Introduction to Computer-Integrated Manufacturing (Chapter 10) Dr.

Sami El ferik

Automation
Definition 1: automatically controlled operation of an apparatus, process, or system by mechanical or electronic devices that take the place of human organs of observation, effort and decision. Definition2: a process without direct human activity in the process

Human beings role in automated systems

Designing the system Monitoring of its operation Maintaining the system Presently, human involvement have been removed from many portions of the production system

Continuous flow processes

Example: oil refineries and chemical plants automation has reached a very high state of development.

Sensors measure critical process variables in real time and feed the measurement back to the control computer. The computer exercises an on-line optimization to determine any needed adjustments in the controlled process components.

Human interaction in continuous flow processes.

The process is fully automated with human monitoring the process in a control room containing readouts of the process variables and parameter settings.

Mass Production of discrete items

Ex: Automobile components. Usually called flow lines or transfer lines. Many special machines arranged sequentially. Work parts are transferred automatically from one machines to another. The machine performs their operations automatically. Ex: Robot welding, painting, parts handling and so on. Automated flow lines are flexible Through the use of computer and flexible manufacturing system

Batch production and job shop production

Introduction of CNC (Computer numerical controlled) machine. Use of flexible manufacturing concept.

Tools change automatically Machine can do several dozen operation 4 general type:

Flexible modules Stand alone FMS Classical FMS Robotized FMS.

Robotics
A programmable, multifunction manipulator designed to move material, parts, tools, or special devices through variable programmed motions for the performance of a variety of tasks. Type of robots.

Stationary robots Mobile robots

Aspects of robots
Four basic components:

Manipulators Actuator Control unit Variety of sensors:

Audio Visual Voice or speech recognition Tactile etc

Use of robots:
Machine loading Material transfer Painting/coating Welding Assembly Inspection Packaging Component insertion

OPEL

CIM
CIM is the integration of

Computer in Product design Computer in process design Computer in Electronic design

CAD

Computer aided process planning Numerical control Group technology Automated storage retrieval and handling Computer aided testing and inspection Computer aided factory management Flexible manufacturing system

CAM

CAD: is hardware and software

Computer in Product design: (3 components)

Design development: Geometric shape Design Analysis: weight volume, center of gravity, effect of temperature etc) Design simulation: system model, simulation and animation software Design review and evaluation Automated drafting Design retrieval and modification.

CAD
Computer in the process design

Model that express the system behavior (dynamic)

Differential equation (physically based) Statistically models Time series models: output is function of the output previous values as well as the input present and previous values. Parameters of the system are changed until the system gives the appropriate response.

CAM
Computer aided process planning Numerical control Group technology Automated storage retrieval and handling Computer aided testing and inspection Computer aided factory management Flexible manufacturing system

Computer aided factory management

Purpose: Coordinate review and control the activities of the entire plant. Integration of all the information and concepts together to manage and control available sources

Think of the big picture of CIM

The role of technology in the implementation and operation of CIM. Automation key elements of CIM The relationship between automation and the humans in the system How CIM can make an operation more effective
Continued.

Functional areas of the enterprise How will CIM impact these areas?
Marketing/Sales Engineering R&D Quality Assurance Warehousing & Distribution Shipping and Receiving Finance & Accounting Information Systems Human Resources Customer Service Manufacturing Material Management

Definitions of CIM
View 1:

technology, tool or method used to improve entirely the design and manufacturing process and increase productivity using computers to help people and machines to communicate

CIM cont.
View 2

series of integrated activities and operations involving the design, materials selection, planning, production, quality assurance, management and marketing of discrete consumer and durable goods (Bunce, 1985) deliberate integration of automated systems logical organization of individual engineering, production and marketing/support functions into a computer integrated system (Bunce, 1985)

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CIM cont

architecture for integration of multiple technologies through computers, linking each individual island of automation to a closed loop business system (Foong, 1991) integration of computer aided design, automatic material handling, robotics, process technologies, manufacturing planning & control, computer aided test, computer aided manufacturing

CIM Wheel 1985

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Percent of Respondents

10

20

30

40

50

60

70

lower mfg. cost

higher product quality

improved prod. control

better responsiveness

reduced inventory

Expected Benefits of CIM

increased flexibility

small lot capability

1993 SME Enterprise Wheel

other

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CIM More than just automation

CIM Can be found at several levels:

Shop floor automation / work cell

islands of automation

Low

Manufacturing Operations
islands are linked together

Information systems integration

Information shared across functional boundaries

Strategic or Supply Chain level

High Integration extends up to customers and down to the suppliers

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