is able to handle these differences without the need for a
changeover in setup and/or program.
This means that the mixture of different styles can be produced

continuously rather than in batches.
The requirement for continuous production of different work unit styles is

that the manufacturing system be designed so that whatever adjustments
need to be made from the part or product style to the next.
These adjustments can be made quickly enough that it is economical to

produce the units in batch sizes of one.
Flexibility in Manufacturing Systems. Flexibility is the term used

for the attribute that allows a mixed model manufacturing system to cope
with a certain level of variation in part or product style without interruptions
in production for changeovers between models.
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Examples in the Manufacturing Systems Classification Schemes
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Introduction to Material Handling
 The movement, storage, protection and control of materials

throughout the manufacturing and distribution process including their
consumption and disposal.
 The handling of materials must be performed safely, efficiently, at low

cost, in a timely manner, accurately (the right materials in the right
quantities to the right locations), and without damage to the materials.
 The cost of material handling is a significant portion of total

production cost, estimates averaging around 20-25%, of total
manufacturing labor cost.
 Material can also be transported manually using no equipment.
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Components of Material Handling
¨ The Materials – products, items, substances and/or people which
are being moved, transported, or physically relocated.
¨ The Move – (origin, travel path, destination, frequency) to be

made.
¨ The Method – (equipment, people, procedures, physical facilities)

to be used to make the move
Material Handling Equation

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Material Handling Taxonomy
Source: College-Industry Council on Material Handling
Education (CICMHE)
Material Handling Equipment
Transport Equipment
Conveyors Cranes Industrial Trucks No Equipment
Positioning Unit Load Formation Storage Identification and

Equipment Equipment Equipment Control
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Positioning Equipment
Equipment used to handle material at a single location so that it is in
the correct position for subsequent handling, machining, transport,
or storage.
Unlike transport equipment, positioning equipment is usually used

for handling at a single workplace.
Material can also be positioned manually using no equipment.
Unit Load Formation Equipment
Equipment used to restrict materials so that they maintain their

integrity when handled as a single load during transport and for
storage.
If materials are self-restraining (e.g., a single part or interlocking

parts), then they can be formed into a unit load with no equipment.
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Storage Equipment.
Equipment used for holding or buffering materials over a period of
time.
Some storage equipment may include the transport of materials (e.g.,

the S/R machines of an AS/RS, or storage carousels).
If materials are block stacked directly on the floor, then no storage

equipment is required.
Identification and Control Equipment.
Equipment used to collect and communicate the information that is

used to coordinate the flow of materials within a facility and
between a facility and its suppliers and customers.
The identification of materials and associated control can be

performed manually with no specialized equipment.
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MATERIAL HANDLING EQUIPMENTS
(1) Transport equipment.

(2) Storage systems,
(3) Unitizing equipment.
(4) Identification and tracking systems
(2) Material Transport Equipment

It includes equipment that is used to move materials inside a factory,
warehouse, or other facility.
This can be divided into the following five categories
a) Industrial trucks
b) Automated guided vehicles (AGVs)
c) Monorails and other rail guided vehicles
d) Conveyors
e) Cranes and hoists
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Industrial trucks
Hand truck Narrow-aisle straddle truck

Two-wheeled hand truck Narrow-aisle reach truck
Dolly Turret truck
Floor hand truck Operator-down turret truck
Pallet jack Operator-up turret truck
Manual pallet jack Order picker
Powered pallet jack Sideloader
Walkie stacker Tractor-trailer
Manual walkie stacker Personnel and burden carrier
Powered walkie stacker Automatic guided vehicle (AGV)
Pallet truck Tow AGV
Platform truck Unit load AGV
Walkie platform truck Assembly AGV
Rider platform truck Light load AGV
Counterbalanced lift truck Fork AGV
Sit-down counterbalanced lift truck
Stand-up counterbalanced lift truck
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(a) Industrial trucks.
Two types: Non-powered and Powered.
Non powered trucks are platforms or containers with wheels that are pushed or
pulled by human workers to move materials.
Powered industrial trucks are steered by human workers. They provide
mechanized movement of materials
Powered Industrial trucks Non Powered Industrial trucks
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(b) Automated guided vehicles (AGVs):
 AGVs are battery-powered, automatically steered vehicles that
follow defined pathways in the floor.
 AGVs are used to move unit loads between load and unload
stations in the facility.
69
(c) Monorails and other rail guided vehicles:
 Self-propelled vehicles that ride on a fixed rail system that is either

on the floor or suspended from the ceiling.
 The vehicles operate independently and are usually driven by electric

motors that pick up power from an electrified rail.
 Like AGVs, routing variations are possible in rail-guided vehicle
systems.
70
(d) Conveyors:
 Conveyors constitute a large family of material
transport equipment that are designed to move
materials over fixed paths, generally in large
quantities or volumes.
 Examples :Roller, Belt, and Tow-line

conveyors.
 Conveyors can be either powered or non-

powered.
 In Powered conveyors the mechanical drive

system is built into the fixed path.
 Non-powered conveyors are activated either

by human workers or by gravity.
71
Transport Equipment - Conveyors
Conveyors are used:

1. When material is to be moved frequently between specific points
2. To move materials over a fixed path
3. When there is a sufficient flow volume to justify the fixed conveyor
investment .
Conveyors can be classified in different ways:

1. Type of product being handled: unit load or bulk load
2. Location of the conveyor: overhead, on-floor, or in-floor
3. Whether or not loads can accumulate on the conveyor
72
Chute conveyor Vertical conveyor
Wheel conveyor Vertical lift conveyor
Roller conveyor Reciprocating vertical conveyor
Gravity roller conveyor Cart-on-track conveyor
Live (powered) roller conveyor Tow conveyor
Chain conveyor Trolley conveyor
Slat conveyor Power-and-free conveyor
Flat belt conveyor Monorail
Magnetic belt conveyor Sortation conveyor
Troughed belt conveyor Diverter
Bucket conveyor Pop-up device
Vibrating conveyor Sliding shoe device
Screw conveyor Tilting device
Pneumatic conveyor Cross-belt transfer device
Dilute-phase pneumatic
conveyor
Carrier-system pneumatic
conveyor
73
Chute Conveyor
Wheel Conveyor
74
Gravity Roller Conveyor
Chain Conveyor
Live (Powered) Roller Conveyor
75
Flat Belt Conveyor
Magnetic Belt
Conveyor
Slat Conveyor
76
77
Bucket Conveyor
Troughed Belt Conveyor
Vibrating
Conveyor
78
Screw Conveyor
Carrier-System Pneumatic Conveyor
Dilute-Phase Pneumatic Conveyor

79
Reciprocating Vertical Conveyor
Cart-On-Track Conveyor
Vertical Lift Conveyor
80
Trolley Conveyor
Tow Conveyor
81
Power-and-Free Conveyor
Monorail 82
Sortation Conveyor
Sortation Conveyor: Diverter

83
Sortation Conveyor: Pop-Up Device
Sortation Conveyor: Sliding Shoe Sorter
84
Sortation Conveyor: Tilting Device
Sortation Conveyor: Cross-Belt Transfer Device
85
(e) Cranes and hoists
 Handling devices for lifting,

lowering, and transporting
materials, often as very heavy
loads.
 Hoists accomplish vertical

lifting; both manually operated
and powered types are available.
 Cranes provide horizontal

travel and generally include one
or more hoists.
86
Monorails, Hoists and Cranes
87
Transport Equipment - Cranes
Jib Crane
Stacker Crane
Bridge Crane
88
Transport Equipment - Cranes
Gantry Crane
89
(2) STORAGE SYSTEMS.
 Although it is generally desirable to reduce the storage of materials in

manufacturing.
 It seems unavoidable that raw materials and work-in-process will spend

some time being stored, even if only temporarily.
 And finished products are likely to spend some time in a warehouse

or distribution center before being delivered to the final customer.
 Accordingly, companies must give consideration to the most

appropriate methods for storing materials and products prior to
during, and after manufacture.
90
Storage methods and equipment can be classified as follows:
(a) Bulk storage.
This consists of simply storing materials in an open floor

area, generally in pallet loads or other containers. It
requires little or no storage equipment.
(b) Rack systems.
Structural frames designed to stack unit loads vertically,

thus increasing the vertical storage efficiency compared to
bulk storage.
(c) Shelving and bins.

Steel shelving comes in standard widths, depths, and
heights to serve a variety of storage requirements, Shelves
can include bins, which are containers for loose items.
91
(d) Drawer storage.
 This storage medium is more costly than shelves, but it

is more convenient. Finding items stored in shelves can
be difficult if the shelf level is too high or too low.
 Drawers compensate for this by pulling out to reveal

their entire contents. Drawer storage is generally used
for tools, hardware, and other small items.
(e) Automated storage systems. Automated and semi

automated systems are available to deposit and withdraw
items into and from the storage compartments.
There are two basic types:
(1) automated storage/retrieval systems, consisting of
rack and shelf systems that are accessed by an automated
or mechanized crane, and
(2) carousel systems that rotate storage bins past a
stationary load/unload station.
92
Storage Equipment
Drive-Through Rack
Selective Pallet Rack
93
Storage Equipment
Drive-In Rack
Flow-Through Rack
94
95
Storage Equipment
Sliding Rack
Push-Back Rack
96
Storage Equipment
Shelves / Bins / Drawers
Storage Carousel
97
Storage Equipment
Mini-load AS/RS
Unit Load AS/RS
98
Storage Equipment
Man-On-Board AS/RS
Split-Case Order Picking System
99
(3) Unitizing Equipment.
(1) Containers used to hold individual items during handling and

(2) Equipment used to load and package the containers.
Containers include pallets, boxes, baskets, barrels, pails, and

drums, this type of equipment is very important for moving materials
efficiently as a unit load, rather than as individual items.
Loading and packaging equipment, inc1udcs palletizers, designed

to automatically load cartons onto pallets and Shrink-wrap plastic
film around them for shipping.
Other wrapping and packaging machines are also included in this

equipment category, as are depalletizers, designed to unload cartons
from pallets.
100
Unit load formation equipment used to restrict materials so that
they maintain their integrity when handled a single load during
transport and for storage.
Advantages of unit loads:
• More items can be handled at the same time, thereby reducing
the number of trips required and, potentially, reducing handling
costs, loading and unloading times, and product damage.
• Enables the use of standardized material handling equipment.
Disadvantages of unit loads:
• Time spent forming and breaking down the unit load.
• Cost of containers/pallets and other load restraining materials
used in the unit load
• Empty containers/pallets may need to be returned to their point
of origin.
101
Examples of unit load containers for material handling:
(a) wooden pallet
tote box
pallet box 102

Tote Pans
Pallets
103
Manual Palletizing
Robotic Pick and Place Palletizers
Shrink-Wrap/Stretch-Wrap
104
(4) Identification and Tracking Systems
 Material handling must include a means of keeping track of
the materials being moved or stored.
 This is done by affixing some kind of label to the item,

carton, or unit load that uniquely identifies it.
 The most common label used today consists of bar codes

that can be read quickly and automatically by bar code
readers.
 This is the same basic technology used by grocery stores and

retail merchandisers.
 Other types of labels include magnetic stripes and radio

frequency tags that are generally capable of encoding more
data than bar codes.
105
Material Handling Equipment
Positioning Equipment
Positioning equipment is used to handle material at a single location so
that the material is in the correct position for subsequent handling,
machining, transport, or storage. Unlike transport equipment,
positioning equipment is usually used for handling at a single
workplace. Material can also be positioned manually using no
equipment.
Manual (no equipment) Hoist

Lift/tilt/turn table Balancer
Dock leveler Manipulator
Ball transfer table Rigid-link manipulator
Rotary index table Articulated jib crane manipulator
Parts feeder Vacuum manipulator
Air film device Industrial robot
106
As compared to manual handling, the use of positioning
equipment can provide the following benefits [Modern
Materials Handling, Sept. 1993]:
• Raise the productivity of each worker when the frequency of

handling is high.
• Improve product quality and limit damage to materials and

equipment when the item handled is heavy or awkward to
hold and damage is likely through human error or inattention.
• Reduce fatigue and injuries when the environment is

hazardous or inaccessible.
107
Rotary Index Table
Lift/Tilt/Turn Table
Rigid-Link Manipulator
Dock Leveler
Parts Feeder
108
Articulated Jib Crane Manipulator Industrial Robot
Vacuum Manipulator
109
CONSIDERATIONS IN MATERIAL HANDLING SYSTEM DESIGN
Design of the system depends on the materials to be handled, quantities and

distances to be moved. Type of production facility served by the handling system,
and other factors, including available budget.
Material Characteristics
 Design of the material handling system must take these factors into account.
110
Cont…
 For example, if the material is a liquid and is to be moved in this state over
long distances in great volumes, then a pipeline is probably the appropriate
transport means.
 But this handling method would be quite inappropriate for moving a liquid
contained in barrels or other containers.
 Materials in a factory usually consist of solid items: raw materials, parts,

and finished or semi finished products.
111
Flow Rate, Routing, and Scheduling
In addition to material characteristics, other factors must be considered in
analyzing system requirements and determining which type of equipment is
most appropriate for the application.
Other factors
(1) Quantities and flow rates of materials to be moved
(2) Routing factors
(3) Scheduling of the moves
(1) Quantities and flow rates of materials to be moved

 If the quantity of a particular material type is small but there are many different
material types to be moved, then the handling system must be designed to be
shared by the various materials moved.
 The amount of material moved, how much material is moved within a given
time period.
 The material moved as individual units, in batches, or continuously.
112
(2) Routing factors
 Pickup and drop-off locations, move distances, routing variations,
and conditions that exist along the routes.
The longer the move distance, the greater the cost.
 Routing variations occur because different materials follow different

flow patterns in the factory or warehouse.
 If these differences exist, the material handling system must be flexible

enough to deal with them.
 Conditions along the route include floor surface condition, traffic

congestion, whether a portion of the move is outdoors, whether the path is
straight line or involves turns and changes in elevation, and the presence
or absence of people along the path.
113
General types of material transport equipment as a
function of material quantity and distance moved
114
(3) Scheduling
 It relates to the timing of each individual delivery.
 The material must be picked up and delivered promptly to its proper

destination to maintain peak performance and efficiency of the overall
system.
 To the extent required by the application, the handling system must he

responsive to this need for timely pickup and delivery of the items.
115
Plant layout
 Layout that optimizes material flow in the building and utilizes the most
appropriate type of handling system.
 The plant layout design should provide: the total area of the facility and areas
within specific departments in the plant.
 Arrangement of equipment in the layout, locations where materials must be

picked up (load stations) and delivered (unload stations), possible routes between
these locations, and distances travelled.
 Opportunities to combine deliveries and potential locations in the layout where

congestion might occur must be considered. Each of these factors affects flow
patterns and selection of material handling equipment.
116
THE 10 PRINCIPLES OF MATERIAL HANDLING
Principle 1. PLANNING PRINCIPLE:

All material handling should be the result of a deliberate plan where the needs,
performance objectives, and functional specification of the proposed methods are
completely defined at the outset.
Principle 2. STANDARDIZATION PRINCIPLE:

Material handling methods, equipment, controls, and software should be
standardized within the limits of achieving overall performance objectives and
without sacrificing needed flexibility, modularity, and throughput.
Principle 3. WORK PRINCIPLE:

Material handling work should be minimized without sacrificing productivity or
the level of service required of the operation.
117
Principle 4. ERGONOMIC PRINCIPLE;
Human capabilities and limitations must be recognized and respected in the
design of material handling tasks and equipment to ensure safe and effective
operations.
Principle 5. UNIT LOAD PRINCIPLE:

Unit loads shall be appropriately sized and configured in a way which achieves
the material flow and Inventory objectives at each stage in the supply chain.
Principle 6. SPACE UTILIZATION PRINCIPLE:

Effective and efficient use must be made of all available space.
Principle 7. SYSTEM PRINCIPLE:

Material movement and storage activities should be fully integrated to form a
coordinated, operational system that spans receiving, inspection, storage,
production, assembly, packaging, unitizing, order selection, shipping,
transportation, and the handling of return 118
Principle 8. AUTOMATION PRINCIPLE:
Material handling operations should be mechanized and/or automated where

feasible to improve operational efficiency, increase responsiveness, improve
consistency and predictability, decrease operating costs, and eliminate repetitive
unsafe manual labour.
Principle 9. ENVIRONMENTAL PRINCIPLE:
Environmental impact and energy consumption should be considered as criteria

when designing or selecting alternative equipment and material handling systems.
Principle 10. LIFE CYCLE COST PRINCIPLE:
A thorough economic analysis should account for the entire life cycle of all material
handling equipment and resulting systems.
119
Automated Storage/Retrieval Systems (AS/RS)
• A storage system that performs storage and retrieval operations with
speed and accuracy under a defined degree of automation.
• The operations are totally automated, computer controlled, and fully

integrated with factory and/or warehouse operations
• Consists of one or more storage aisles that are each serviced by a

storage/retrieval machine
Objectives and Reasons for Automating
Storage Operations
 To increase storage capacity
 To increase storage density
 To recover factory floor space currently used for WIP
 To improve security
 To reduce labor cost and/or increase productivity
 To improve safety
 To improve inventory control
 To improve stock rotation
 To improve customer service
 To increase through output
121
AS/RS Types
Unit load AS/RS
• A large automated system designed to handle unit
loads stored on pallets or in other standard
containers
• Computer controlled, and the S/R machines are

automated and designed to handle the unit load
containers
Deep-lane AS/RS
• A high-density unit load storage system that is
appropriate when large quantities of stock are
stored
• Number of separate stock types is relatively small
• Each rack is designed for "flow-through," with

input on one side and output on the other side.
Unit load on pallet
carousel storage system AS/RS with one aisle
123
Miniload AS/RS
• Used to handle small loads (individual parts or supplies) that are contained in
bins or drawers in the storage system
• The S/R machine is designed to retrieve the bin and deliver it to a pickup and
deposit (P&D) station at the end of the aisle
• The P&D station is operated by a human worker
Man-on-board AS/RS
• An alternative approach to the problem of retrieving individual items from
storage
• A human operator rides on the carriage of the S/R machine
• Permits individual item to be picked directly at their storage locations

Miniload AS/RS
Man-on-board AS/RS
125
126
Automated item retrieval system
• Designed for retrieval of individual items or small product cartons.
• The items are stored in lanes rather than bins or drawers.
Vertical lift storage modules (VLSM)
• Vertical lift automated storage/retrieval systems (VL-AS/RS)
• The aisle is vertical
• With heights of 10 m (30 ft) or more, are capable of holding large

inventories
• Saving valuable floor space in the factory

Components and Operating Features of an AS/RS
(1) Storage structure
(2) S/R machine
(3) Storage modules (e.g., pallets for unit loads)
(4) One or more pickup-and-deposit stations
In addition, a control system is required to operate the AS/RS
(1) Storage structure

• Rack framework, made of fabricated steel, which supports the loads contained
in the AS/RS
• Rack structure must possess sufficient strength and rigidity
• Compartments in the structure must be designed to accept and hold the storage
modules
• Used to support the roof and siding of the building in which the AS/RS resides
Automated Storage/Retrieval Systems (AS/RS)
(2) S/R Machine
• To accomplish storage transactions

- Delivering loads from the input station into storage, and
- Retrieving loads from storage and delivering them to the output station
• Must be capable of horizontal and vertical travel to align its carriage

(which carries the load) with the storage compartment in the rack structure
• Consists of a rigid post on which is mounted a rail system for vertical

motion of the carriage.
• Wheels are attached at the base to permit horizontal travel.
• A parallel rail at the top of the storage structure is used to maintain

alignment of the pole and carriage with respect to the rack structure
• The carriage includes a transfer mechanism to move loads into and from
their storage compartments.
(3) Storage modules
• The unit load containers of the stored material.
• Includes pallets, steel wire baskets and containers, special drawers.
• Made to a standard base size that can be handled automatically by the
carriage shuttle of the S/R machine.
• The standard size is also designed to fit in the storage compartments of
the rack structure.
(4) Pickup-and-deposit stations

• It is where loads are transferred into and out of the AS/RS.
• Located at the end of the aisles for access by the external handling
system.
• Designed to be compatible with both the S/R machine shuttle and the
external handling system
• Common methods to handle loads includes manual load/unload, fork
lift truck, conveyor (e.g.,roller),and AGVS.
(5) Control system
• Computer controls and programmable logic controllers are used

to determine the required location and guide the S/R machine to its
destination.
• Computer control permits the physical operation of the AS/RS to

be integrated with the supporting information and record-keeping
system.
• Automatic controls can be superseded or supplemented by manual

controls.
Automated storage/retrieval system
133
AS/RS applications
(1) Unit load storage and handling
(2) Order picking
(3) Work-in-process storage systems
• Unit load storage and retrieval applications are represented by the unit
load AS/RS and deep-lane storage systems
• Order picking involves retrieving materials in less than full unit load
quantities.
• In Work-in-process (WIP) storage, it is desirable to minimize the amount

of work-in-process, it is also important to effectively manage WIP that
unavoidably does exist in a factory.
134
Reasons that justify the installation of automated storage
systems
• Buffer storage in production
• Support of just-in-time delivery
• Kitting of parts for assembly
• Compatible with automatic identification systems
• Computer control and tracking of materials
• Support of factory wide automation

Automated Guided Vehicle Systems (AGVS)
• A material handling system that uses independently operated, self-

propelled vehicles guided along defined pathways.
• Vehicles arc powered by on-board batteries that allow many hours of

operation (8-16 hr is typical) between recharging.
• Compared to other handling systems, the pathways are modest.
• Appropriate where different materials are moved from various load

points to various unload points.
• Suitable for automating material handling in batch production and mixed

model production.
• Divided into the three categories:

(1) Driverless trains
(2) Pallet trucks
(3) Unit load carriers
• Automated Guided Vehicle Systems (AGVS)
137
(1) AGV driverless trains
• Consists of a towing vehicle [which is the AGV) that pulls one or more
trailers to form a train
• Common applications is moving heavy payloads over large distances in

warehouses or factories with or without intermediate pickup and drop-off
points along the route.
• It consists of 5-10 trailers and is an efficient transport system.
• The towing capacity is up to 60,000 pounds

AGV driverless trains
139
(2) Automated guided pellet trucks
• Used to move palletized loads along

predetermined routes.
• The vehicle is backed into the loaded pallet

by a human worker.
• The capacity of an AGVS pallet truck

ranges up to several thousand kilograms.
• Some trucks are capable of handling two

pallets rather than one.
• Fork lift AGV - This vehicle can achieve

significant vertical movement of its forks to
reach loads on racks and shelves.
AGV Pallet Truck
141
(3) AGV unit load carriers
• Used to move unit loads from one station to another.
• Equipped for automatic loading and unloading of pallets by means of

powered rollers, moving belts, mechanized lift platforms, or other devices
built into the vehicle deck.
• Light load guided vehicles are designed to move small loads (single
parts. small baskets) through plants of limited size engaged in light
manufacturing.
• An assembly line AGV is designed to carry a partially completed

subassembly through a sequence of assembly workstations to build the
product.
Unit load carrier
143
Why consider AGVs?
• Reduces the labor cost.
• Flexible.
• Intelligent.
• Time consuming.
• Can significantly reduce production & warehouse costs.
• Transforming the materials handling industry.
144
Wired navigation
• The wired sensor is placed on bottom of the AGV’S
and is placed facing the ground.
• A slot is cut in the ground and a wire is placed

approximately 1 inch below the ground.
• The sensors detects the radio frequency being

transmitted from the wire and follows it.
145
wired navigation AGV’S
146
Guide tape navigation
• The AGV’S( some known as automated guided carts or AGC’S)
use magnetic tape for the guide path.
• The AGC’S is fitted with the appropriate

guide sensors to follow the path of the tape.
• It is considered a “passive” system since it

does not require the guide medium to be
energized as wire does.
147
Guide tape navigation AGV’S
148
Laser target navigation
• The AGV’S carry’s a laser transmitter and receiver
on a rotating turret.
• The laser is sent off then received again the angle
and distances are automatically calculated and
stored into AGV’S memory.
• The AGV’S has reflector map stored in memory
and can correct its position based on errors between
the expected and received measurements.
• It can then navigate to a destination target using the
constantly updating position.
149
Common AGV Applications
Automated Guided Vehicles can be used in a wide variety of
applications to transport many different types of material
including pallets, rolls, racks, carts, and containers.
Raw Material Handling:-

AGVs are commonly used to transport raw materials such as
paper, steel, rubber, metal, and plastic. This includes
transporting materials from receiving to the warehouse, and
delivering materials directly to production lines.
Work-in-Process Movement:-
Work-in-Process movement is one of the first applications where
automated guided vehicles were used, and includes the repetitive
movement of materials throughout the manufacturing process.
150
Finished Product Handling:-
Moving finished goods from manufacturing to storage or

shipping is the final movement of materials before they are
delivered to customers. These movements often require the
gentlest material handling because the products are complete
and subject to damage from rough handling.
151
Automated guided vehicle systems are used in a growing
number and variety of applications.
Driverless train operations,
Storage and distribution,
Assembly line applications,
Flexible manufacturing systems
Office mail delivery and hospital material transport.
152
Pallet handling Finished goods handling
153
What is Flexible Manufacturing
System?
A flexible manufacturing system (FMS) is a form of
flexible automation in which several machine tools
are linked together by a material-handling system,
and all aspects of the system are controlled by a
central computer.
154
What are The Features of FMS?
 An FMS is distinguished from an automated
production line by its ability to process more than
one product style simultaneously.
 At any moment, each machine in the system may be

processing a different part type.
 FMS can let us make changes in production

schedule in order to meet the demands on different
products.
155
 New product styles can be introduced into
production with an FMS, so long as they are to be
used on the products that the system can process.
 This kind of system is, therefore, ideal when there are

likely to be changes in demands.
156
Distinguishing Characteristics:
 An automatic materials handling subsystem links
machines in the system and provides for automatic
interchange of work pieces in each machine.
 Automatic continuous cycling of individual machines

Complete control of the manufacturing system by
the host computer.
 Lightly manned, or possibly unmanned
157
Flexible Manufacturing System
•Introduction
•Test
•Types
•Components
•Merits and Demerits
158
Flexible Manufacturing System (FMS)
• The highly automated GT machine cell consisting of a group of
processing workstations (usually CNC machine tools).
• Interconnected by an automated material handling and storage

system.
• Controlled by a distributed computer system.
• Capable of processing a variety of different part styles

simultaneously at the various workstations.
• Mix of part styles and quantities of production can be adjusted in

response to changing demand patterns.
• Most suited for the mid-variety, mid-volume production range.

Flexibility test or criteria
Four reasonable tests of flexibility in an automated manufacturing system:
o Part variety test - Can the system process different part

styles in a non batch mode?
o Schedule change test - Can the system readily accept

changes in production schedule, and changes in either part
mix or production quantities?
o Error recovery test - Can the system recover gracefully

from equipment malfunctions and breakdowns, so that
production is not completely disrupted?
o New part test - Can new part designs be introduced into the
existing product mix with relative ease?
160
Types of Flexibility in FMS
 Machine flexibility
 Production flexibility
 Mix flexibility
 Product flexibility
 Routing flexibility
 Volume flexibility
 Expansion flexibility
o Machine flexibility - Capability to adapt a given machine
(workstation) in the system to a wide range of production
operations and part styles
- Depends on the factors such as
• Setup or changeover time
• Ease of machine reprogramming (ease with which
part programs can be downloaded to machines)
• Tool storage capacity of machines
• Skill and versatility of workers in the system.
o Production flexibility - The range of part styles that can be

produced on the system
Depends on the factors such as
- Machine flexibility of individual stations
• Range of machine flexibilities of all stations in the
system
162
Mix flexibility - Ability to change the product mix while
machining the same total production quantity
• Similarity of parts in the mix
• Relative work content times of parts produced
• Machine flexibility
Product flexibility - Ease with which design changes can be

accommodated
-ease with which new products can be introduced
- How closely the new part design matches the existing
part family.
• Range of machine flexibilities of all stations in the
system
• Off line part program preparation
o Routing flexibility - Capacity to produce parts through
alternative workstation sequences in response to equipment
breakdowns, tool failures, and other interruptions at individual
stations.

• Similarity of parts in the mix
• Similarity of workstations
• Duplication of workstations
• Cross-training of manual workers
• Common tooling
o Volume flexibility - Ability to economically produce parts in
high and low total quantities of production, given the fixed
investment in the system
• Level of manual labour performing production
• Amount invested in capital equipment.
o Expansion flexibility - Ease with which the system can be

expanded to increase total production quantities

• Expense of adding workstations
• Ease with which layout can be expanded
• Type of part handling system used
• Ease with which properly trained workers can be added.
165
FMS
Types of Flexible Manufacturing System (FMS)
1. Number of machines
• Single machine cell
• Flexible manufacturing cell
• Flexible manufacturing system
Single Machine Cell

• Consists of one CNC machining center combined with a parts
storage system for unattended operation
• Designed to operate in either a batch mode or a flexible mode
or in combinations of the two.
• Error recovery cannot be satisfied because if the single machine

breaks down, production stops.
Single Machine Cell
168
Flexible Manufacturing Cell
• Consists of two or three processing workstations (typically
CNC machining centers or turning centers) plus a part
handling system
• The part handling system is connected to a load/unload station
• Satisfies the four flexibility tests

Flexible Manufacturing System
• Four or more processing workstations connected
mechanically by a common part handling system and
electronically by a distributed computer system
• Includes non processing workstations that support production
• The computer control system of an FMS is larger and more

sophisticated
2. Level of flexibility
• Dedicated FMS
• Random-order FMS
Dedicated FMS
• Designed to produce a limited variety of part styles
• Special manufacturing system
• The part family is likely to be based on product commonality rather than

geometric similarity
• The product design is stable
• Special Purpose machine
Random-order FMS
• More appropriate when the part family is large
• Capable of processing parts in various sequences
FMS Components
• Workstations
• Material handling and storage systems
• Computer Control System
• Human Resources
FMS- Components
(1) Workstations
• Depends on the type of work accomplished by the system
Types of workstations typically found in an FMS
(i) Load/Unload Stations

- Physical interface between the FMS and the rest of the factory.
- Loading and unloading can be accomplished either manually or by automated

handling systems.
- Load/unload station should be ergonomically designed.
- Mechanized cranes and other handling devices are installed to assist the
operator.
- Certain level of cleanliness must be maintained at the workplace.
- Should include a data entry unit and monitor for communication between the
operator and the computer system.
(ii) Machining Station
- CNC machining center
- Automatic tool changing and tool storage, use of palletized workparts, CNC,
and capacity for distributed numerical control (DNC)
(iii) Other Processing Stations

- Other processing operations in addition to machining.
- Sheet metal fabrication processes.
- Press working operations, such as punching, shearing, and certain bending

and forming processes.
- Automate the forging process.

(iv) Assembly
- Designed to perform assembly operations
- Flexible automated assembly systems
- Industrial robots are used as the automated workstations
(v) Other Stations and Equipment

- Inspection can be incorporated into an FMS
- Coordinate measuring machines, special inspection probes that can be used

in a machine tool spindle and machine vision
- Stations for cleaning parts and/or pallet fixtures
- Central coolant delivery systems for the entire FMS
- Centralized chip removal systems often installed below floor level.

(2) Material Handling and Storage System
(i) Functions of the Handling System
- Random, independent movement of work parts between stations.
- Handle a variety of work part configurations.
- Temporary storage.
- Convenient access for loading and unloading work parts.
- Compatible with computer control.
176
(ii) Material Handling Equipment
Primary handling system - material handling systems used to transfer parts
between stations
- Include a variety of conventional material transport equipment, in-line

transfer mechanisms and industrial robots
- Supported by an automated storage system
Secondary handling system

 To transfer work from the primary system to the machine tool or
other processing station and to position the parts with sufficient
accuracy and repeatability to perform the processing or assembly
operation
 Reorientation of the workpart if necessary to present the surface that

is to be processed
 Buffer storage of parts to minimize work change time and maximize

station utilization.
(iii) FMS Layout Configurations
- Material handling system establishes the FMS layout
FMS layout can be divided into five categories:

(a) In-line layout (b) Loop layout (c) Ladder layout
(d) Open field layout, and (e) Robot-centered cell
(a) In-line layout

- The machines and handling system are arranged in a straight line
- The parts progress from one workstation to the next in a well-defined

sequence.
- Work always moving in one direction and no back flow
- Operation of this type of system is similar to a transfer line
- For in-line systems requiring greater routing flexibility, a linear transfer

system that permits movement in two directions can be installed.
In-line FMS layout
One direction flow similar to a transfer line
linear transfer system with secondary part handling system at each

station to facilitate flow in two directions.
(b) Loop layout
- The workstations are

organized in a loop that
is served by a part
handling system in the
same shape
- Parts usually flow in one

direction around the
loop, with the capability
to stop and be
transferred to any station
- An alternative form of
loop layout is the
rectangular layout.
(c) Ladder layout
- Consists of a loop with rungs between the

straight sections of the loop, on which
workstations are located
- The rungs increase the possible ways of

getting from one machine to the next, and
obviate the need for a secondary handling
system.
(d) Open field layout
- Consists of multiple loops and ladders and

may include sidings as well.
- Generally appropriate for processing a large

family of parts.
(e) Robot centered cell
- Uses one or more robots as the material handling system.
- Industrial robots can be equipped with grippers that make them well suited
for the handling of rotational parts.
- Robot-centered FMS layouts are often used to process cylindrical or disk-

shaped parts.
(3) Computer Control System
• Distributed computer system that is interfaced to the workstations, material
handling system, and other hardware components
• Consists of a central computer and microcomputers controlling the

individual machines and other components
Functions performed by the FMS computer control system are
- Workstation control
• The individual processing or assembly stations operate under

some form of computer control.
• For a machining system, CNC is used to control the individual

machine tools.
- Distribution of control instructions to workstations
• Central intelligence to coordinate the processing at individual

stations.
• Part programs must be downloaded to machines.
• DNC.
- Production control
• Routing an applicable pallet to the load/unload area.
• Providing instructions to the operator for loading the desired work

part.
186
- Traffic control
• The management of the primary material handling system that moves
work parts between stations
• Actuating switches at branches and merging points.
• Stopping parts at machine tool transfer locations.
• Moving pallets to load/unload stations.
- Shuttle control
• Concerned with the operation and control of the secondary handling
system at each workstation
• Each shuttle must be coordinated with the primary handling system
- Work piece monitoring

• Monitor the status of each cart/ pallet in the primary and secondary
handling systems
- Tool control
• Tool location
• Tool life monitoring.
- Performance monitoring and reporting
- Diagnostics
• To indicate the probable source of the problem when a malfunction
occurs.
• To plan preventive maintenance in the system and to identify
Impending failures.
• To reduce breakdowns and downtime and increase availability of
the system.
Structure of FMS application software system.
(4) Human Resources in FMS
Humans are needed to manage the operations of the FMS.
Functions performed includes
• Loading raw workparts into the system
• Unloading finished parts (or assemblies) from the system
• Changing and setting tools
• Equipment maintenance and repair
• NC part programming in a machining system
• Programming and operating the computer system
• Overall management of the system

FMS Benefits
• Increased machine utilization
• Fewer machines required
• Reduction in factory floor space required
• Greater responsiveness to change
• Reduced inventory requirements
• Lower manufacturing lead times
• Reduced direct labor requirements and higher labor productivity
• Opportunity for unattended production

The Disadvantages of FMS
 Expensive, costing millions of dollars
 Substantial pre-planning activity
 Sophisticated manufacturing systems
 Limited ability to adapt to changes in product
 Technological problems of exact component
positioning and precise timing necessary to process a
component
192
FMS PLANNING AND IMPLEMENTATION ISSUES
• FMS planning and design issues.
• FMS operational issues.
FMS planning and design issues
• Part family considerations FMS operational issues
• Scheduling and dispatching
• Processing requirements • Machine loading
• Physical characteristics of the work parts • Part routing
• Production volume, • Part grouping

• Tool management
• Types of workstations • Pallet and fixture allocation
• Variations in process routings and FMS layout
• Material handling system
• Work-in-process and storage capacity
• Tooling and Pallet fixtures. 193

What is Manufacturing?
Value addition processes by which raw materials of low
utility and value due to its inadequate material properties and
poor or irregular size, shape and finish are converted into
high utility and valued products with definite dimensions,
forms and finish imparting some functional ability.
Value addition by manufacturing
194
What is Value?
• Every Product or service has value.
• Manufacturing organization buys raw material and converts it

into a product through a series of process.
• The value of the raw material gets additional value at every

stage of conversion and, finally becomes the “Product
Value”.
• The customer plays a key role in fixing the value of the

product/service.
• In case the customer is not willing to buy a particular product

It means that it has no value. 195
• The value of a product or service is decided by what the
customer is willing to pay for it.
• The customer keeps looking for maximum value at a

competitive price.
• If the customer finds that a product costs more than the value
he is getting, then he will not buy the product anymore.
196
What does the customer want?
• On Time Delivery
• Full Order Execution
• Local Availability Products
• Good Quality
• Low Price
• Good Technical Support
197
Customer Requirements?
• In earlier days, the demand for the product used to be more and
availability less.
• Today, the customer has become very knowledgeable and at the

same time has vast choices to select from.
• Globally customers have the following three top requirements
1. On time delivery
2. Good quality
3. Low price.
198
What others want?
199
?
• How to meet all these requirements?
• The only way out is to find a solution which will give faster
delivery, reduced price, good quality products on a continuous
basis.
• “Lean Manufacturing” is considered as the best cultural change any

organization can adopt so that it can meet the global challenges and
stay in the competition.
• Survival of an organization depends on how quickly it can adopt to

the “Lean Manufacturing Culture”
200
What is Lean & Lean Manufacturing?
• Identification and elimination of waste in all the process involved
(Lean)
• Increasing the speed by reducing the process time (Lean

Manufacturing)
• Lean Manufacturing can be applied to every process.
• Results in reduction of cost and faster action
• So, it is a business philosophy that continuously improves all the

processes involved in a manufacturing environment, irrespective of
what types of products are being manufactured.
201
Value Added Time
202
So, the following activities do not add any value to the customer
* Inspection – four times

* Waiting at all stages
* Transporting the castings – 1360 metres
* Rework at all stages
* Scrap at final stage
203
Key implications of Lean Manufacturing
204
What is Waste (Muda)?
• If the customer is not willing to pay for any process or product
feature, such process or product is considered as waste.
• So, waste is anything that consumes resources and does not add
value to the customer.
• During the manufacturing process, the material goes through various

process and, finally, gets delivered as a product.
• During this journey, there are many process which do not add any
value to the customer.
• Such NVA steps increase the cost of the product.
205
• Globally, industries have identified the following are waste,
• High Inventory
• Scrap
• Rework
• Repair
• Low Productivity
• Downtime
• Poor yield
• Cycle time inconsistency
• Unutilized machinery and equipments
• Overtime
• Long Lead time
• Delay
• Waiting for inspection
• Excess Labour
There are many more visible wastes 206

Top Seven Wastes
• Mistake that require rectification (rework or scrap)
• Production of inventory that no one wants
• Processing steps that are not needed
• Unnecessary transport of material and sub-assemblies
• Unnecessary movement of employees involved in the production process
• People waiting in the downstream processes for the completion of the

upstream work
• Producing goods or services which do not meet the specific needs of

customers. 207
Key Principles of Lean Manufacturing
• Recognition of waste – The first step is to recognize what does and
does not create value from the customer’s perspective. Any material,
process or feature which is not required for creating value from the
customer’s perspective is waste and should be eliminated. For
example, transporting materials between workstations is waste
because it can potentially be eliminated.
• Standard processes – Lean requires an the implementation of very

detailed production guidelines, called Standard Work, which clearly
state the content, sequence, timing and outcome of all actions by
workers. This eliminates variation in the way that workers perform
their tasks.
208
• Continuous flow – Lean usually aims for the implementation of a continuous
production flow free of bottlenecks, interruption, backflows or waiting. When
this is successfully implemented, the production cycle time can be reduced by
as much as 90%.
• Pull-production – Also called Just-in-Time (JIT), Pull-production aims to

produce only what is needed, when it is needed. Production is pulled by the
downstream workstation so that each workstation should only produce what
is requested by the next workstation.
• Quality at the Source – Lean aims for defects to be eliminated at the source
and for quality inspection to be done by the workers as part of the in-line
production process.
• Continuous improvement – Lean requires striving for perfection by

continually removing layers of waste as they are uncovered. This in turn
requires a high level of worker involvement in the continuous improvement
process.
209
Lean Manufacturing Tools and
Methodologies
210
• Lean Manufacturing is similar to climbing a mountain
• People (climbers)
• Support (team work)
• Effective use of correct tools and procedures (grappling hooks

and ropes etc)
• Goal
211
25 ESSENTIAL LEAN TOOLS
Lean Tool What Is It? How Does It Help?
5S Organize the work area: Eliminates waste that results

Sort (eliminate that which is not from a poorly organized work
needed) area (e.g. wasting time looking
Set In Order (organize remaining items) for a tool).
Shine (clean and inspect work area)
Standardize (write standards for above)
Sustain (regularly apply the standards)
Andon Visual feedback system for the plant

floor that indicates production status,
alerts when assistance is needed, and
empowers operators to stop the
production process.
212
Acts as a real-
time communication tool for
the plant floor that brings
immediate attention to
problems as they occur – so
they can be instantly
addressed.
Bottleneck Identify which part of Improves throughput by

Analysis the manufacturing process limits the strengthening the weakest link
overall throughput and improve the in the manufacturing process.
performance of that part of the
process.
213
Continuous Manufacturing where work-in- Eliminates many forms of
Flow process smoothly flows through waste (e.g.Inventory, waiting
production with minimal (or no) time, and transport).
buffers between steps of the
manufacturing process.
214
Gemba (The A philosophy that reminds us to get Promotes a deep and thorough
Real Place) out of our offices and spend time on understanding of real-world
the plant floor – the place where real manufacturing issues – by
action occurs. first-hand observation and by
talking with plant floor
employees.
Heijunka A form of production scheduling that Reduces lead times (since

(Level purposely manufactures in much each product or variant is
Scheduling) smaller batches by sequencing manufactured more
(mixing) product variants within the frequently) and inventory
same process. (since batches are smaller)
215
Jidoka Design equipment to partially After Jidoka, workers can
(Autonomation) automate the manufacturing process frequently monitor multiple
"intelligent (partial automation is typically much stations (reducing labor costs)
automation" or less expensive than full automation) and many quality issues can be
"automation and to automatically stop when detected immediately
with a human defects are detected. (improving quality).
touch."
Hoshin Align the goals of the company Ensures that progress

Kanri(Policy (Strategy), with the plans of middle towards strategic goals is
Deployment) management (Tactics) and the work consistent and thorough –
performed on the plant floor (Action). eliminating the waste that
comes from poor
communication and
inconsistent direction.
Just-In-Time Pull parts through production based Highly effective in reducing

(JIT) on customer demand instead of inventory levels. Improves
pushing parts through production cash flow and reduces space
based on projected demand. Relies on requirements.
many lean tools, such as Continuous
Flow, Heijunka, Kanban,
Standardized Work and Takt Time.
216
Kaizen A strategy where employees work Combines the collective
(Continuous together proactively to achieve talents of a company to create
Improvement) regular, incremental improvements in an engine for continually
the manufacturing process. eliminating waste from
manufacturing processes.
Kanban (Pull A method of regulating the flow of Eliminates waste from

System) goods both within the factory and inventory and overproduction.
with outside suppliers and customers. Can eliminate the need for
Based on automatic replenishment physical inventories (instead
through signal cards that indicate relying on signal cards to
when more goods are needed. indicate when more goods
need to be ordered).
Overall Framework for measuring Provides a benchmark/baseline

Equipment productivity loss for a given and a means to track progress
Effectiveness manufacturing process. Three in eliminating waste from a
(OEE) categories of loss are tracked: manufacturing process. 100%
Availability (e.g. down time) OEE means perfect production
Performance (e.g. slow cycles) (manufacturing only good
Quality (e.g. rejects) parts, as fast as possible, with
no down time).
217
Agile Manufacturing is a method for manufacturing which
combine our organization, people and technology into
integrated and coordinated whole.
218
219
220
221
222
223
224
Industry 4.0
The four industrial revolutions:

(1) Mechanization through water and steam power. (1760 – 1840)
(2) Mass production and assembly lines powered by electricity. (1870 – 1914)
(3) Computerization and automation. (1960 – 20??)
(4) Smart factories and cyber-physical systems. (Now)
225
Industry 4.0
Industry 4.0 represents the fourth industrial revolution

in manufacturing and industry.
Industry 4.0 is the current industrial transformation

with automation, data exchanges, cloud, cyber-physical
systems, robots, Big Data, AI, IoT and (semi-)
autonomous industrial techniques to realize smart
industry and manufacturing goals in the intersection of
people, new technologies and innovation.
226
Essential technological components of the fourth
industrial revolution.
IoT (Internet of Things), the convergence of IT and OT, rapid
application development, digital twin simulation models,
cyber-physical systems, advanced robots and cobots,
additive manufacturing, autonomous production, consistent
engineering across the entire value chain, thorough data
collection and provisioning, horizontal and vertical
integration, the cloud, big data analytics, virtual/augmented
reality and edge computing amidst a shift of intelligence
towards the edge (artificial intelligence indeed with a
convergence of AI and IoT and other technologies):
227
Artificial Intelligence and Expert Systems -
Artificial Intelligence (AI) is a branch of computer science, which

focuses on the development of computer systems to simulate the processes
of problem solving and duplicate human brain functions.
Expert systems (ES) are a category of programs based on the theory and
methods of artificial intelligence.
228
Artificial Intelligence is a theoretical approach to help in decision making
and not directly in line with the routine operations of a company.
We use CIM to smooth out the flow of information in conducting daily

activities related to the manufacturing system.
Specifically, we use CIM modules to do the clerical and editorial activities,

thus freeing ourselves to do the analytical and strategy activities.
Even With these higher activities we use the CIM modules to access data
and to manipulate data.
But the creative thought or idea generating is entirely the domain of men
and women, not machines.
Now we have AI available to help us even with the creative process.
229
AI can help by giving us logical supposition based on data but not related
directly to the specifics of data.
This is the next evolutionary phase of computer use as the industrial

revolution merges with the information age.
The major innovation AI provides in industry is accomplished by AI

subgroup called expert systems.
Expert systems are logical extensions to conventional programs.
The expert systems we use a clever set of programs that allow the data base
to search for information and then use that information to add to the original
logic rules.
This is very useful for many engineering activities.
Example: Diagnosis of failures in maintenance activities, process planning

when many potential solutions exist, and aspects of statistical process
control in which specific results are required, hence intelligent monitoring
routines are needed. 230
AI programs have terminology specific to them.
Working memory
Knowledge base
Inference Engine
Working memory consists of the knowledge of the people considered
experts in the technology we are trying to emulate.
Instinctive knowledge of the experts.

Problem definition
Symptoms
Root cause
Elimination of root cause (solution)
231
ESPRIT - CIM OSA MODEL
 European Strategic Program for Research and Development in
Information Technology (ESPRIT) is an industrially oriented
R&D program with the aim of improving the competitiveness of the
European Community industries.
 The ESPRIT strategy has been the creation of an environment in

which multi-vendor production systems can be implemented at
reasonable cost. (OSA refers to Open System Architecture).
 It was developed by AMICE, a consortium of 30 major European

vendors and users of CIM systems (e.g. IBM, HP, DEC, Siemens,
Fiat, and Daimler-Benz) for ESPRIT.
 Within the framework of the CIM-OSA concept, it is possible to

construct CIM architectures for various manufacturing industries
and applications from basic building blocks according to defined
guidelines. 232
CIM-OSA integrating infrastructure.
 Integrating infrastructure
is provided to organize and
schedule the enterprise
activities.
 Since activities, information

and control are treated as
three different entities, it is
possible to make changes in
one entity without greatly
affecting another one.
 The dynamic feature of the

model enhances the
flexibility of an enterprise to
quickly adapt to changing
material and information
flow. 233
CIM-OSA separates functions using two interrelated concepts.
 The CIM-OSA modeling Framework in which specific and generic functions are
clearly separated.
 The CIMOSA Integrating Infrastructure supporting execution of generic

functions and linking specific functions.
 It is effectively the communication system, which interconnects all of the

functions in the CIM system.
CIMOSA defines four modeling views of the enterprise functions:
 The function view describes work flows.
The information view describes the Inputs and Outputs of Functions.
The Resource View describes the structure of resources (Humans, machines, and
control and information systems).
The Organization View defines authorities and responsibilities.

234
Operating Environment to Apply CIM-OSA Model
235
THE NIST - AMRF HIERARCHICAL MODEL
 At National Institute of Standards and Technology (NIST, Germany),

an Advanced Manufacturing Research Facility (AMRF) was built and
operated to work out the hardware and software standards for
computer controlled manufacturing system.
 A hierarchical computer and sensor system is assumed to plan and

control the manufacturing operations.
 Like the other models, the NIST model greatly facilitates the
configuration of a control system for manufacturing.
 The model is of particular value to small and medium sized batch

operations.
236
 The NIST - AMRF model consists of three columns, a management
information system (MIS), a control system and a design and
planning system.
 The design and process planning system prepares the

manufacturing documents.
 The order initiates the manufacturing, design and process planning

activities.
 Every information needed for making the product like material

selection, determination of machining operations and sequences
(process plan), calculations of machining parameters, part
scheduling, is generated.
237
NIST-AMRF Model
238
The MIS knows the order priorities, status of manufacturing
equipment, material availability, on-line processing status, quality of
products etc.
The sensors in the shop floor level collect status information about the
manufacturing process and send this information to all levels.
Components can be added and deleted with a minimum of effort and

disturbance to the activities on the shop floor.
The central database contains a complete state description of the

factory at any given time, and thus the system can respond immediately to
any production change or disturbance.
239
THE SIEMENS MODEL OF CIM
 The Siemens model of CIM comprises the main functions of planning,

sales, purchasing, production planning and control, computer aided
design, computer aided quality control and computer aided
manufacture interconnected by intensive information flow.
The requirements for a factory wide data processing system are:
• What kind of data is generated?

• What kind of data is needed and where are they used?
• Who administers and maintains the data?
• Who is responsible for what data?
• What data are kept in common database?
• Where must data be obtained from and where must data be sent?
240
 In order to be able to process the data in a comprehensive
manufacturing system, a hierarchical model of an enterprise is
used.
 A steady flow of instructions from the upper levels to the

lower ones.
 In order to control and synchronize parallel activities on each

level, an intensive horizontal data flow takes place.
 Siemens model also incorporates a Computer Aided

Organization (CAO), which comprises accounting, personnel
and finance.
241
Siemens Concept of CIM
242
THE CIM MODEL OF DIGITAL EQUIPMENT CORPORATION
 The Digital Equipment Corporation (DEC) CIM is the improvement
of a manufacturing processes with the aid of the computer and the
integration of the information processing of all enterprise activities.
 The entire control system is divided into functional modules, which
reflect the business and the data.
 CIM design starts with the analysis of all manufacturing activities and
identifies their functions and data flow.
 This assists the layout of physical system leading to a functional
model and a physical model of a manufacturing system and its
subsystems.
 A well-structured information technology model supports the
individual activities of this model.
 The system integration is a strong effort within the framework of this
CIM model.
 The scope of integration comprises the business functions, data
structure, hardware-software architecture and information systems.
243
Business function integration:
 For this activity, the business functions are defined and all computer
programs are assembled to support them.
 Combining the internal process functions and defining the data exchange
mainly achieve the integration.
Data structure integration:

 Successful system integration is achieved by organizing all data in a
defined physical database in which the logical associations are well
structured.
 An attempt is made to set up distinct data structures for the various
applications and to define algorithms, which establish links between the
data structures.
244
Infrastructure integration:
 The system architecture is conceived as a distributed environment using

heterogeneous hardware and software components.
 Features included are transportable software and application

packages, device independent storage and retrieval, unique query
languages, common networks and protocols, and possibilities of
adapting quickly to technology changes.
Information system integration:
 System integration is considered to be an ongoing incremental process,

which adapts to the ever-present changes of business functions, data
structures and infrastructures.
245
CIM Model of DEC
246
THE IBM CONCEPT OF CIM
 The IBM CIM architecture facilitates the integration of an

enterprise’s business processes and information requirements.
 Introduction of technologies and practices like downsizing,

distributed processing, and client-server implementation.
Enablers are of two types:
(i) Systems enabler:
This simplifies integration by establishing an infrastructure of

common system services to store and manage data, send and
receive data, present data view to users and applications, and
manage workflow among applications.
247
(ii) Application enabler:
 The application enablers provide a broader range of integration of services.
 They provide additional services for families of applications that can be based
on the services provided by the system enablers at the enterprise level.
 This provides a high degree of independence from computing platforms and

applications in data sharing.
REPOSITORY AND DATA STORE

 The IBM CIM architecture uses
operational repositories and
data stores to manage an
enterprise’s data.
 This contains shared data

elements, and data definitions
recognized throughout the
enterprise.
The IBM CIM Architecture
248
LEVELS OF INTEGRATION-IBM CIM
i. Integration within application families:
ii. Interoperability among application families:
249
iii. Data and workflow integration
250
Machine Tools
 NC part program consists of a combination of machine tool code and
machine specific instructions.
 It contains geometric information about part geometry and motion

statements to move the cutting tool.
 Cutting speed, feed-rate and auxiliary functions (coolant on and off,

spindle direction) are programmed according to surface finish and
tolerance requirements.
 Part programmers who prepare part programs for NC machine tools

must understand the coordinate systems of these machine tools and how
they work.
 NC machine tool consists of the MCU (machine control unit) in the

machine tool itself.
 MCU reads the part program and controls the machine tool operation.
251
 After reading the part program, the MCU decodes it to provide
commands and instructions to the various control loops of the
machine axes of motion.
 The MCU performs two functions

 Reads the part program
 Controls the machine tool.
 It consists of two units one for each function:

 The DPU (data processing unit) reads and decodes the part
program statements.
 Processes the decoded information, and provide data to the
CLU (control loop unit).
 The CLU received the data from the DPU and converts it to
control signals.
252
Motion of Machine Tools
 A workpiece is machined to the finished shape by allowing a
relative motion between the workpiece and the cutting tool.
 Such relative motion can be provided by holding the workpiece

stationary and moving the cutting tool as in milling and
drilling.
 By moving the cutting tool and the workpiece simultaneously

as turning.
 Each motion of the machine tool requires its own axis of motion.
 Axis of motion is defined as an axis where relative motion

between the cutting tool and workpiece occurs.
253
Classification of Machine Tools according to
simultaneous control of motion axes
 2 axis machine:
Simultaneously control the
tool along only two axes.
 Tool is parallel to and

independently controlled
along the third axis.
 2 1/2 axis machine: Tool can

be controlled to follow an
inclined Z axis control plane.
254
 3 axis machine: Tool is controlled
along the three axes (X,Y and Z)
simultaneously
 Tool orientation does not change

with tool motion.
 Multi axis machine: Tool axis

orientation varies with the tool
motion in three dimensions.
 6 axis machine is capable of

moving the tool simultaneously
along each primary axis and in the
mean time, simultaneously rotate it
about each primary axis.
255
Type of machining
 Point to point machining : cutting

tool performs operations on the
workpiece at specific points.
 Examples are Drilling operation

and punching holes and bending
tubes.
 Continuous path machining :

cutting tool is always in contact
with the workpiece.
 Examples are Milling operation.
256
Type of structure
NC machine tool: The DPU is a tape

reader.
 Each time the NC program needs to

be executed to machine a new part.
CNC machine tool: The DPU is a

ROM.
 The reader used to read an NC

program only once to originally load
the program to the machine ROM.
 If the same NC program is used on

various machine tools, it has to be
loaded separately into each machine.
257
258
DNC machine tool: It consists of a central computer to which a group of
CNC machine tools are connected via a communication network.
 Computer stores the NC programs. It also downloads these programs to

any number of CNC machine tools in the network.
 Performs Feedback task-data collection, processing and reporting as well

as providing communications .
 It centralizes the system monitoring.
259
iv. Enterprise optimization
260

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Computer Integrated Manufacturing

CIM – Methodology involving a consistent system based approach to

CIM concept starts with integration of various aspects of production

CIM is thus essentially a means of organising and controlling the

 For example, the product data is created during design has to be

CIM has several software tools to address the above needs

 Integrate and control the design and manufacturing processes.

 Manage all the finances in the system.

 Increase sales by controlling product demand.

 To strengthen the relationship between the supplier and the

 Plan production and deliveries more efficiently

 Shorter delivery time.

 The architecture of CIM provides the structure of computer hardware

 Communication is the critical aspect of the CIM architecture to integrate.

 In CIM environment, local area network (LAN) is needed on the shop

 The architecture of the CIM provides a consistent base to enterprise’s

Computers and controllers

 Management Information System, Sales

Nine major elements of a CIM system are

 The specifications of the product, the projection of manufacturing

 It is accomplished through geometric modeling and computer aided design

 Complex designs are usually carried out by several teams working

 The planning department takes the database established by the

 Planning involves several subsystems dealing with materials, facility,

 In a CIM system, this planning process should be constrained by the

 The purchase departments is responsible for placing the purchase

 Manufacturing Engineering is the activity of carrying out the production

 In CIM, this requires activities like CNC programming, simulation and

 Often, the need to meet fluctuating market demand requires the

Factory automation equipment further enriches the database with

 It consists of computer controlled process machinery such as CNC

 Warehousing is the function involving storage and retrieval of raw

 In today’s complex outsourcing scenario and the need for just-in-time

 Finance deals with the resources pertaining to money.

 Planning of investment, working capital, and cash flow control,

 Information Management is perhaps one of the crucial tasks in CIM.

 This involves master production scheduling, database management,

 Shorter delivery time.

 More realistic inventories.

 Shorter production time.

 Reduced lead times.

 Improved product quality.

 Increases responsiveness and competitiveness.

 Engineering Design: Speed of designing product is faster due to

 Research and Development: CIM adapt quickly to market changes and

 Manufacturing Operations: The resources and information available

The information required for manufacturing is complex covering a wide range of

i. Product Data: Data about parts to be manufactured. It includes text and

ii. Manufacturing Data: The information as to how the parts are to be

1. Designing assemblies and performing tolerance analysis.

2. Preparing production drawings of assemblies, individual parts, tooling.

3. Creating analytical models of parts for structural, kinematical and thermal

4. Calculating weights, volumes, centres of gravity and other mass properties

5. Classifying existing parts according to shape, function, and the process

6. Preparing part lists and bill of materials (BOM).

7. Preparing process plans for individual part manufacture and assembly

9. Designing work cells and programming the movement of components

10. Controlling engineering changes and maintaining associatively

11. Preparing programs to handle components or manipulate production

12. Preparing inspection programs including programs for CNC co-

13. The exchange of graphic information has been advanced with

 Integrate existing data.

Share data among users.

Incorporate changes quickly and effectively.