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Manufacturing process develops tremendously to

increase
❖ production, capacity, productivity and quality to
INTRODUCTION TO COMPUTER INTEGRARED maximize profit.
MANUFACTURING (CIM)
Depending on the role of people and type of tool utilized,
manufacturing can be distinguished with four
development stages:
I. Manual: craft manufacturing
II. Mechanized: machine controlled by people
Filmon .F III. Automated/ program driven: machine controlled by
programmed computer
IV. Computer integrated manufacturing: machine controlled by
hierarchical computers

▪ Mechanization is the precursor of automation Automation: process of predetermined sequence of

operations with little or no people involvement.
• It is defined as transfer of skills and manual activities to
machine operations ❑ It is a technology concerned with the application of
mechanical, electronic and computer based systems
• Mechanization: the use of energy of non-living systems to operate and control production achieved through
to carry-out process operations. various devices such as:
➢ Sensors, Actuators, and techniques capable of:
❖ It reduce labor cost, improve working conditions,
✓ Observing the manufacturing process,
enhance quality of products and increase production
✓ Making decisions to the needed changes and
output.
✓ Controlling all aspects of it

➢ The difference b/n mechanization and automation is

that automation provides feedback for controlling
the system.

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✓ In modern manufacturing operations, portion of the ✓ These two categories overlap to same extent.
productions processes are automated and/or ✓ Because automated system at the factory floor are themselves
often connected to the manufacturing support and management
computerized. People are appear to make the systems
information system operating at the plant and enterprise level.
functional.
✓ The term CIM is used to indicate this extensive use of
✓ Direct labors are responsible for operating the facilities computers in production systems
and professional staffs are responsible for the
manufacturing support systems. Potential
Manufacturing
Support Systems Computerization
✓ The automated elements of the production systems Applications
Computer
❖ Automation of manufacturing systems in the factory
Manufactur Integrated
❖ Computerization of the manufacturing support ing System Facilities Potential Manufacturing
systems Automation
• Factories and
Application
Equipments

Possibilities of automation and computerization in production system

Model of manufacturing
Conceptual model of Automation and CIM - Factory operations and information processing activities
✓ In manufacturing firms, physical production activities are
different from information processing activities Product Design
✓

Physical activities: direct contact with product. Manufacturing

Business Functions
Planning
❖ Includes: processing, assembling, material handling and
inspection operations
The information processing activities: a ring surrounding the Factory operations
Raw ❖ Processing Finished
factory Materials
❖ Material handling products
✓ Provides the data and knowledge required to successfully
❖ Inspection, etc
produce the product. These include:
(1) Includes: business functions (2) Product design
(3)Manufacturing planning (4) Manufacturing
control Manufacturing Control

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Product design ✓ Automated manufacturing systems operate on the

Product development physical product such as
Engineering drawing
➢ Processing, assembly, inspection, or material
Bills of materials
handling
Business Manufacturing
Functions Planning Basic types of automated manufacturing system
Customers Marketing Process planning
Firms ✓ Fixed automation
Sales Master Schedule
Order entry Operations Requirement ✓ Programmable automation
Customer billing Planning
Capacity Planning ✓ Flexible automation

Production Control
Shop floor control
Quality control
Inventory control

Information processing cycle in typical manufacturing firm

Fixed Automation Programmable Automation

The sequence of processing/assembly operations is fixed by ✓ Designed with the capability to change the sequence of
the equipment configuration. operations to accommodate various product configurations.
Each operation in the sequence is simple. ✓ Sequence of operations is controlled by programs
Feeding of rotating spindle ➢ Programs=set of instructions that can be read and interpreted by
It is the integration and coordination of many such operations the systems
into one piece of equipment that makes the system complex. ➢ New programs can be prepared and entered to the equipment to
produce new product
Typical Features Typical features
High initial investment for custom-engineered equipment ✓ High investment in general purpose equipments
✓ Low production rate than fixed automation
High production rate
✓ Flexible to deal = high product variability
Capable for low product variety ✓ Suitable for batch production
The economic justification is found in very large quantity Programmable automated-systems are used in low and
at high rates medium volume production
Cost can be spread over very large number of units ✓ Reprogramming for new orders = change in production
life cycle

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Flexible Automation
An extension of programmable automation.

Product Variability
Capable of producing a variety of parts
There is no time los for changeover b/n part styles, during Programmable
programming and altering the physical set up Automation Flexible
✓ The difference b/n part processed are not significant Automation
Hence, can produce various combinations and schedules of
parts Manual
Fixed
Production Automation
Typical feature
High investment for custom-engineered systems
Continuous production of variable mixtures of products
Medium production rates 100 10,000 1,000,000
Flexible to deal with product design variations Product Quantity

Relative Position of Type of Automation

Ex - FMS

❖ To increase lobar productivity by increasing production rate

❖ Five possible levels of automation in production plant
❖ To reduce the ever-increasing labor cost in the
industrialized society Description/Example
level
❖ To mitigate the effect of labor shortages in advanced Enterprises Corporate Information System
5 level
nations
❖ To reduce or eliminate routine manual and clerical tasks
4 Plant level Production System
❖ To improve workers safety by transferring from the process
to a supervisory role
Cell or system Manufacturing System –
❖ To improve product quality: greater uniform and conformity 3
level Groups of Machines
to specifications
❖ To reduce manufacturing lead time b/n customer order and manufacture
2 Individual Machines
product delivery – providing competitive advantage level
❖ To perform process (manually difficult): high precision,
Sensors, Actuators and
miniaturization 1 Device level
other hardware elements
❖ To avoid the high cost of not automating

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Plant Level
Device Level Receives instruction from the corporate information system
and translates into operational plans for production.
❖ This the lowest automation level
❖ Include: actuators, sensors, and other complementary Function include: order processing, process planning,
components inventory control, purchasing, MRP, and quality control.

Machine level Enterprise Level

❖ Device level is assembled in to individual levels The highest level of automation
Contains corporate information system
Cell or system level:
❖ It is a group of machines or workstations connected and Contains all functions necessary to manage the company =
supported by material handling systems, computers marketing and sales, accounting, design, research,
and/or other equipment aggregate planning and master production scheduling
❖ Operates under instructions from the plant level

❖ To implement process control, the computer must ❖ The components required to implement this interface
collect data from and transmit signals to the production include:
➢ Sensors for measuring continuous and discrete process
process variables
➢ Actuators that drive continuous and discrete process
❖ The digital computer operates on digital (binary) data; parameters
whereas at least some of the data from the process are ➢ Devices that convert continuous analog signals to digital data
continuous (analog). ➢ Devices that convert digital data into analog signals
➢ Input/output devices for discrete data.
❖ Accommodations for this difference must be made in
the computer-process interface

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Actuators
Sensors
❖ An actuator is a hardware device that converts a controller
❖ Measuring devices for feedback control in command signal into a change in a physical parameter.
manufacturing process are composed of two things:
sensors and transducers ❖ The change in the physical parameter is usually mechanical, such
as position or velocity change.
❖ The sensor detects the physical variable of interest
(such as temperature. force. or pressure). ❖ An actuator is a transducer, because it changes one type of physical
quantity, say electric current, into another type of physical quantity,
❖ The transducer converts the physical variable into an
say rotational speed of an electric motor
alternative form (commonly electrical voltage),
quantifying the variable in the conversion. Analog- To-Digital Conversion (ADC)
❖ A calibration procedure is required to establish the ❖ Continuous analog signals from the process must be converted into
relationship between the physical variable to be measured digital values to be used by the computer.
and the converted output signal (such as voltage). ❖ And digital data generated by the computer must be converted to
analog signals to be used by analog actuators.

Digital-to-Analog Conversion (DAC)

The DAC transform the digital output of the computer
in to the continuous signal to drive an analog actuator
or other analog device.
DAC is the reverse process of ADC
There are two steps for DAC
❖ Decoding: digital output of the computer is converted in
to series of analog values at discrete moment in time.
➢ Digital value to binary register that controls a reference
voltage source
❖ Data holding: each successive value is changed in to
Step, in analog-to-digital conversion of continuous analog signals from process. continuous signal

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END OF THE CHAPTER