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Computer Integrated Manufacturing
AMT 2508
Shanmuga Raja
(BVB0912004)
Module leader : Prof. Ramdas Chandrashekar
Sandeep .N
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Introduction
Computer Integrated Manufacturing (CIM) is an approach to
control entire manufacturing process using computers through theprinciple of networking.
The integration allows possibilities such as,
Data sharing across different functions of the plant. Closed loop controlled process based on real time sensing.
Using a common database for information interchange.
Encompassing product virtualization, realization, control and
maintenance. Mass customization.
Relieves human intervention to larger extent, improvising
quality, cost and delivery.
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Elements and Resources of CIM
Computer aided techniques
CAD (computer-aided design) CAE (computer-aided engineering)
CAM (computer-aided manufacturing) CAPP (computer-aided process planning) CAQ (computer-aided quality assurance) PPC (production planning and control) ERP (enterprise resource planning) A business system integrated by a common
database.
Devices and Equipment
CNC, Computer numerical controlled machine tools DNC, Direct numerical control machine tools
PLCs, Programmable logic controllers Robotics Computers Controllers Networks Interfacing
Monitoring equipmentTechnology
FMS, (flexible manufacturing system) ASRS, automated storage and retrieval system AGV, automated guided vehicle Robotic
Automated conveyance systems
Other
Lean manufacturing Quality program
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Group technology
Group technology is a technique involved in, grouping similar
parts with design and manufacturing characteristics and create acell based on rationalization of overall attributes.
The benefits of GT are,
Reduces Work In Process (WIP) by optimization of part flow.
Provides reliable work-piece statistics.
Facilitates accurate estimation of machine tool requirements
and logical machine loadings.
Provides for better machine tool utilization and better use of
tools, fixtures and people.
Limitations.
Problem in part identification among large group.
Re-arrangement of machines in appropriate cells.
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Group technology
The technique used to form Part families are,
Visual Inspection
Coding and Classification
Production Flow Analysis
Cost effective, suitable for less
part count.
Experienced personnel are
required to identify
MonocodePolycode Polycode
Systematic classification
through Monocode, Polycode
or Hybrid code
Time consuming process
Algorithms are used for
classification and cell
formation.
Flexibility is an issue.
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CAPP - Variant
Variant or Retrieval CAPP uses similarities between the stored
part, followed with necessary amendment on the feature attributes
so as to adapt the new part configuration.
Variant CAPP is basically,
GT based
Computer aids for editing
Parameters selection
Pros:
Easier to create and cost effective. Have a structured standard sequencing.
Cons:
Manual editing is not consistent Knowledge and experience of planner
limits the plan effectiveness.
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CAPP - Generative
Generative CAPP, is a planning technique based from first
principle. It relies mainly on an expert system to deduce the part
attributes and uses decision logic to advocate the sequence.
Generative CAPP is basically,
Some kind of decision logic
Decision tree/table
Artificial Intelligence
Objective-Oriented
Still experience based
Pros:
No need to rely on GT because ofdecision logic.
No need to maintain & update database.
Cons:
Creating the logic is too cumbersome. High Investment.
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Material Planning in CIM
Aggregate
Production Plan
(APP)
Master
Production
Schedule (MPS)
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Production
Activity Control
(PAC)
MaterialRequirement
Planning (MRP)
Material Planning in CIM
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Flexible Manufacturing System
FMS, is an automated reprogrammable manufacturing system
offering solution to wide variety of products.
Elements of FMS:
Computer controlled
Production Machines
(CNC / DNC).
Support systems (APC,
ATC).
Material handling
systems (RGV, AGV).
Automated Storage &
Retrieval system (ASRS). Buffer storage.
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FMS Layout
In-Line layout
Loop layout
Rectangular layout
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FMA Layout
Ladder layout Open field layout Robot centered layout
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Production MonitoringShop floor production activity is monitored for,
Real time date
To check output parameters for controlled process.
To warn the concerned in uncertain event.
To provide diagnostic information.
Cell performance data
To analyze cell utilization. To assess the part flow time.
To check the inventory level.
Direct Digital Controller
(DDC)Programmable Logic Controller
(PLC)
Distributed Control System
(DCS)
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Sensors in automation
Sensors are devices which detects the presence or absence of
conditions and forwards the signal for monitoring or manipulation.
Non contact sensors are preferred because it eliminates any
alignment issue, faster sensing and longer life. Some of its types
are,
Inductive sensor (Electromagnetic field)
Capacitive sensor (Electrostatic field)
core coilOscillator Magnetic Field
Without Object With Object
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Sensors in automation
Ultrasonic sensor (Sound waves)
Photoelectric sensor (Light energy)
Transmitter Receiver
Without Object
With Object
S
E
S
E
Without Object
With Object
Mirror
S
E
S
E
Without Object
With Object
ObjectDiffuse SensorTransmitter +Receiver
Transmitter
Receiver
Thru beam type Retro-reflective type Diffused type
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Industrial Robots
Cartesian Robot
Polar Robot Jointed Arm
Robot
Selective Compliant
Articulated Robot Arm
(SCARA)
Cylindrical Robot
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Industrial Robots
End effector
Grippers
Tools
Robot Programming is done by, Walk through.
Lead through.
Simulation and offline programming.
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Material handling
1. Containers and Unitizing Equipment
Containers
Unitizers
2. Material Transport Equipment
Conveyors
Industrial Vehicles
AGV, RGV
Monorails, Hoists, and Cranes
Material handling system can be categorized as,
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Material handling
3. Storage and Retrieval Equipment
Unit Load Storage and Retrieval
Unit Load Storage Equipment Unit Load Retrieval Equipment
Small Load Storage and Retrieval
4. Automatic Data Collection and
Communication Equipment
Automatic Identification and Recognition
Automatic Paperless Communication
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References
21
Prof. Ramdas Chandrashekar (2013) Module notes: Computer Integrated
Manufacturing, Bangalore: MSRSAS
Prof. Anatoly Sachenko (n.d,) Lecture 6. Computer Integrated Manufacturing Systems
[online] available from
[13 Mar 2013]
Dr. R. A. Wysk (2011) ISE789 -- Manufacturing Systems, [online] available from [13 Mar
2013]
Tom Foster (n.d,) Flexible Manufacturing System, [online] available from
[14 Mar 2013]Mikell P. Groover (2008) Automation, Production Systems, and Computer-Integrated
Manufacturing, [online] available from [14 Mar 2013]
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References
22
Festo (2007) Basics of Automation Technology, [online] available from
[14 Mar 2013]
Nuigalway (2007) Industrial Robot, [online] available from
[14 Mar 2013]
Dr. MuzafferKapanolu (2003) Material Handling, [online] available from
[14 Mar 2013]
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