ME 2402 Computer Integrated Manufacturing (CIM) WITH QB

A Course Material on
Computer Integrated Manufacturing
By
Mr. T.Manokaran ME,MBA
ASSISTANT PROFESSOR
DEPARTMENT OF MECHANICAL ENGINEERING
SASURIE COLLEGE OF ENGINEERING
VIJAYAMANGALAM 638 056
QUALITY CERTIFICATE
This is to certify that the e-course material

Subject Code
: ME 2402
Subject
: Computer Integrated Manufacturing.
Class
: IV Year Mechanical Engineering.
being prepared by me and it meets the knowledge requirement of the university curriculum.
Signature of the Author

Name: T.Manokaran ME,MBA
Designation: Assistant Professor.
This is to certify that the course material being prepared by Mr.T.Manokaran is of adequate
quality. He has referred more than five books among them minimum one is from aborad author.
Signature of HD
Name: E.R.Sivakumar ME, (Ph.D)
SEAL
ME2402
COMPUTER INTEGRATED MANUFACTURING
LTPC 3 00 3
OBJECTIVE:
This course will enable the student
To gain knowledge about the basic fundamental of CAD.
To gain knowledge on how computers are integrated at various levels of planning
and manufacturing understand computer aided planning and control and computer
monitoring.
UNIT I
COMPUTER AIDED DESIGN
9
Concept of CAD as drafting and designing facility, desirable features of CAD package,
drawing features in CAD Scaling, rotation, translation, editing, dimensioning, labeling,
Zoom, pan, redraw and regenerate, typical CAD command structure, wire frame modeling,
surface modeling and solid modeling (concepts only) in relation to popular CAD packages.
UNIT II
COMPONENTS OF CIM
9
CIM as a concept and a technology, CASA/Sme model of CIM, CIM II, benefits of CIM,
communication matrix in CIM, fundamentals of computer communication in CIM CIM data
transmission methods seriel, parallel, asynchronous, synchronous, modulation,
demodulation, simplex and duplex. Types of communication in CIM point to point
(PTP), star and multiplexing. Computer networking in CIM the seven layer OSI model,
LAN model, MAP model, network topologies star, ring and bus, advantages of
networks in CIM
UNIT III
GROUP TECHNOLOGY AND COMPUTER AIDED PROCESS

PLANNING
9
History Of Group Technology role of G.T in CAD/CAM Integration part familiesclassification and coding DCLASS and MCLASS and OPTIZ coding systems facility
design using G.T benefits of G.T cellular manufacturing.Process planning - role of process
planning in CAD/CAM Integration approaches to computer aided process planning variant
approach and generative approaches CAPP and CMPP systems.
UNIT IV
SHOP FLOOR CONTROL AND INTRODUCTION TO FMS
9 shop
floor control phases factory data collection system automatic identification methods
Bar code technology automated data collection system.
FMS components of FMS types FMS workstation material handling and storage system
FMS layout- computer control systems applications and benefits.
UNIT V
COMPUTER AIDED PLANNING AND CONTROL AND COMPUTER

MONITORING
9
Production planning and control cost planning and control inventory management
material requirements planning (MRP) shop floor control. Lean and Agile
Manufacturing. Types of production monitoring systems structure model of manufacturing
process control and strategies direct digital control.
TOTAL: 45 PERIODS
TEXT BOOK:
1. Mikell. P. Groover Automation, Production Systems and Computer Integrated
Manufacturing, Pearson Education 2001.
REFERENCES:
1. Mikell. P. Groover and Emory Zimmers Jr.,CAD/CAM, Prentice hall of India Pvt.
Ltd., 1998.
2. James A. Regh and Henry W. Kreabber, Computer Integrated Manufacturing,
Pearson Education second edition, 2005.
3. Chris McMahon and Jimmie Browne, CAD CAM Principles, Practice and
Manufacturing Management, Pearson Education second edition, 2005.
4. Ranky, Paul G., Computer Integrated Manufacturing, Prentice hall of India Pvt. Ltd.,
2005.
5. Yorem Koren, Computer Integrated Manufacturing, McGraw Hill, 2005.
6. P N Rao, CAD/CAM Principles and Applications, TMH Publications, 2007.
CONTENTS
Chapter
Topic
Page no
UNIT I - COMPUTER AIDED DESIGN

1.1.
Concept of CAD
1.2.
CAD system - Hardware & Software.
1.3.
Features of CAD packages.
1.3.1.
Graphic Entities.
1.3.2.
Graphic Utilities.
1.3.3.
CAD Drawing Editing Commands.
1.3.4.
Graphic Transformations.
Geometric Modeling
1.4.1.
Wireframe Modeling
1.4.2.
Surface Modeling
10
1.4.3.
Solid Modeling
10
1.4.4.
Solid Modeling Vs Surface Modeling.
11
1.4.
1.5.
Advantages and Applications of CAD packages
12.
UNIT II - COMPONENTS OF CIM

2.1.
Concept or Technology of CIM.
14
2.2.
CIM System Hardware & Software
15
2.3.
CIM Wheel Elements.
16
2.4.
Computer Communication in CIM
17
2.5.
Communication Network in CIM.
17
Types of Communication Network in CIM.
18
2.6.
ISO / OSI model 7 layers of OSI model.
19
2.7.
LAN Components.
20
2.8.
LAN Topologies.
2.5.1.
20
UNIT III - GROUP TECHNOLOGY AND

COMPUTER AIDED PROCESS PLANNING
3.1.
Concept of Group Technology.
20
3.2.
Benefits of G.T. in CIM.
21
3.3.
Methods for Part Family.
22
3.4.
Cellular Manufacturing.
23
3.5.
Process Planning.
24
3.5.1.
Computer Aided Process Planning.
24
3.5.2.
Variant or Retrieval approach.
25
3.5.3.
Generative approach.
26
UNIT IV - SHOP FLOOR CONTROL AND

INTRODUCTION TO FMS
4.1.
Concept of SFC.
28
4.2.
Functions of SFC
29
4.2.
Functions of shop floor control SFC
29
4.3.
Factory Data Collection System
30
4.4.
Automatic identification methods
32
4.5.
Barcode Technology in automatic data collection system
33
4.6.
Flexible manufacturing system FMS
35
4.6.1.
Components of FMS systems;
35
4.6.2.
Benefits of FMS
36
4.6.3.
Types of FMS
37
UNIT V - COMPUTER AIDED PROCESS PLANNING AND

CONTROL AND COMPUTER MONITORING.
5.1.
Production Planning and control
39
5.2.
Inventory management in CIM
42
5.3.
Material requirements planning (MRP) in CIM
43
5.4.
Shop Floor Control.
46
5.5.
Agile and Lean manufacturing in CIM
48
5.6.
Direct digital control (DDC)
50
Question Bank.
52
ME 2402
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LTPC 3 0 03
UNIT I
9
Concept of CAD as drafting and designing facility, desirable features of CAD package,
drawing features in CAD Scaling, rotation, translation, editing, dimensioning, labeling,
Zoom, pan, redraw and regenerate, typical CAD command structure, wire frame modeling,
surface modeling and solid modeling (concepts only) in relation to popular CAD
packages.
UNIT II
COMPONENTS OF CIM
9
CIM as a concept and a technology, CASA/Sme model of CIM, CIM II, benefits of CIM,
communication matrix in CIM, fundamentals of computer communication in CIM CIM
data transmission methods seriel, parallel, asynchronous, synchronous, modulation,
demodulation, simplex and duplex. Types of communication in CIM point to point
(PTP), star and multiplexing. Computer networking in CIM the seven layer OSI model,
LAN model, MAP model, network topologies star, ring and bus, advantages of
networks in CIM
UNIT III GROUP TECHNOLOGY AND COMPUTER AIDED PROCESS
PLANNING
9
History Of Group Technology role of G.T in CAD/CAM Integration part familiesclassification and coding DCLASS and MCLASS and OPTIZ coding systems facility
design using G.T benefits of G.T cellular manufacturing.
Process planning - role of process planning in CAD/CAM Integration approaches to
computer aided process planning variant approach and generative approaches CAPP
and CMPP systems.
UNIT IV
SHOP FLOOR CONTROL AND INTRODUCTION TO FMS
9
shop floor control phases factory data collection system automatic identification
methods Bar code technology automated data collection system.
FMS components of FMS types FMS workstation material handling and storage
system FMS layout- computer control systems applications and benefits.
UNIT V
COMPUTER AIDED PLANNING AND CONTROL AND COMPUTER

MONITORING
9
Production planning and control cost planning and control inventory management
material requirements planning (MRP) shop floor
control. Lean and
Agile
Manufacturing. Types of production monitoring systems structure model of
manufacturing process control and strategies direct digital control.
TEXT BOOK:
TOTAL: 45 PERIODS
1. Mikell. P. Groover Automation, Production Systems and Computer Integrated

Manufacturing, Pearson Education 2001.
SCE 2015-16
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MECHANICAL ENGINEERING
SCE 2015-16 MECHANICAL ENGINEERING
ME 2402
UNIT I
Pre Requisite Discussions:
The 21st century business environment can be characterized by expanding global
competition and produce of increasing variety and lower demand.
CAD / CAM / CIM are considered as a key component strategy for manufacturing
enterprises to achieve this. During the last twenty years the CIM technology is undergone
considerable changes.
The CAD /CAM technology has become more sophisticated and seamless
integrations between different applications is no longer an issue. The intranet and wide web
can now help to achieve significant time compression in product developments.
Concept:
The display of the drawing or the geometric models of the component in CAD uses
the technology of computer graphics.
The techniques of raster technology scan conversion, clipping, removal of hidden
lines and hidden surfaces, coloring, and texture are briefly dealt in this unit.
1.1. Concept of CAD;
Computer-aided design (CAD) is the use of computer systems to assist in the
creation, modification, analysis, or optimization of a design. CAD software is used to
increase the productivity of the designer, improve the quality of design, improve
communications through documentation, and to create a database for manufacturing. CAD
output is often in the form of electronic files for print, machining, or other manufacturing
operations.
Computer-aided design is used in many fields. Its use in designing electronic systems
is known as Electronic Design Automation, or EDA. In mechanical design it is known as
Mechanical Design Automation (MDA) or computer-aided drafting (CAD), which
includes the process of creating a technical drawing with the use of computer software.
CAD software for mechanical design uses either vector-based graphics to depict the
objects of traditional drafting, or may also produce raster graphics showing the overall
appearance of designed objects. However, it involves more than just shapes. As in the
manual drafting of technical and engineering drawings, the output of CAD must convey
information, such as materials, processes, dimensions, and tolerances, according to
application-specific conventions. CAD may be used to design curves and figures in twodimensional (2D) space; or curves, surfaces, and solids in three-dimensional (3D) space.
Computer-aided manufacturing (CAM) is the use of computer software to control
machine tools and related machinery in the manufacturing of work pieces. This is not the
only definition for CAM, but it is the most common; CAM may also refer to the use of a
computer to assist in all operations of a manufacturing plant, including planning,
management, transportation and storage.
Its primary purpose is to create a faster production process and components and
tooling with more precise dimensions and material consistency, which in some cases, uses
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only the required amount of raw material (thus minimizing waste), while simultaneously
reducing energy consumption.
CAM is now a system used in schools and lower educational purposes. CAM is a
subsequent computer-aided process after computer-aided design (CAD) and sometimes
computer-aided engineering (CAE), as the model generated in CAD and verified in CAE can
be input into CAM software, which then controls the machine tool.
CAD, CAM and CIM ;
CAD/CAM involves the use of computers to make Design and Manufacturing more
profitable.
Parts of CIM use CAD/CAM techniques and products to try and make the factory
fully connected using computers.
The essential difference is CAD/CAM provides the tools, CIM is the philosophy
which is used when organizing the computers, programs, etc. and all the information
that flows between them. CIM focuses on connecting the various CAD/CAM
modules.
1.2. CAD system;

The cad system consists of two basic components; they are
Computer Hardware;
- It consists of graphic workstations,
- Graphic input devices like keyboard, mouse etc.,
- Graphic output devices like printer and plotters.
Computer Software;
- It consists of operating system for basic operations,
- Software package used for geometric modeling,
- Application software for design, analysis and synthesis.
Elements of CAD; (or) Various phases of CAD;
The design process in a CAD system consists of 4 stages / phases, they are;
Geometric modeling,
Design analysis and optimization,
Design review and evaluation,
Documentation and drafting.
1.3...Features of CAD Packages;
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operations.
Mechanical Design Automation (MDA) or computer-aided drafting (CAD), which includes
the process of creating a technical drawing with the use of computer software.
CAD may be used to design curves and figures in two-dimensional (2D) space; or
curves, surfaces, and solids in three-dimensional (3D) space.
CAD is an important industrial art extensively used in many applications, including
automotive, shipbuilding, and aerospace industries, industrial and architectural
design, prosthetics, and many more. CAD is also widely used to produce computer
animation for special effects in movies, advertising and technical manuals, often
called DCC digital content creation. The modern ubiquity and power of computers
means that even perfume bottles and shampoo dispensers are designed using
techniques unheard of by engineers of the 1960s. Because of its enormous economic
importance, CAD has been a major driving force for research in computational
geometry, computer graphics (both hardware and software), and discrete differential
geometry.
The design of geometric models for object shapes, in particular, is occasionally called
computer-aided geometric design (CAGD).
Computer-assisted surgery (CAS)
Computer-aided surgical simulation (CASS)
Computational fluid dynamics (CFD)
Component information system (CIS)
Computer-integrated manufacturing (CIM)
Computer Numerical Controlled (CNC)
1.3.1.. Drawing entities;

A drawing is created using a no. of entities. A large no. of options are
provided to draw the entities depending upon the requirements. Common entities are;
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Point,
Circle,
1.3.2. Drawing Utilities;
* Line,
*Polygon,
* Arc,
*Spline,
* Ellipse,
*Rectangle, etc.,
Drawing utilities include several functions to have the creation and storage of
drawings. Common utilities are;
*Screen size, * Line type,

*Grid,
*Snap,,
* Scaling
*Units, ,
* Layers,
*file utilities, etc.,
1.3.3.. Editing commands in CAD;

It is necessary to make the corrections and alterations to the entities of a
drawing. Editing commands are used for this process.
A few editing commands are listed below,
*Erase,
*Mirror
*Move,
*Rotate,
*Array,
*Trim,
*Fillet,
*Copy
* Chamfer
*Scale, etc.,
Various Edit and Inquiry commands in CAD;

Editing an entity or group of entities in Autocad requires the entity or the group to
be selected. There are three ways of doing this :
1) Autocad can be set to allow the user to select the objects first, and then accept commands
to process them. This is called noun/verb selection. This mode of operation can be
enabled/disabled using the DDSELECT command which opens up a dialogue box.
2) The commands can be given first, and the objects can be specified when the user is
prompted for them.
3) The SELECT command can be used to select a specific selection set, which can be
referred to in subsequent editing operations.
Editing with grips :
Selected objects can be edited by manipulating grips that appear on the selected entity. The
Grips mode can be enabled with the DDGRIPS command which opens up a dialogue box.
The editing operations possible using grips are :
Stretch, Move, Rotate, Scale and Mirror
1.
Erasing unwanted objects and retrieving accidentally removed ones :
The ERASE command permanently removes specified objects. To erase only the drawn
object, enter "L" at the 'select oblects' prompt.
2.
The OOPS command restores only the most recently erased objects.
3.
Copying and Moving :
The commands available are :
MOVE, COPY, ROTATE, SCALE, MIRROR, STRETCH and ARRAY
The MOVE and COPY commands are for recreating the object at another place.
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The COPY command retains a copy in the original place while the MOVE command does
not.
4.
The SCALE command allows the size of objects to be changed. It scales the
object about a reference point, by expanding/shrinking it equally in all directions.
SCALE can be used to rescale an entire drawing in one go.
5.
The ARRAY command creates multiple copies of entities in a rectangular or polar
pattern. To change the orientation of the array, use SNAP Rotate command or
SNAPANG system variable.
6.
Changes, Cuts and Constructions : These commands allow you to change
properties of objects (like color, layer,etc.) and modify objects by trimming
/extending their ends, and cutting sections out of them. They can also be used to
draw fillet arcs, chamfer lines, parallel lines, offset curves, and construction markers.
The available commands are :
CHANGE, DDEDIT, BREAK, TRIM, EXTEND, FILLET, CHAMFER, OFFSET, DIVIDE,
and MEASURE
The CHANGE command is used to change the following :
color, elevation, layer, linetype, thickness
Characteristics other than the above can also be changed by specifying a point
instead of choosing one of the above properties. Then this "change point" is used to modify
the object depending on whether the object is a line or a circle, etc. The "change point"
method works for multiple entities also.
Variations of the CHANGE command are : DDCHPROP and CHPROP
The DDEDIT command allows editing of both text and attribute definitions. The
command can be used either in paper space or in model space, whichever is active
when the command is issued. It cannot be used on text attributes that are part of a
block.
The BREAK command erases part of a line, trace, circle, arc or 2D polyline The
end points of the part are specified by the user.
The TRIM command is used to trim objects such that they end exactly at cutting
edges defined by other intersecting objects.
The EXTEND command is the complement of the TRIM command because it lets
you extend an object till it meets another object.
The FILLET command connects two lines, arcs or circles by means of a smoothly
fitted arc of specified radius.
The CHAMFER command is similar : it trims two intersecting lines a specified
distance from the intersection and connects the trimmed ends with a new line
segment.
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The OFFSET command constructs an entity parallel to the specified one, either
through a given point or at a given distance.
The DIVIDE command lets you divide an entity into several equal-length parts,
placing markers along the object at the dividing points.
The MEASURE command is similar to the DIVIDE command : it measures an
entity and places markers at specified intervals.
Polyline, Mesh, and Block Editing :

There are two basic commands for this : PEDIT and EXPLODE. PEDIT is used to edit 2D
and 3D polylines, and 3D polygon meshes.
The EXPLODE command breaks up a complex entity as follows :
A Block or associative Dimension is replaced with copies of simple entities comprising the
Block or Dimension. Polylines are replaced with simple and arcs; 3D polygon meshes with
3D faces and polyface meshes with 3D faces, lines and points.
Undoing commands :
U command : causes the most recent command to be undone.
REDO command : reverses the effect of the most recent U command.
UNDO command : can undo several commands simultaneously.
Inquiry commands are commands which allow the user to inquire into locations
and relationships into entities.
Inquiry commands available in Autocad are :
LIST : lists data for an entity.
DBLIST : lists data for every entity in the drawing.
ID : gives co-ordinates of a point specified in the graphics window.

DIST : measures angle and distance between
1.3.4. 2D transformations in CAD;
In computer graphics drawing are created by serious primitives which are
represented by the coordinates of their end points.
Certain changes in these drawings can be made by performing some
mathematical operations on these coordinates. The basic transformations are Scaling,
Rotation, translation, etc..,
1.4. Geometric modeling;

Geometric modeling involves the use of a CAD system to develop a mathematical
description of the geometry of an object. The mathematical description, called a geometric
model is contained in computer memory. These operations include creating new geometric
models from basic building blocks available in the system. Geometric modeling is a branch
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of applied mathematics and computational geometry that studies methods and algorithms for
the mathematical description of shapes.
The shapes studied in geometric modeling are mostly two- or three-dimensional,
although many of its tools and principles can be applied to sets of any finite dimension.
Today most geometric modeling is done with computers and for computer-based
applications. Two-dimensional models are important in computer typography and technical
drawing. Three-dimensional models are central to computer-aided design and manufacturing
(CAD/CAM), and widely used in many applied technical fields such as civil and mechanical
engineering, architecture, geology and medical image processing.
Geometric models are usually distinguished from procedural and object-oriented
models, which define the shape implicitly by an opaque algorithm that generates its
appearance. They are also contrasted with digital images and volumetric models which
represent the shape as a subset of a fine regular partition of space; and with fractal models
that give an infinitely recursive definition of the shape.
However, these distinctions are often blurred: for instance, a digital image can be
interpreted as a collection of colored squares; and geometric shapes such as circles are
defined by implicit mathematical equations. Also, a fractal model yields a parametric or
implicit model when its recursive definition is truncated to a finite depth.
Geometric modeling techniques;
These are various types of geometric models used in CAD,
Based on the dimensioning,

Two dimensional modeling,
Three dimensional modeling.
Based on the modeling,
Wire frame modeling,
Surface modeling,
Solid modeling.
2D Vs 3D;
2D models are best utilized for design problems, such as flat objects and
layouts of building.
3D models are capable of modeling an object in three dimensional according
to user instructions.
This is helpful in conceptualizing the object since in true 3D models can be
displayed in various views and form different angles.
1.4.1. Wire-frame modeling technique in CAD;
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A wire-frame model is a visual presentation of a three-dimensional (3D) or physical

object used in 3D computer graphics. It is created by specifying each edge of the physical
object where two mathematically continuous smooth surfaces meet, or by connecting an
object's constituent vertices using straight lines or curves. The object is projected onto a
display screen by drawing lines at the location of each edge. The term wire frame comes
from designers using metal wire to represent the three-dimensional shape of solid objects.
3D wire frame allows to construct and manipulate solids and solid surfaces. The 3D solid
modeling technique efficiently draws higher quality representations of solids than the
conventional line drawing.
Using a wire-frame model allows visualization of the underlying design structure of a
3D model. Traditional two-dimensional views and drawings can be created by appropriate
rotation of the object and selection of hidden line removal via cutting planes. Since wireframe renderings are relatively simple and fast to calculate, they are often used in cases
where a high screen frame rate is needed (for instance, when working with a particularly
complex 3D model, or in real-time systems that model exterior phenomena). When greater
graphical detail is desired, surface textures can be added automatically after completion of
the initial rendering of the wire frame. This allows the designer to quickly review Chan
solids or rotate the object to new desired views without long delays associated with more
realistic rendering.
The wire frame format is also well suited and widely used in programming tool paths
for direct numerical control (DNC) machine tools. Hand-drawn wire-frame-like illustrations
date back as far as the Italian Renaissance.[1] Wire-frame models were also used extensively
in video games to represent 3D objects during the 1980s and early 1990s when properly
filled 3D objects would have been too complex to calculate and draw with the computers of
the time. Wire-frame models are also used as the input for computer-aided manufacturing
(CAM). There are mainly three types of 3D CAD models. Wire frame is one of them and it
is the most abstract and least realistic. Other types of 3D CAD models are surface and solid.
This method of modeling consists of only lines, points and curves defining the edges of an
object.
Advantages of Wireframe Modeling;
Simple to construct,
Designer needs little training.
It needs less memory space,
It takes less manipulation time,
It is best suitable for manipulation as orthographic, isometric and perspective
views.
B-rep Boundry representation;
B-rep construction consists of entering all boundary edge for all surfaces.
This is similar or copying an engineering drawing into the computer, line by line,
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surface by surface, with one important qualification. The lines must be entered and
surfaces oriented in such a way that they create valid volumes.
CSG Constructive Solid Geometry;
CSG technique uses Boolean combinations or primitives solids to build a part.
The Boolean operations are addition (+), subtraction (-), as illustrated in three
dimensions.
1.4.2. Surface modeling
Surface modeling is defining an objects exterior with an infinitesimally thin skin.
This skin is created by lofts, sweeps, and NURBS curves - i.e. sculptured surfaces with lots
of curvature. The surfaces are either defined by poles or guide curves. A surface is
considered a solid only when it is completely enclosed. It is used to make technical surfaces
(e.g. air plane wing) or aesthetic surfaces (e.g. cars hood).
It was developed for the aerospace and automotive industries in the late 70s.
Rhinoceros 3D and Alias Studio Tools are examples of a surface modeling programs. It is
generally considered more difficult than solids modeling, but the models are more robust
because the programs arent generally feature based. Later changes have to modify the
existing geometry as opposed to just editing the original feature, which is more difficult but
keeps the model from collapsing when one feature interferes with another.
1.4.3. Solid modeling technique in CAD

Solid modeling (or modelling) is a consistent set of principles for mathematical and
computer modeling of three-dimensional solids. Solid modeling is distinguished from related
areas of geometric modeling and computer graphics by its emphasis on physical fidelity.[1]
Together, the principles of geometric and solid modeling form the foundation of computeraided design and in general support the creation, exchange, visualization, animation,
interrogation, and annotation of digital models of physical objects.
The use of solid modeling techniques allows for the automation of several difficult
engineering calculations that are carried out as a part of the design process. Simulation,
planning, and verification of processes such as machining and assembly were one of the
main catalysts for the development of solid modeling. More recently, the range of supported
manufacturing applications has been greatly expanded to include sheet metal manufacturing,
injection molding, welding, pipe routing etc.
Beyond traditional manufacturing, solid modeling techniques serve as the foundation
for rapid prototyping, digital data archival and reverse engineering by reconstructing solids
from sampled points on physical objects, mechanical analysis using finite elements, motion
planning and NC path verification, kinematic and dynamic analysis of mechanisms, and so
on.
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A central problem in all these applications is the ability to effectively represent and
manipulate three-dimensional geometry in a fashion that is consistent with the physical
behavior of real artifacts. Solid modeling research and development has effectively
addressed many of these issues, and continues to be a central focus of computer-aided
engineering.
Advantages of Solid Modeling;
It is complete and unambiguous.
Suitable for automated applications like creating part program without much
human involvement.
1.4.4. Solids vs. Surface Modeling;
Computer aided design (CAD) isnt like a car in that you can use it pretty well even
if you dont know how it works. It pays to know what happening under the hood when
using CAD. It is important to know about surface and solids modeling because it does affect
the way you model, and it is important to know if you are switching platforms. It is also very
important to know about for rapid prototyping.
Surfaces and solids are the underlying math that defines the geometry of the forms
you create. There are three ways to define 3D geometry: solids, surfaces and wireframes.
Wireframes dont play much of a role in CAD, but primarily in digital content creation
(DCC) and gaming. The easiest way to understand the difference between surface and solids
modeling is to think of a water balloon; the water in the balloon would be solids modeling,
while the latex skin would be surface modeling. Need more of an explanation? No problem.
Solids modeling;
Solids modeling is defining an object with geometric mass. Solids modeling
programs usually create models by creating a base solid and adding or subtracting from it
with subsequent features. Features such as extrudes, extrude cuts, revolves, radii, chamfers,
etc. Examples of solids modeling programs are Solid works, CATIA, and Pro Engineer. It
was originally developed for machine design, and is used heavily for engineering with large
part assemblies, digital testing and rapid prototyping.
Surface modeling;
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1.5. Advantages & Applications of CAD;
High productivity and reduced lead time,
Accuracy in design,
Better central over the complete project process,
Modifications in design relatively easy,
Simulations of the computer generated model can reduce or eliminate
prototype testing,
Effective creation of manufacturing documentation,
Optimized solution can be received,
Better communication and presentations.
Applications CAD software package;
Automated industries,
Manufacturing companies,
Aerospace designs,
Civil engineering plans and Electrical circuits, etc..,
Glossary;
Computer-aided design (CAD)

Auto cad by auto desk is one of the best professional design and drafting programs
on the markets.
IRON CAD 3D CAD software for foundries by nova cast.
Solid works powerful 3D CAD software for mechanical design. Simple windows
interfaces with unique drag and do capabilities help designers and engineers build
assemblies in record time.
Pro E - Highly rated 3D mechanical design suite which assists designers and
manufacturing engineering with product development across all industries.
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UNIT II
COMPONENTS OF CIM

Computer Integrated Manufacturing, known as CIM, is the phrase used to describe
the complete automation of a manufacturing plant, with all processes functioning under
computer control and digital information tying them together
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The heart of computer integrated manufacturing is CAD/CAM. Computer-aided

design (CAD) and computer-aided manufacturing (CAM) systems are essential to reducing
cycle times in the organization. CAD/CAM is a high technology integrating tool between
design and manufacturing. CAD techniques make use of group technology to create similar
geometries for quick retrieval.
CAD/CAM integrated systems provide design/drafting, planning and scheduling, and
fabrication capabilities. CAD provides the electronic part images, and CAM provides the
facility for tool path cutters to take on the raw piece.
CIM Concept Vs CIM Technology
CIM is both a concept and a technology.

For top management, CIM is a concept, a blueprint for success.
For middle managers and line managers, CIM is a technology
Concept or Technology
Some people view CIM as a concept, while others merely as a technology. It is
actually both. A good analogy of CIM is man, for what we mean by the word man
presupposes both the mind and the body. Similarly, CIM represents both the concept and the
technology. The concept leads to the technology which, in turn, broadens the concept.
The meaning and origin of CIM
The CIM will be used to mean the integration of business, engineering,
manufacturing and management information that spans company functions from marketing
to product distribution
2.1. CIM Definition;
CIM is the integration of the total manufacturing enterprise through the use of
integrated systems and data communication coupled with new managerial philosophies
that improve organizational and personnel efficiency.
Computer integrated manufacturing is defined as the effective use of computers to
design the products, plan the production ,control the operations and perform the various
business related functions needed in a manufacturing firm.
Objective of CIM;
The main aim of CIM is to use the advanced information processing
technology into all areas of manufacturing industry in order
To make the total process more productive and efficient;
increase product reliability;
Decrease the cost of production and maintenance relating to the
manufacturing system as well as to the product; and
Reduce the number of hazardous jobs and
Subsystems in computer-integrated manufacturing
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A computer-integrated manufacturing system is not the same as a "lights-out"

factory, which would run completely independent of human intervention, although it is a big
step in that direction. Part of the system involves flexible manufacturing, where the factory
can be quickly modified to produce different products, or where the volume of products can
be changed quickly with the aid of computers. Some or all of the following subsystems may
be found in a CIM operation:
2.2. CIM system Hardware & Software;
CIM Hardware consists of manufacturing equipments and Computer related

hard ware with the office equipment.
CIM Software consists of computer programs to carry out the various
functions and transfer the data from various areas of the industry.
Elements of CIM hardware;

Manufacturing equipment such as CNC machines, robots, DNC / FMS systems, work
holding and tool handling devices, Storage devices, sensors, shop floor data collection
devices, inspection machine etc.
Computers ,Controllers, CAD /CAM systems, workstations, data entry terminals, bar
code readers, printers ,plotters, modems, cables, connectors etc.
Elements of CIM software;
Automation;
MIS- management information system

Sales, marketing, finance
Data base 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
Work flow automation,
Business process engineering, Network management,
Automation may be defined as the process of having machines follow a

predetermined sequence of operations with little or no human labor, using specialized
equipment and devices that perform and control manufacturing processes.
Islands of automation;
The individually automated workstations or processes are called islands of
automation. In other words the term islands of automation represents the various
technologies that facilitate manufacturing automation in isolation, without having
integrated with other manufacturing technologies.
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Major elements of CIM systems;
Marketing,
Product design,
Planning,
Purchase,
Manufacturing engineering,
Factory automation hardware,
warehousing, finance, and
nformation management
2.3. CIM Wheel Components:
Distinct components of CIM wheel
Manufacturing / Human resource management

Marketing
Strategic planning
Finance
Product and process design and planning
Manufacturing planning and control
Factory automation
2.4. Computer communication in CIM;

Communication in the nervous systems of CIM and this is an integral part of CIM.
The development in communication / network engineering have made implement of
CIM easier that before.
Various needs of communication;
The information need for manufacturing in a company requires as follows.
Person-to-person, computer-to-computer, machine-to-machine, person to
computer or computer to person, person to machine or machine to person,
computer to machine or machine to computer
Fundamental needs of computer communications;
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Data: entities that convey meaning

Information: the content or interpretation of data
Signals: electric or electromagnetic encoding of data
Signaling: the act of propagating the signal along a medium
Transmission: propagating of data by processing of signals
Data Transmission Methods.
Serious & Parallel Communications.

Synchronous & Asynchronous methods.
Simplex & Duplex methods.
2.5. Communication Networks;

A communication network is the backbone of an enterprise integration. Networks
help to unify a company by linking together all the computerized devices irrespective of their
physical location.
Through networks the whole enterprise can be integrated, including suppliers and
customers. For example, sales and marketing can send customer requirements for new
products to design engineering.
A CAD generated bill of materials can then be transferred to material requirements
planning(MRP) systems. Product design information can be transmitted to manufacturing
for use in process planning.
There are wo main types of communication networks:
1) Telecommunication Networks;
2) Computer communication Networks.
Telecommunication network is mainly used for voice communication.Computer
communication network is a system of interconnected computers and other devices capable
exchanging information.
2.5.1.Types of Computer networks;
The computer networks can be classified into four categories depending upon
the physical separations of the communication devices.
Miniature - <50m
Small - <500m
Medium - <1km
Large - >1km - WAN & LAN.
Local Area Network;

Local Area Network is intended to serve a number of users who are
physically located close together.
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Wide Area Network;

Wide Area Network more like to telephone network, tying different people in
different buildings, cities or even countries.
Network Topologies.
There are several commonly used network topology or ways of routing the
interconnections. It classified as Star, Ring, Bus topologies.
2.6. Seven Layers of OSI model;
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The protocol layers are;
The physical layer
The data link layer
The network layer
The transport layer
The session layer
The presentation layer
The application layer
2.7. Components of LAN;

The various components of LAN are listed below;
Computers,
Network interface card,
Network cable,
Network server,
Central mass storage.
2.8. Network Topologies;

Star topology
Ring topology
Bus topology
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Tree topology
Star network communications
The star network consists of a central control station to which each of the individual
devices or user stations are connected. To send messages from one workstation to the other
is through the central station.
Ring network communication
In ring network communication the individual stations are connected in a continuous
ring .Each station has a neighboring station on either side. To communicate from one station
to other, the message must be relayed from station to station until it finally arrives at its
designated destination station.
Bus network communication
The bus network consists of a single main transmission line to which the individual
devices are attached. Any device or station can communicate with any other device in the
network by sending its message through the bus with the address of the desired recipient.
Glossary;

Computer-aided engineering (CAE)
Computer-aided industrial design (CAID)
Computer-aided manufacturing (CAM)
Computer-aided rule definition (CARD)
Computer-aided rule execution (CARE)
Computer-aided software engineering (CASE)
Automated Guided Vehicle (AGV)
Manufacturing Automation Protocol (MAP)
Flexible manufacturing module (FMM)
Flexible manufacturing cell (FMC)
Flexible manufacturing group (FMG)
Flexible fabrication-machining-assembly system (FFMAS)
Shop Floor Control (SFC).
UNIT III
GROUP TECHNOLOGY AND
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Group technology (GT) is a philosophy that implies the notion of recognizing and
exploiting similarities in three different ways:
1. By performing like activities together
2. By standardizing similar tasks
3. By efficiently storing and retrieving information about recurring problems
Large manufacturing system can be decomposed into smaller subsystems of part families
based on similarities in design attributes and manufacturing features.
Concept of Group technology;
Group technology is a manufacturing philosophy in which similar parts are
identified and grouped together to take the advantage of their similarities in manufacturing
and design. Similar parts are arranged in to part families.
Advantages of group technology
Product design benefits- 10 % reduction in the number of drawings
Tooling and setup benefits 69 % reduction of setup time.
Materials handling benefits
Production and inventory control benefits
-70 % reduction in production time
-62 % reduction in work in process inventories
-82 % reduction in overdue orders
Employee satisfaction
Process planning procedures
3.1. Group technology (GT);
Group technology (GT) is a manufacturing philosophy to increase production
efficiency by grouping a variety of parts having similarities of shape, dimension, and/or
process route.
Group technology is a manufacturing philosophy in which similar parts are identified
and grouped together to take the advantage of their similarities in manufacturing and design.
Part family;
A part family is a collection of parts which are similar either because of geometric
shape and size or because similar processing steps are required in their manufacture.
Design attributes:
Part configuration (round or prismatic)
Dimensional envelope (length to diameter ratio)
Surface integrity (surface roughness, dimensional tolerances)
Material type
Raw material state (casting, forging, bar stock, etc.)
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Manufacturing attributes:
Operations and operation sequences (turning, milling, etc.)
Batch sizes
Machine tools
Cutting tools
Work holding devices
Processing times
3.1. Benefits of Group Technology
Group technology, when successfully implemented, offers many benefits to industries.
GT benefits can be realized in a manufacturing organization in the following areas:
1. Production design
2. Tooling and setups
3. Materials handling
4. Production and inventory control
5. Process planning Management and employees.
1. Benefits in product Design
The main advantages of GT for product design come in cost and time savings,
because design engineers can quickly and easily search the database for parts that either
presently exist or can be used with slight modifications, rather than issuing new part
numbers.
A similar cost savings can be realized in the elimination of two or more identical parts
with different part numbers. Another advantage is the standardization of designs. Design
features such as corner radii, tolerances, chamfers, counter bores and surface finishes can be
standardized with GT.
2.Benefits in Tooling and Setups
In the area of tooling, group jigs and fixtures are designed to accommodate every
member of a part family. Also work holding devices are designed to use special adapters in
such a way that this general fixture can accept each part family member. Since setup times
are very short between parts in a family, a group layout can also result in dramatic reductions
in setup times.
3.Benefits in material handling:
GT facilitates a group layout of the shop. Since machines are arranged as cells, in a
group layout, the materials handling cost can be reduced by reducing travel and facilitating
increased automation.
4.Benefits in production and inventory Control
GT simplifies production and planning control. The complexity of the problem has
been reduced from a large portion of the shop to smaller groups of machines. The production
scheduling is simplified to a small number of parts through the machines in that cell.
5.Benefits in Process Planning
The concept of group technology parts classification and coding lead to an
automated process planning system. Grouping parts allows an examination of the various
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planning/route sheets for all members of a particular family. Once this has been
accomplished, the same basic plans can be applied to other members, thereby optimizing the
shop for the group.
6.Benefits to Management and Employees
It is understood that GT simplifies the environment of the manufacturing firm, which
provides significant benefit to management.
Simplification reduces the cumbersome paper work.
Simplification also improves the work environment.
In the GT work environment, the supervisor has in depth knowledge of the work
performed and better control.
3.3. General methods used for part families;
1. Visual inspection,
2. Parts classification and coding system, and
3. Production flow analysis.
Production Flow analysis;
Production Flow analysis (PFA) is a method for identifying part families and
associated machine groupings that uses the information contained on production route sheets
rather on part drawings.
Various steps of PFA
1. Data collection
2. Part sorting and routing
3. PFA chart
4. Analysis
Parts classification and coding system
1. system based on part design attributes
2. system based on manufacturing attributes
3. system based on design and manufacturing attributes
Code structures used in GT application;
Attribute codes (or polycodes or chain type structure).
Hierarchical codes (or monocodes or tree structure).
Decision-tree codes (or hybrid codes or mixed codes).
Coding systems;
Coding is the systematic process of establishing an alphanumeric value for parts on
selected part features. Classification is the grouping of parts based on code values. This
method is the most time consuming of the three methods, in parts classification and coding,
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similarities among parts are identified and these similarities are related in a coding system.
Three categories of part similarities can be distinguished 1. Design attributes which
are concerned with part characteristics such as, geometry, size and material, and 2.
Manufacturing attributes consider the processing steps required to make a part.3.system
based on both attributes.
There are three basic coding structures
1. Hierarchical codes (or monocodes)
2. Attributes codes (or polycodes)
3. Decision tree codes (or hybrid codes)
Coding systems
Through more than 100 coding systems are available, the following coding systems are
widely recognizes in industries
1. Opitz classification system
6. CUTPLAN system
2. DCLASS system
7. COFORM
3. CODE system
8. RNC system
4. MICLASS system
9. Part analog system
5.KK-3 system
10. Brish system.
3.4. Cellular manufacturing;
Cellular manufacturing (CM) is an application of group technology in which
dissimilar machines have been aggregated into cells, each of which is dedicated to the
production of a part family.
The machines in a multi station system with variable routing may be manually
operated, semi-automatic, or fully automated. When manually operated or semi automatic
the machine groups are often called machine cells, and the use of these cells in a factory is
called cellular manufacturing.
Design considerations guiding the cell-formation.;
Parts/products to be fully completed in the cell.
Higher operator utilization.
Fewer operations than equipment.
Balanced equipment utilization in the cell.
Types of cell design
1. Single machine cell
2. Group machine cell with manual handling
3. Group machine cell with semi-integrated handling
4. Flexible manufacturing system
Determining the best machine arrangement
Factors to be considered:
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Volume of work to be done by the cell
Variations in process routings of the parts

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Part size, shape, weight and other physical attributes
3.5. Process planning;

Process Planning is the systematic determination of the methods by which a product
is to be manufactured, economically and competitively.
Role of process planning
Interpretation of product design data
Selection of machining processes.
Selection of machine tools.
Determination of fixtures and datum surfaces.
Sequencing the operations.
Selection of inspection devices.
Determination of production tolerances.
Determination of the proper cutting conditions.
Calculation of the overall times.
Generation of process sheets including NC data.
Process planning techniques;
Manual approach
Computer aided process planning techniques
Retrieval type CAPP system (Variant type CAPP system)
Generative type CAPP system
3.5.1. Computer/Aided Process Planning;
CAPP refers to computer/aided process planning.
CAPP is used to overcome the drawbacks of manual process planning.
With the use of computers on the process planning one can reduce the routine clerical
work of manufacturing engineers.
Also it provides the opportunity to generate rational, consistent and optimal

plans.
Computer aided process planning system offers the potential for reducing the routine
clerical work of manufacturing engineers.
It provides the opportunity to generate routings which are rational, consistent and
perhaps even optimal.
Retrieval type CAPP (Variant type) systems;
For each part family a standard process plan is established and stored in computer
files and then it is retrieved for new work parts which belong to that family.
Because of the alterations that are made in the retrieved process plan, the CAPP
system is known as variant system.
Generative CAPP system;
Generative process planning involves the use of computer to create an individual
process plan automatically without human assistance.
The computer would employ a set of algorithms to progress through the various
technical and logical decisions toward a final plan.
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3.5.2. Variant or Retrieval approach;

A retrieval CAPP system, also called a variant CAPP system, has been widely used
in machining applications. The basic idea behind the retrieval CAPP is that similar parts will
have similar process plans.In this system., a process plan for a new part is created by
recalling., identifying and retrieving an existing plan for a similar part, and making the
necessary modifications for the new part.
In fact, the variant CAPP is a computer assisted extension of the manual approach.
The computer assists by providing an efficient system for data management, retrieval ,
editing and high speed printing of the process plans. The retrieval CAPP system has the
capacity to alter an existing process plan. Thats why it is also known as variant CAPP
system.
Procedure for using Retrieval CAPP system
A retrieval CAPP system is based on the principles of group technology (GT) and
parts classification and coding. In this system, for each part family a standard process plan
(i.e., route sheet) is prepared and stored in computer files. Through classification and coding,
a code number is generated. These codes are often used to identify the part family and the
associated standard plan. The standard plan is retrieval and edited for the new part.
Variant CAPP system procedure.
Step 1 :Define the coding scheme
Adopt existing coding or classification schemes to label parts for the purpose of
classification. In some extreme cases, a new coding scheme maybe developed.
Step 2 :Group the parts into part families
Group the part families using the coding scheme defined in Step 1. based on some
common part features. A standard plan is attached to each part family (see step 3) . Often, a
number of part types are associated with a family, thereby reducing the total number of
standard process plan.
Step 3: Develop a standard process plan for each part family based on the common features
of the part types. This process plan can be used for every part type within the family with
suitable modifications.
Step 4.: Retrieve and modify the standard plan:
When a new part enters the system, it is assigned to a part family based on the coding and
classification scheme. Then the corresponding standard process plan is retrieved and
modified to accommodate the unique features of the new part.
Advantages of Retrieval CAPP system:
Once a standard plan has been written, a variety of parts can be planned.
Comparatively simple programming and installation ( compare with generative
CAPP systems) is required to implement a planning system.
Efficient processing and evaluation of complicated activities and decisions, thus
reducing the time and labour requirements.
Standardized procedures by structuring manufacturing knowledge of the process
planners to companys needs.
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Lower development and hardware costs.

Draw backs of Retrieval CAPP system
The components to be planned are limited to similar components previously planned.
Maintaining consistency in editing is difficult.
Experienced process planners are still required to modify the standard plan for the
specific component.
3.5.3. Generative approach;
In the generative approach, an automatic computerized system is used to synthesize
or generate each individual process plan automatically and without reference to any prior
plan. The automatic computerized system normally consists of decision logic, formulas,
technology algorithms and geometry based data to uniquely determine the many processing
decisions required for generating process plans.
Unlike the retrieval CAPP no standard manufacturing plans are predefined or stored.
Instead, the computer automatically generates a unique operation/ route sheet whenever the
part is ordered. Thus the generative CAPP system automatically generates the process plan
based on decision logics and pre-coded algorithms. The computer stores the rules of
manufacturing and the equipment capabilities (not any group of process plans).
When using a system, a specific process plan for a specific part can be generated
without any involvement of a process planner. The human role in running the system
includes (i) inputting the GT code of the given part design, and (ii) monitoring the function.
Components of Generative CAPP system
The various components of a generative system are,
A part description, which identifies a series of component characteristics, including
geometric features, dimensions, tolerances and surface condition.
A subsystem to define the machining parameters for example using look up tables
and analytical results for cutting parameters.
A subsystem to select and sequence individual operations.
Decision logic is used to associate appropriate operations with feautures of a
component, and heuristics and algorithms are used to calculate operation steps, times
and sequences.
A database of available machines and tooling.
A report generator which prepares the process plan report.
Advantages of Generative CAPP
The generative CAPP has the following advantages:
It can generate consistent process plans rapidly.
New components can be planned as easily as existing components.
It has potential for integrating with an automated manufacturing facility to provide
detailed control information.
3.5.4. Networking methods with necessary sketches;
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Networking is a convenient technique for typing together the various islands of

automations and in the process makes integration possible through high speed data exchange
between different automated segments.
Networking of computers was initially adopted successfully by service sectors like
banking, air lines and train reservation etc..,
Communication networks can be classified in four ways depending upon the physical
separation of communicating devices.
1. Miniature (<50m) such networks are concerned with the interconnection of multiple
computational elements.
2. Small (<500m) these are concerned with the interconnection of multiple computational
units.
3. Medium (<1km) these are concerned with the interconnection of multiple computational
units. These are connected through a local area network or internet.
4. Large (>1km) large networks involve connection of remote mainframes, networking of
mini computer systems to a remote mainframe or terminals etc. it can be city wide or country
wide or world wide. With internet becoming more and more popular, the intranet internet
extranet technologies have found favor with manufacturing companies.
Network Wiring methods;
There are two basic ways by which three or more nodes can be incorporated in a
network. These are point to point and multi drop.
PC
PC
PC
PC
PC
PC
PC
PC
Point to point
Multi drop
UNIT IV
SHOP FLOOR CONTROL AND
INTRODUCTION TO FMS
Data is defined as the raw, unreduced information that is available on each
component of a CIM system like a personal computer, robot, workstation or a CNC machine.
A data may consist of numerical values, names, alphanumeric characters, codes and
instructions. Data structure is a diagrammatic representation of a data base. It shows the
record types used and the relationships between them. Data Base Management System
consists of a collection of interrelated data and a set of programs to access that data.
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4.1. Concept of Shop floor control;

The systems that accomplish the production planning, development of master
schedule, capacity planning and materials requirement planning is called shop floor control.
Shop floor control is defined as a method of controlling the work in process in the factory.
Shop floor control comprises the methods and systems used to prioritize, track, and
report against production orders and schedules. It includes the procedures used to evaluate
current resource status, labor, machine usage, and other information required to support the
overall planning, scheduling, and costing systems related to shop floor operation. Shop floor
control typically calculates work in process based on a percentage of completion for each
order and operation that is useful in inventory valuations and materials planning.
Shop floor control is responsible for the detailed management of activities and the
flow of materials inside the plant, including employees, materials, machines, and production
time. Shop floor control activity typically begins after planning (e.g., with MRP, ERP); once
planned, orders and purchase requisitions are created. Shop floor control attends to the
following functions (sequentially):
Planned orders
Conversion of planned orders to process/production
Production and process order scheduling
Capacity requirements planning
Material availability assessment
Release of production/process orders
Material withdrawals
Order confirmations
Goods receipt documentation
Order settlement
Shop floor control may also include identifying and assessing vulnerabilities and
risks due to the shop floor environment, employees, process, and the technologies employed
at the shop-floor level. Based on the assessment of these factors, shop floor control initiates
measures to keep risk at an acceptable minimum level.
Best practices for shop floor control include:
Efficiently execute, prioritize, and release work orders to the shop floor with realtime status of progress and completion.
Deliver accurate and up-to-date information on materials consumption and
availability, which is essential for reliable inventory planning and costing.
Effectively execute change management processes to ensure that the proper revision
of products, bills of materials, and processes are always in place for production.
Automate shop floor equipment control and data collection to reduce human errors
and increase productivity.
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Provide the correct manufacturing SOPs, technical drawings, and diagnostics to shop
floor operators to reinforce training and ensure proper processing.
Download setup programs directly to equipment based on product and process
specifications.
With fully interactive access to shop floor control software, supervisors can monitor shop
activities and make better decisions on the spot, especially using mobile computing
equipment.
Shop Floor Control are methods and systems used to prioritize, track, and report
against production orders and schedules. They include the procedures used to evaluate
current resource status, and the update of labor, machine hour, and other associated
information as required to support the overall planning, scheduling, and costing systems.
4.2. Functions of shop floor control SFC;
Priority control and assignment of shop orders

Maintain information on work in process for MRP.
Monitor shop order status information.
Provide production output data for capacity control processes.
Shop floor control

The three phases of shop floor control
1. Order release
2. Order scheduling
3. Order progress
Purpose of order release in SFC;
The purpose of order release module is to provide the necessary documentation that
accompanies an order as it processed through the shop. These documents collectively called
as shop packets.
Purpose of order scheduling in SFC;
The purpose of order scheduling is to make assignments of the orders to various
machines in the factory. Order scheduling satisfies the first function of SFC. i.e. Priority
control and assignment of work orders.
Function of order progress in SFC;
The order progress module performs the remaining three functions of SFC.
To provide data relative to work in process
Shop order status
Capacity control.
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Data structure:
Data structure is a diagrammatic representation of a data base. It shows the record
types used and the relationships between them. Data Base Management System consists of a
collection of interrelated data and a set of programs to access that data.
Functions of a Data Management system;
User functions:
Data vault and document management
Process and work flow management
Product structure management
Data classification and retrieval
Project management
Utility functions:
Data communication and notification
Data transport
Data translation
Image services
System administration.
4.3. Factory Data Collection System;
FDC system is used to collect data for monitoring order progress in SFC. The
following are important data collected by the FDC system.
Number of products (piece counts) completed at a certain machine.

Number of parts scrapped (or) Number of parts reworked.
Direct labor time spent
Equipment breakdown.
Purpose of data collection system;

The purpose of the data collection system in shop floor control is to provide basic
data for monitoring order progress.
In computerized SFC system the data are submitted to the order progress module for
analysis and generation of work order status reports and exception reports.
Types of data collection systems;
On-line data collection systems

Off-line data collection systems
Types of data collected from the shop floor;

Machine data,
Operator data,
Tooling data,
Data relating to jobs to be done,
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Materials data,
Materials handling data,
Scheduling data,
Process planning data, and
Inspection data.
Data collection techniques in shop floor control?
Job traveler
Employee time sheet
Operation tear strips or punched cards included with shop packet
Centralized shop floor terminals
Individual work centre terminals
Computer process monitoring (Computer assisted data collection systems);

Computer process monitoring is a data collection system in which the computer is
directly connected to the workstation and associated equipment for the purpose of observing
the operation.
Components used to build a computer process monitoring system
Transducers and sensors,
Analog to digital converters (ADC),
Multiplexers,
Real time clocks, and
Other electronic devices
Configurations of computer assisted data collection systems
Or (Automated data collection system)?
Data logging systems
Data acquisition systems
Multilevel scanning

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On-line versus batch systems
Data input techniques
Job traveler
Employee time sheets
Operation tear strips
Prepunched cards
Providing key board based terminals
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o One centralized terminal

o Satellite terminals
o Workstation terminals
Data acquisition system ( DAS );
The data acquisition system that collects data from the various production operations
for direct communication to a central computer. Hence it is called as online system.
4.4. Automatic identification methods;
Automatic identification is a term that refers to various technologies used in
automatic or semi automatic acquisition of product data for entry into a computer system.
Bar codes
Radio frequency systems
Magnetic stripe
Optical character recognition
Machine vision
Classifications of bar codes according to the dimensions of width

High density
Medium density
Low density
: X dimension is 0.010 in. or less.

: X dimension is between 0.010 and 0.030 in.
: X dimension is 0.030 in. or greater.
4.5. Barcode Technology in automatic data collection system;

A bar code (often seen as a single word, barcode) is the small image of lines (bars)
and spaces that is affixed to retail store items, identification cards, and postal mail to identify
a particular product number, person, or location. The code uses a sequence of vertical bars
and spaces to represent numbers and other symbols. A bar code symbol typically consists of
five parts: a quiet zone, a start character, data characters (including an optional check
character), a stop character, and another quiet zone.
barcode symbol
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A barcode is an optical machine-readable representation of data relating to the object

to which it is attached. Originally barcodes systematically represented data by varying the
widths and spacings of parallel lines, and may be referred to as linear or one-dimensional
(1D). Later they evolved into rectangles, dots, hexagons and other geometric patterns in two
dimensions (2D). Although 2D systems use a variety of symbols, they are generally referred
to as barcodes as well. Barcodes originally were scanned by special optical scanners called
barcode readers. Later, scanners and interpretive software became available on devices
including desktop printers and smartphones.
An early use of one type of barcode in an industrial context was sponsored by the
Association of American Railroads in the late 1960s. Developed by General Telephone and
Electronics (GTE) and called KarTrak ACI (Automatic Car Identification), this scheme
involved placing colored stripes in various combinations on steel plates which were affixed
to the sides of railroad rolling stock. Two plates were used per car, one on each side, with the
arrangement of the colored stripes representing things such as ownership, type of equipment,
and identification number. The plates were "read" by a trackside scanner located, for
instance, at the entrance to a classification yard while the car was moving past The project
was abandoned after about ten years because the system proved unreliable after long-term
use in the field.
Barcodes became commercially successful when they were used to automate supermarket
checkout systems, a task for which they have become almost universal. Their use has spread
to many other tasks that are generically referred to as automatic identification and data
capture (AIDC). The very first scanning of the now ubiquitous Universal Product Code
(UPC) barcode was on a pack of Wrigley Company chewing gum in June 1974.
Other systems have made inroads in the AIDC market, but the simplicity,
universality and low cost of barcodes has limited the role of these other systems until the
2000s (decade), over 40 years after the introduction of the commercial barcode, with the
introduction of technologies such as radio frequency identification, or RFID.
Barcode Reader
A barcode reader is used to read the code. The reader uses a laser beam that is
sensitive to the reflections from the line and space thickness and variation. The reader
translates the reflected light into digital data that is transferred to a computer for immediate
action or storage. Bar codes and readers are most often seen in supermarkets and retail
stores, but a large number of different uses have been found for them. They are also used to
take inventory in retail stores; to check out books from a library; to track manufacturing and
shipping movement; to sign in on a job; to identify hospital patients; and to tabulate the
results of direct mail marketing returns.
Very small bar codes have been used to tag honey bees used in research. Readers
may be attached to a computer (as they often are in retail store settings) or separate and
portable, in which case they store the data they read until it can be fed into a computer.
There is no one standard bar code; instead, there are several different bar code
standards called symbologies that serve different uses, industries, or geographic needs. Since
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1973, the Uniform Product Code (UPC), regulated by the Uniform Code Council, an
industry organization, has provided a standard bar code used by most retail stores. The
European Article Numbering system (EAN), developed by Joe Woodland, the inventor of
the first bar code system, allows for an extra pair of digits and is becoming widely used.
POSTNET is the standard bar code used in the United States for ZIP codes in bulk mailing.
The following table summarizes the most common bar code standards.
Barcode Scanning Technology
Scanning technology is constantly evolving and providing industries with more
choices in data capture solutions. Two competing data capture devices: the laser scanner and
the digital imager have many businesses facing a tough decision.
Deciding which scanning technology is right for your application can be a difficult
task. Knowing the advantages and applications in which these two technologies are used is
the first step to success.
The key to deciding between these two technologies is determining which fits the
requirements and budget of your business most accurately.
2D Data Matrix Code

Both laser scanners and digital images are programmed to decode specific
symbologies, or the language, of barcodes. The symbology used in the application can
help determine which scanning technology will provide the most benefit. The use of 2dimensional (2D) symbologies is on the rise in many markets, making digital imagers a
better choice. However, for applications that dont require reading 2D barcodes, laser
scanners are a cost-effective option.
Types of bar code readers;
Fixed beam reader,
Moving beam reader.
Smart cards
Smart cards are made of plastic.
They are of the size of a credit card and are embedded with one or more microchips.
These have a 8 bit or higher level microprocessors and a storage capacity of about 8kB256kB. Personal identification numbers prevent their unauthorized use.
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4.6. Flexible manufacturing system FMS;

A flexible manufacturing system consists of a group of processing stations,
interconnected by means of a automated material handling and storage systems, and
controlled by an integrated computer system.
FMS Flexibility:
The three capabilities that a manufacturing system must process in order to the flexible
1. The ability to identify and distinguish among the different incoming part or
product styles processed by the system.
2. Quick changeover of operating instructions.
3. Quick changeover of physical setup. Flexibility is an attribute that applies to both
manual and automated systems. In manual systems the human workers are often the
enables of the systems flexibility.
Types of flexibility;
The flexibility allows a mixed model manufacturing system to cope with level of
variation in part or product style without interruptions in production for changeover between
models. It is generally a desirable feature of a manufacturing system.
The feature of flexibility is broadly classified in to following ways

1. Machine flexibility
2. Part flexibility
3. Route flexibility
4. Volume flexibility
5. Man flexibility.
FMS technology is approaches to simultaneously manufacture different parts in the
shortest time possible, with the highest quality and at the lowest costs possible. To do this a
maximum of management of management information must be available for the FMS host to
work with. When this is achieved there are several types of flexibility available; to an FMS
user.
1. FMS user flexibility
2. FMS supplier flexibility.
The first area is that in which the FMS user is interested. This most important area.
The available flexibilities are provided for the FMS user to be able to satisfy the demands of
their customers.
The second type of flexibility concerns the method of applying FMSs.this is of
extreme interest to the FMS host supplier. Every FMS applications different, and no. of
FMS supplier can start from scratch to supply a FMS host solution every time for each new
FMS user. A suppliers solution need to be flexible enough to integrate the different machine
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types in to different FMS configurations and layouts for different product mixes.
4.6.1. Components of FMS systems;
Workstations
Material handling and storage
Computer control system
Human resources
1. Workstations
The first element in the FMS is work stations; it may,
Load/unload stations
Machining stations
Other processing stations
Assembly
2. Material handling and storage systems

For the belowmentioned functions are the material handling device
Random, independent movement of workparts between stations.
Handle a variety of workpart configurations.
Temporary storage.
Convenient access for loading and unloading workpartcontrol.s.
Compatible with computer
The material handling is classified in ot two types they are,
Primary material handling
Secondary material handling
The material handling function in a FMS is often shared between two systems:
1. Primary handling system - establishes the basic layout of the FMS and is
responsible for moving work parts between stations in the system.
2. Secondary handling system - consists of transfer devices, automatic pallet changers,
and similar mechanisms located at the workstations in the FMS.
3. Computer control system
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Workstation control
Distribution of control instructions to workstations
Production control
Traffic control
Shuttle control
Work piece monitoring
Tool control
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Performance monitoring and reporting
Diagnostics
4. Human resources
For loading and unloading the materials in the machines and for the
maintenance works the human resource are required in the flexible manufacturing
system.
4.6.2. Benefits of FMS
The various benefits are listed below,
Higher machine utilization

Reduced work in process
Lower manufacturing lead time
Greater flexibility in production scheduling.
4.6.3. Types of FMS;

FMS layout
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In-line layout
Loop layout
Ladder layout
Open field layout
Robot centered layout

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Glossary;
Production Planning and Control - PPC

Master Production Planning - MPP
Manufacturing Requirements Planning - MRP
Manufacturing Resource Planning - MRPII
Factory Data Collection - FDC
Flexible manufacturing module - (FMM)
Flexible manufacturing cell - (FMC)
Flexible manufacturing group - (FMG)
Flexible fabrication-machining FFM
Automated Guided Vehicle AGV.
UNIT V
COMPUTER AIDED PROCESS PLANNING AND

CONTROL AND COMPUTER MONITORING.
Demand for information and automation systems in manufacturing is soaring.
Systems in demand include programmable controls, robotic systems, supervisory controls,
data acquisition and information management systems. These systems deliver high-quality,
reliable and repeatable solutions to our customers, improving their processes. In our work
designing and implementing these systems, we have observed ten important emerging
trends:
5.1. Production Planning and control;

Production planning and control may be defined as the direction as the
direction and coordination of a firms material and physical facilities towards the
attainment of pre specified Production of goods, with production efficiency.
Production planning;
Deciding which products to make, how many of each, and when they should
be completed. Planning the manpower and equipment resources needed to accomplish
the production plan. Scheduling the production and delivery of the parts and products ;
Production control;
Production control is concerned with determining whether the necessary
resources to implement the production plan have been provided or not.
Activities of production control;
Shop floor control;

Inventory control;
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Manufacturing resource planning (MRP II); and

Just-in-time manufacturing systems.
The term production system may refer to:
In operations management and industrial engineering, a production system comprises

both the technological elements (machines and tools) and organizational behavior
(division of labor and information flow) needed to produce something.
In computer science, a production system (or production rule system) is a computer
program typically used to provide some form of artificial intelligence.
Toyota Production System, organizes manufacturing and logistics at Toyota
The Computer Animation Production System (CAPS) is a proprietary collection of
software, scanning camera systems, servers, networked computer workstations, and
custom desks developed by The Walt Disney Company together with Pixar in the
late-1980s.
Subsea Production Systems are typical wells located on the sea floor, shallow or deep
water.
Production control is the activity of monitoring and controlling any particular

production or operation. Production control is often run from a specific control room or
operations room
Role of Production Control in the Production Cycle.

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Basic Process Control Strategies

In a simple control system, a process variable (PV) is measured and compared with a
setpoint value (SP). A manipulated variable (MV, or output) signal is generated by the
controller and sent to a final control element, which then influences the process variable to
achieve stable control. The algorithm by which the controller develops its output signal is
typically PID (Proportional-Integral-Derivative), but other algorithms may be used as well:
This form of simple control may be improved upon and expanded for a greater range
of process applications by interconnecting multiple controllers and/or redirecting
measurement and control signals in more complex arrangements. An exploration of some of
the more common control system configurations is the subject of this chapter.
5.2. Inventory management in CIM

Definition - Inventory
Inventory management is primarily about specifying the size and placement of
stocked goods. Inventory management is required at different locations within a facility or
within multiple locations of a supply network to protect the regular and planned course of
production against the random disturbance of running out of materials or goods.
The lead time, carrying costs of inventory, asset management, inventory forecasting,
inventory valuation, inventory visibility, future inventory price forecasting, physical
inventory, available physical space for inventory, quality management, replenishment,
returns and defective goods and demand forecasting and also by replenishment Or can be
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defined scope of inventory management also concerns the fine lines between replenishment
as the left out stock of any item used in an organization. inventory is liabilities of a business.
The overseeing and controlling of the ordering, storage and use of components that a
company will use in the production of the items it will sell as well as the overseeing and
controlling of quantities of finished products for sale. A business's inventory is one of its
major assets and represents an investment that is tied up until the item is sold or used in the
production of an item that is sold. It also costs money to store, track and insure inventory.
Inventories that are mismanaged can create significant financial problems for a business,
whether the mismanagement results in an inventory glut or an inventory shortage.
Inventory or stock refers to the goods and materials include that a business holds for
the ultimate purpose of resale (or repair).
Inventory management is a science primarily about specifying the shape and percentage of
stocked goods. It is required at different locations within a facility or within many locations
of a supply network to precede the regular and planned course of production and stock of
materials.
The scope of inventory management concerns the fine lines between replenishment
lead time, carrying costs of inventory, asset management, inventory forecasting, inventory
valuation, inventory visibility, future inventory price forecasting, physical inventory,
available physical space for inventory, quality management, replenishment, returns and
defective goods, and demand forecasting. Balancing these competing requirements leads to
optimal inventory levels, which is an ongoing process as the business needs shift and react to
the wider environment.
Inventory management involves a retailer seeking to acquire and maintain a proper
merchandise assortment while ordering, shipping, handling, and related costs are kept in
check. It also involves systems and processes that identify inventory requirements, set
targets, provide replenishment techniques, report actual and projected inventory status and
handle all functions related to the tracking and management of material. This would include
the monitoring of material moved into and out of stockroom locations and the reconciling of
the inventory balances. It also may include ABC analysis, lot tracking, cycle counting
support, etc. Management of the inventories, with the primary objective of
determining/controlling stock levels within the physical distribution system, functions to
balance the need for product availability against the need for minimizing stock holding and
handling costs.
Definition - Inventory management
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The scope of inventory management also concerns the fine lines between
replenishment lead time, carrying costs of inventory, asset management, inventory
forecasting, inventory valuation, inventory visibility, future inventory price forecasting,
physical inventory, available physical space for inventory, quality management,
replenishment, returns and defective goods and demand forecasting and also by
replenishment Or can be defined as the left out stock of any item used in an organization.
inventory is liabilities of a business.
Inventory Control;
Inventory Control is the supervision of supply, storage and accessibility of items in
order to ensure an adequate supply without excessive oversupply.
It can also be referred as internal control - an accounting procedure or system
designed to promote efficiency or assure the implementation of a policy or safeguard assets
or avoid fraud and error etc.
Inventory control may refer to:
In economics, the inventory control problem, which aims to reduce overhead cost
without hurting sales.
In the field of loss prevention, systems designed to introduce technical barriers to
shoplifting
Inventory or stock refers to the goods and materials that a business holds for the
ultimate purpose of resale (or repair).
Inventory management is a science primarily about specifying the shape and
percentage of stocked goods. It is required at different locations within a facility or within
many locations of a supply network to precede the regular and planned course of production
and stock of materials.
5.3. Material requirements planning (MRP) in CIM;

It is a production planning, scheduling, and inventory control system used to manage
manufacturing processes. Most MRP systems are software-based, while it is possible to
conduct MRP by hand as well.
An MRP system is intended to simultaneously meet three objectives:
Ensure materials are available for production and products are available for delivery
to customers.
Maintain the lowest possible material and product levels in store
Plan manufacturing activities, delivery schedules and purchasing activities.
History Of MRP
Prior to MRP, and before computers dominated industry, Reorder point (ROP) /
reorder-quantity (ROQ) type methods like EOQ (Economic Order Quantity) had been used
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in manufacturing and inventory management. In 1964, as a response to the Toyota

Manufacturing Program, Joseph Orlicky developed Material Requirements Planning (MRP).
The first company to use MRP was Black & Decker in 1964, with Dick Alban as project
leader. Orlicky's book Material Requirements Planning has the subtitle The New Way of Life
in Production and Inventory Management (1975). By 1975, MRP was implemented in 700
companies. This number had grown to about 8,000 by 1981.
In 1983 Oliver Wight developed MRP into manufacturing resource planning (MRP
II). In the 1980s, Joe Orlicky's MRP evolved into Oliver Wight's manufacturing resource
planning (MRP II) which brings master scheduling, rough-cut capacity planning, capacity
requirements planning, S&OP in 1983 and other concepts to classical MRP. By 1989, about
one third of the software industry was MRP II software sold to American industry ($1.2
billion worth of software).[2]
[1]
Functions of MRP;
The basic functions of an MRP system include: inventory control, bill of material
processing, and elementary scheduling. MRP helps organizations to maintain low inventory
levels. It is used to plan manufacturing, purchasing and delivering activities.
"Manufacturing organizations, whatever their products, face the same daily practical
problem - that customers want products to be available in a shorter time than it takes to make
them. This means that some level of planning is required."
Companies need to control the types and quantities of materials they purchase, plan
which products are to be produced and in what quantities and ensure that they are able to
meet current and future customer demand, all at the lowest possible cost. Making a bad
decision in any of these areas will make the company lose money. A few examples are given
below:
If a company purchases insufficient quantities of an item used in manufacturing (or

the wrong item) it may be unable to meet contract obligations to supply products on
time.
If a company purchases excessive quantities of an item, money is wasted - the excess
quantity ties up cash while it remains as stock and may never even be used at all.
Beginning production of an order at the wrong time can cause customer deadlines to
be missed.
MRP is a tool to deal with these problems. It provides answers for several questions:
What items are required?

How many are required?
When are they required?.
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MRP can be applied both to items that are purchased from outside suppliers and to subassemblies, produced internally, that are components of more complex items.
MRP - Function of MRP;
It is a planning technique. It translates the master production schedule (MPS)
of end products into a detailed schedule for the raw materials and parts used in those end
products.
BOM;
The bill of materials (BOM) designates what itemsand how many of each are used to
make up a specified final product.
Benefits of MRP
The benefits of implementing MRP system are:
Reduced inventory levels.
Better Production scheduling
Reduced production lead time.
Better machine utilization.
Improved product quality.
Material requirements planning (MRP) is a production planning and inventory
control system used to manage manufacturing processes. Most MRP systems are softwarebased, while it is possible to conduct MRP by hand as well.
1. Ensure materials are available for production and products are available for delivery
to customers.
2. Maintain the lowest possible material and product levels in store
3. Plan manufacturing activities, delivery schedules and purchasing activities.
5.4. Shop Floor Control
Shop floor control is responsible for the detailed management of activities and the flow
of materials inside the plant, including employees, materials, machines, and production time.
Shop floor control activity typically begins after planning (e.g., with MRP, ERP); once
Planned orders
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Order confirmations
Order settlement
Shop floor control may also include identifying and assessing vulnerabilities and
risks due to the shop floor environment, employees, process, and the technologies employed
at the shop-floor level. Based on the assessment of these factors, shop floor control initiates
measures to keep risk at an acceptable minimum level.
specifications.
equipment.
5.5. Agile and Lean manufacturing in CIM

Agile manufacturing is a term applied to an organization that has created the
processes, tools, and training to enable it to respond quickly to customer needs and market
changes while still controlling costs and quality.
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An enabling factor in becoming an agile manufacturer has been the development of

manufacturing support technology that allows the marketers, the designers and the
production personnel to share a common database of parts and products, to share data on
production capacities and problems particularly where small initial problems may have
larger downstream effects.
It is a general proposition of manufacturing that the cost of correcting quality issues
increases as the problem moves downstream, so that it is cheaper to correct quality problems
at the earliest possible point in the process.
at the earliest possible point in the process.
Agile manufacturing is seen as the next step after Lean manufacturing in the
evolution of production methodology. The key difference between the two is like between a
thin and an athletic person, agile being the latter. One can be neither, one or both. In
manufacturing theory, being both is often referred to as leagile.
According to Martin Christopher, when companies have to decide what to be, they
have to look at the Customer Order Cycle (the time the customers are willing to wait) and
the leadtime for getting supplies. If the supplier has a short lead time, lean production is
possible. If the COC is short, agile production is beneficial.
Lean manufacturing or lean production, often simply "lean", is a systematic
method for the elimination of waste ("Muda") within a manufacturing process. Lean also
takes into account waste created through overburden ("Muri") and waste created through
unevenness in work loads ("Mura"). Working from the perspective of the client who
consumes a product or service, "value" is any action or process that a customer would be
willing to pay for.
Essentially, lean is centered on making obvious what adds value by reducing everything else.
Lean manufacturing is a management philosophy derived mostly from the Toyota
Production System (TPS) (hence the term Toyotism is also prevalent) and identified as
"lean" only in the 1990s TPS is renowned for its focus on reduction of the original Toyota
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seven wastes to improve overall customer value, but there are varying perspectives on how
this is best achieved. The steady growth of Toyota, from a small company to the world's
largest automaker, has focused attention on how it has achieved this success.
Agile manufacturing;
larger downstream effects. It is a general proposition of manufacturing that the cost of
correcting quality issues increases as the problem moves downstream, so that it is cheaper to
correct quality problems at the earliest possible point in the process.
Lean manufacturing ;
Lean manufacturing, Lean Enterprise, or lean production, often simply, "lean", is a
production philosophy that considers the expenditure of resources in any aspect other than
the direct creation of value for the end customer to be wasteful, and thus a target for
elimination. Working from the perspective of the client who consumes a product or service,
"value" is any action or process that a customer would be willing to pay for.
Direct digital control (DDC);
is the automated control of a condition or process by a digital device

(computer). DDC is considered by many to be a more modern, granular and responsive
update to older HVAC control systems based upon PLC technologies. In those older PLC
based systems, each zone was self-sufficient and contained all of the instrumentation and
control elements needed to consider analog and digital inputs and then take actions
according to rules. The complexity came from the desire to expand these 'zones' from a few
dozen points and a handful of controlled elements to much broader building-wide systems.
Connecting PLCs together becomes complex, and the creation of rules which would be
loaded individually into each PLC impractical.
DDC on the other hand takes a more centralized network-oriented approach. All
instrumentation is gathered by various analog and digital converters which use the network
to transport these signals to the central controller.
The centralized computer then follows all of its production rules (which may
incorporate sense points anywhere in the structure) and causes actions to be sent via the
same network to valves, actuators, and other HVAC components that can be adjusted.
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Central controllers and most terminal unit controllers are programmable, meaning the
direct digital control program code may be customized for the intended use. The program
features include time schedules, setpoints, controllers, logic, timers, trend logs, and alarms.
The unit controllers typically have analog and digital inputs, that allow measurement
of the variable (temperature, humidity, or pressure) and analog and digital outputs for control
of the medium (hot/cold water and/or steam). Digital inputs are typically (dry) contacts from
a control device, and analog inputs are typically a voltage or current measurement from a
variable (temperature, humidity, velocity, or pressure) sensing device.
Digital outputs are typically relay contacts used to start and stop equipment, and
analog outputs are typically voltage or current signals to control the movement of the
medium (air/water/steam) control devices. Usually abbreviated as "DDC".
It is the automated control of a condition or process by a digital device (computer).
A very early example of a DDC system meeting the above requirements was
completed by the Australian business Midac in 1981-1982 using R-Tec Australian designed
hardware.
Basically, lean manufacturing technique consists of four steps. First step is to realize
that there are wastes in the system to be removed. Although this seems like a crazy idea, this
is the step which creates the requirement for the movement towards lean manufacturing.
Many organizations do not realize that they have tons of hidden wastes with them. Therefore
they do not have the requirement to remove them from the system. So they will have their
problems forever and they will try to find solutions for these problems forever.
The End
ME2402 Computer Integrated Manufacturing

Question Bank
UNIT I COMPUTER AIDED DESIGN
Part - A (2 Marks)
1. Define CAD;
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Computer aided design can be defined as any design that involves the
effective use of computers to create, modify or document an engineering design.
2. CAD system;
The cad system consists of two basic components; they are;
Computer Hardware;
- It consists of graphic workstations,
- Graphic input devices like keyboard, mouse etc.,
- Graphic output devices like printer and plotters.
Computer Software;
- It consists of operating system for basic operations,
- Software package used for geometric modeling,
- Application software for design, analysis and synthesis.
3. Elements of CAD; (or) Various phases of CAD;

The design process in a CAD system consists of 4 stages / phases, they are;
Geometric modeling,
Design analysis and optimization,
Design review and evaluation,
Documentation and drafting.
4. Drawing entities;
A drawing is created using a no. of entities. A large no. of options are
provided to draw the entities depending upon the requirements.
Common entities are;
Point,
Circle,
* Line,
*Polygon,
* Arc,
*Spline,
* Ellipse,
*Rectangle, etc.,
5. Drawing Utilities;
Drawing utilities include several functions to have the creation and storage of
drawings. Common utilities are;
*Screen size, * Line type,
* Scaling
* Layers,
*Grid,
*Units, ,
*file utilities, etc.,
*Snap,,
6. Editing commands in CAD;
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It is necessary to make the corrections and alterations to the entities of a

drawing. Editing commands are used for this process.A few editing commands are
listed below,
*Erase,
*Move,
*Array,
*Fillet,
* Chamfer
*Mirror
*Rotate,
*Trim,
*Copy
*Scale, etc.,
7. Geometric modeling;
Geometric modeling involves the use of a CAD system to develop a
mathematical description of the geometry of an object.
The mathematical description, called a geometric model is contained in
computer memory. These operations include creating new geometric models from
basic building blocks available in the system.
8. Geometric modeling techniques;

These are various types of geometric models used in CAD,
Based on the dimensioning,

Two dimensional modeling,
Three dimensional modeling.
Based on the modeling,
Wire frame modeling,
Surface modeling,
Solid modeling.
9. 2D Vs 3D;
2D models are best utilized for design problems, such as flat objects and
layouts of building.
3D models are capable of modeling an object in three dimensional according
to user instructions.This is helpful in conceptualizing the object since in true 3D
models can be displayed in various views and form different angles.
10. Advantages of CAD;

High productivity and reduced lead time,
Accuracy in design,
Better central over the complete project process,
Modifications in design relatively easy,
Simulations of the computer generated model can reduce or
eliminate prototype testing,
Effective creation of manufacturing documentation,
Optimized solution can be received,
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11. Various 2D transformations;

In computer graphics drawing are created by serious primitives which are
represented by the coordinates of their end points.
Certain changes in these drawings can be made by performing some
mathematical operations on these coordinates. The basic transformations are Scaling,
Rotation, translation, etc..,
12. Applications CAD software package;
The CAD system is applied, wherever we need to draw, design, and any
facilities related to that.
Automated industries,
Manufacturing companies,
Aerospace designs,
Civil engineering plans,
Electrical circuits, etc..,
13. CAD software package;

Auto CAD, CATIA, Iron CAD, Pro-E, Turbo CAD, Solid Edge, etc..,
14. Advantages of Wireframe Modeling;
Simple to construct,
Designer needs little training.
It needs less memory space,
It takes less manipulation time,
It is best suitable for manipulation as orthographic, isometric and perspective
views.
15. B-rep Boundry representation;
B-rep construction consists of entering all boundary edge for all surfaces.
This is similar or copying an engineering drawing into the computer, line by line,
surface by surface, with one important qualification. The lines must be entered and
surfaces oriented in such a way that they create valid volumes.
16. CSG Constructive Solid Geometry;
CSG technique uses Boolean combinations or primitives solids to build a part.
The Boolean operations are addition (+), subtraction (-), as illustrated in three
dimensions.
17. Advantages of Solid Modeling;
It is complete and unambiguous.
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Suitable for automated applications like creating part program without much
human involvement.
Part - B (16 Marks)

1. Explain the Computer Aided Design in manufacturing?
operations.
Mechanical Design Automation (MDA) or computer-aided drafting (CAD), which includes
the process of creating a technical drawing with the use of computer software.
CAD may be used to design curves and figures in two-dimensional (2D) space; or
curves, surfaces, and solids in three-dimensional (3D) space.
CAD is an important industrial art extensively used in many applications, including
automotive, shipbuilding, and aerospace industries, industrial and architectural
design, prosthetics, and many more. CAD is also widely used to produce computer
animation for special effects in movies, advertising and technical manuals, often
called DCC digital content creation. The modern ubiquity and power of computers
means that even perfume bottles and shampoo dispensers are designed using
techniques unheard of by engineers of the 1960s. Because of its enormous economic
importance, CAD has been a major driving force for research in computational
geometry, computer graphics (both hardware and software), and discrete differential
geometry.
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The design of geometric models for object shapes, in particular, is occasionally called
computer-aided geometric design (CAGD).
Computer Numerical Controlled (CNC)
Electronic design automation (EDA)
2. Explain the Geometric modeling in CAD?

Geometric modeling is a branch of applied mathematics and computational geometry
that studies methods and algorithms for the mathematical description of shapes.
The shapes studied in geometric modeling are mostly two- or three-dimensional,
although many of its tools and principles can be applied to sets of any finite dimension.
Today most geometric modeling is done with computers and for computer-based
applications. Two-dimensional models are important in computer typography and technical
drawing. Three-dimensional models are central to computer-aided design and manufacturing
(CAD/CAM), and widely used in many applied technical fields such as civil and mechanical
engineering, architecture, geology and medical image processing.
Geometric models are usually distinguished from procedural and object-oriented
models, which define the shape implicitly by an opaque algorithm that generates its
appearance. They are also contrasted with digital images and volumetric models which
represent the shape as a subset of a fine regular partition of space; and with fractal models
that give an infinitely recursive definition of the shape.
However, these distinctions are often blurred: for instance, a digital image can be
interpreted as a collection of colored squares; and geometric shapes such as circles are
defined by implicit mathematical equations. Also, a fractal model yields a parametric or
implicit model when its recursive definition is truncated to a finite depth.
3. Explain the Solid modeling technique in CAD?
Solid modeling (or modelling) is a consistent set of principles for mathematical and
computer modeling of three-dimensional solids. Solid modeling is distinguished from related
areas of geometric modeling and computer graphics by its emphasis on physical fidelity.[1]
Together, the principles of geometric and solid modeling form the foundation of computeraided design and in general support the creation, exchange, visualization, animation,
interrogation, and annotation of digital models of physical objects.
The use of solid modeling techniques allows for the automation of several difficult
engineering calculations that are carried out as a part of the design process. Simulation,
planning, and verification of processes such as machining and assembly were one of the
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main catalysts for the development of solid modeling. More recently, the range of supported
manufacturing applications has been greatly expanded to include sheet metal manufacturing,
injection molding, welding, pipe routing etc.
Beyond traditional manufacturing, solid modeling techniques serve as the foundation
for rapid prototyping, digital data archival and reverse engineering by reconstructing solids
from sampled points on physical objects, mechanical analysis using finite elements, motion
planning and NC path verification, kinematic and dynamic analysis of mechanisms, and so
on. A central problem in all these applications is the ability to effectively represent and
manipulate three-dimensional geometry in a fashion that is consistent with the physical
behavior of real artifacts. Solid modeling research and development has effectively
addressed many of these issues, and continues to be a central focus of computer-aided
engineering.
4. Explain the Wire-frame modeling technique in CAD?
A wire-frame model is a visual presentation of a three-dimensional (3D) or physical

object used in 3D computer graphics. It is created by specifying each edge of the physical
object where two mathematically continuous smooth surfaces meet, or by connecting an
object's constituent vertices using straight lines or curves. The object is projected onto a
display screen by drawing lines at the location of each edge. The term wire frame comes
from designers using metal wire to represent the three-dimensional shape of solid objects.
3D wire frame allows to construct and manipulate solids and solid surfaces. The 3D solid
modeling technique efficiently draws higher quality representations of solids than the
conventional line drawing.
Using a wire-frame model allows visualization of the underlying design structure of a
3D model. Traditional two-dimensional views and drawings can be created by appropriate
rotation of the object and selection of hidden line removal via cutting planes.
Since wire-frame renderings are relatively simple and fast to calculate, they are often
used in cases where a high screen frame rate is needed (for instance, when working with a
particularly complex 3D model, or in real-time systems that model exterior phenomena).
When greater graphical detail is desired, surface textures can be added automatically after
completion of the initial rendering of the wire frame. This allows the designer to quickly
review chansolids or rotate the object to new desired views without long delays associated
with more realistic rendering.
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The wire frame format is also well suited and widely used in programming tool paths
for direct numerical control (DNC) machine tools.
Hand-drawn wire-frame-like illustrations date back as far as the Italian
Renaissance.[1] Wire-frame models were also used extensively in video games to represent
3D objects during the 1980s and early 1990s when properly filled 3D objects would have
been too complex to calculate and draw with the computers of the time. Wire-frame models
are also used as the input for computer-aided manufacturing (CAM).
There are mainly three types of 3D CAD models. Wire frame is one of them and it is
the most abstract and least realistic. Other types of 3D CAD models are surface and solid.
This method of modelling consists of only lines, points and curves defining the edges of an
object
5. Write the differences between the Solids vs. Surface Modeling? What and why you
need to know?
Computer aided design (CAD) isnt like a car in that you can use it pretty well even
if you dont know how it works. It pays to know what happening under the hood when
using CAD. It is important to know about surface and solids modeling because it does affect
the way you model, and it is important to know if you are switching platforms. It is also very
important to know about for rapid prototyping.
Surfaces and solids are the underlying math that defines the geometry of the forms
you create. There are three ways to define 3D geometry: solids, surfaces and wireframes.
Wireframes dont play much of a role in CAD, but primarily in digital content creation
(DCC) and gaming.
The easiest way to understand the difference between surface and solids modeling is
to think of a water balloon; the water in the balloon would be solids modeling, while the
latex skin would be surface modeling. Need more of an explanation? No problem.
Solids modeling
Solids modeling is defining an object with geometric mass. Solids modeling
programs usually create models by creating a base solid and adding or subtracting from it
with subsequent features. Features such as extrudes, extrude cuts, revolves, radii, chamfers,
etc.
Examples of solids modeling programs are Solidworks, CATIA, and ProEngineer. It
was originally developed for machine design, and is used heavily for engineering with large
part assemblies, digital testing and rapid prototyping.
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Surface modeling
6. Write the functions of various Edit and Inquiry commands in CAD?

Editing an entity or group of entities in Autocad requires the entity or the group to
be selected. There are three ways of doing this :
1) Autocad can be set to allow the user to select the objects first, and then accept commands
to process them. This is called noun/verb selection. This mode of operation can be
enabled/disabled using the DDSELECT command which opens up a dialogue box.
2) The commands can be given first, and the objects can be specified when the user is
prompted for them.
3) The SELECT command can be used to select a specific selection set, which can be
referred to in subsequent editing operations.
Editing with grips :
Selected objects can be edited by manipulating grips that appear on the selected entity. The
Grips mode can be enabled with the DDGRIPS command which opens up a dialogue box.
The editing operations possible using grips are :
Stretch, Move, Rotate, Scale and Mirror
7.
Erasing unwanted objects and retrieving accidentally removed ones :
The ERASE command permanently removes specified objects. To erase only the drawn
object, enter "L" at the 'select oblects' prompt.
8.
The OOPS command restores only the most recently erased objects.
9.
Copying and Moving :
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The commands available are :

MOVE, COPY, ROTATE, SCALE, MIRROR, STRETCH and ARRAY
The MOVE and COPY commands are for recreating the object at another place.
The COPY command retains a copy in the original place while the MOVE command does
not.
10.
The SCALE command allows the size of objects to be changed. It scales the
object about a reference point, by expanding/shrinking it equally in all directions.
SCALE can be used to rescale an entire drawing in one go.
11. The ARRAY command creates multiple copies of entities in a rectangular or polar
pattern. To change the orientation of the array, use SNAP Rotate command or
SNAPANG system variable.
12. Changes, Cuts and Constructions : These commands allow you to change
properties of objects (like color, layer,etc.) and modify objects by trimming
/extending their ends, and cutting sections out of them. They can also be used to
draw fillet arcs, chamfer lines, parallel lines, offset curves, and construction markers.
The available commands are :

CHANGE, DDEDIT, BREAK, TRIM, EXTEND, FILLET, CHAMFER, OFFSET, DIVIDE,
and MEASURE
The CHANGE command is used to change the following :
color, elevation, layer, linetype, thickness
Characteristics other than the above can also be changed by specifying a point
instead of choosing one of the above properties. Then this "change point" is used to modify
the object depending on whether the object is a line or a circle, etc. The "change point"
method works for multiple entities also.
Variations of the CHANGE command are : DDCHPROP and CHPROP
The DDEDIT command allows editing of both text and attribute definitions. The
command can be used either in paper space or in model space, whichever is active
when the command is issued. It cannot be used on text attributes that are part of a
block.
The BREAK command erases part of a line, trace, circle, arc or 2D polyline The
end points of the part are specified by the user.
The TRIM command is used to trim objects such that they end exactly at cutting
edges defined by other intersecting objects.
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The EXTEND command is the complement of the TRIM command because it lets
you extend an object till it meets another object.
The FILLET command connects two lines, arcs or circles by means of a smoothly
fitted arc of specified radius.
The CHAMFER command is similar : it trims two intersecting lines a specified
distance from the intersection and connects the trimmed ends with a new line
segment.
The OFFSET command constructs an entity parallel to the specified one, either
through a given point or at a given distance.
The DIVIDE command lets you divide an entity into several equal-length parts,
placing markers along the object at the dividing points.
The MEASURE command is similar to the DIVIDE command : it measures an
entity and places markers at specified intervals.
Polyline, Mesh, and Block Editing :

There are two basic commands for this : PEDIT and EXPLODE. PEDIT is used to edit 2D
and 3D polylines, and 3D polygon meshes.
The EXPLODE command breaks up a complex entity as follows :
A Block or associative Dimension is replaced with copies of simple entities comprising the
Block or Dimension. Polylines are replaced with simple and arcs; 3D polygon meshes with
3D faces and polyface meshes with 3D faces, lines and points.
Undoing commands :
U command : causes the most recent command to be undone.
REDO command : reverses the effect of the most recent U command.
UNDO command : can undo several commands simultaneously.
Inquiry commands are commands which allow the user to inquire into locations
and relationships into entities.
Inquiry commands available in Autocad are :
LIST : lists data for an entity.
DBLIST : lists data for every entity in the drawing.
ID : gives co-ordinates of a point specified in the graphics window.
DIST : measures angle and distance between two points.
AREA : finds are of specified enclosure.
UNIT II COMPONENTS OF CIM

Part - A (2 Marks)
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1. CIM
Computer-integrated manufacturing (CIM) is the manufacturing approach of using
computers to control the entire production process.
integrated systems and data communication coupled with new managerial philosophies
that improve organizational and personnel efficiency.
Computer integrated manufacturing is defined as the effective use of computers to
design the products, plan the production ,control the operations and perform the various
business related functions needed in a manufacturing firm.
2. What is the main objective of CIM?
The main aim of CIM is to use the advanced information processing
technology into all areas of manufacturing industry in order
To make the total process more productive and efficient;
increase product reliability;
Decrease the cost of production and maintenance relating to the
manufacturing system as well as to the product; and
Reduce the number of hazardous jobs and
3. Automation.
Automation may be defined as the process of having machines follow a
predetermined sequence of operations with little or no human labor, using specialized
equipment and devices that perform and control manufacturing processes.
4. Islands of automation
The individually automated workstations or processes are called islands of
automation. In other words the term islands of automation represents the various
technologies that facilitate manufacturing automation in isolation, without having
integrated with other manufacturing technologies.
5. Difference between CAD, CAM AND CIM

CAD/CAM involves the use of computers to make Design and Manufacturing more
profitable.
Parts of CIM use CAD/CAM techniques and products to try and make the factory
fully connected using computers.
The essential difference is CAD/CAM provides the tools, CIM is the philosophy
which is used when organizing the computers, programs, etc. and all the information
that flows between them.
CIM focuses on connecting the various CAD/CAM modules.
6. Computer-aided technologies
Computer-aided technologies (CAx) is a broad term that means the use of computer
technology to aid in the design, analysis, and manufacture of products.
Advanced CAx tools merge many different aspects of the product lifecycle
management (PLM), including design, finite element analysis (FEA), manufacturing,
production planning, product
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Computer-aided engineering (CAE)
Computer-aided industrial design (CAID)
Computer-aided manufacturing (CAM)
Computer-aided requirements capture (CAR)
Computer-aided rule definition (CARD)
Computer-aided rule execution (CARE)
Computer-aided software engineering (CASE)
7. CIM system Hardware & Software.

8. CIM Wheel or CIM Components:
Distinct components of CIM wheel

Manufacturing / Human resource management
Marketing
Strategic planning
Finance
Product and process design and planning
Manufacturing planning and control
Factory automation
9. Computer communication network in CIM

Communication in the nervous systems of CIM and this is an integral part of
CIM.
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The development in communication / network engineering have made

implement of CIM easier that before.
10. What are the various communication needs of CIM?

The information need for manufacturing in a company requires as follows.
Person-to-person, computer-to-computer, machine-to-machine, person to
computer or computer to person, person to machine or machine to person,
computer to machine or machine to computer
11. What are the fundamental needs of computer communications?
Data: entities that convey meaning
Information: the content or interpretation of data
Signals: electric or electromagnetic encoding of data
Signaling: the act of propagating the signal along a medium
Transmission: propagating of data by processing of signals
12. What are the nine major elements of CIM systems?
Marketing, Product design, Planning, Purchase, Manufacturing engineering,
Factory automation hardware, warehousing, finance, and Information management
13. Data Transmission Methods.
Serious & Parallel Communications.
Synchronous & Asynchronous methods.
Simplex & Duplex methods.
15. Types of Computer networks
The computer networks can be classified into four categories depending upon
the physical separations of the communication devices.
Miniature - <50m
Small - <500m
Medium - <1km
16. Local Area Network;

Local Area Network is intended to serve a number of users who are
physically located close together.
17. Wide Area Network;
18. Network Topologies.
19. Seven Layers of OSI model.
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1.
2.
3.
4.
5.
6.
7.
Physical layer,
Data link layer,
Network layer,
Transport layer,
Session layer,
Presentation layer,
Application layer.
20. Components of LAN;

The various components of LAN are listed below;
Computers,
Network interface card,
Network cable,
Network server,
Central mass storage.
21. Database
The data base can be defined as a collection data in a single location
defined to be used by different programmers for a variety of
applications.
The database of a company will include data required for various
departments like design, purchase, manufacturing technology,
personnel, marketing and sales, finance inventory etc.
22. Differentiate data and information.
The data refers to the value stored in the database and information to
the meaning as understood by the user.
23. Network Topologies.
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Reasons for having database for the company
Redundancy can be reduced
Inconsistency can be avoided
The data can be shared
Standards can be enforced
Security restrictions can be applied
Integrity can be maintained
Conflicting requirements can be balanced
Different types of design data related to CIM
Standards-national, international, trade or company standards
Material specifications and properties
Design theories and rules of thumb.
Data based on experience
Test results of products and proto types
Service feedback
Results of analysis of the product
Datas on competitors product.
Part - B ( 16 Marks)
1.
Explain the CIM system.
Computer-integrated manufacturing (CIM) is the manufacturing approach of using

computers to control the entire production process. This integration allows individual
processes to exchange information with each other and initiate actions. Through the
integration of computers, manufacturing can be faster and less error-prone, although the
main advantage is the ability to create automated manufacturing processes. Typically CIM
relies on closed-loop control processes, based on real-time input from sensors. It is also
known as flexible design and manufacturing.
A computer-integrated manufacturing system is not the same as a "lights-out"
factory, which would run completely independent of human intervention, although it is a big
step in that direction. Part of the system involves flexible manufacturing, where the factory
can be quickly modified to produce different products, or where the volume of products can
be changed quickly with the aid of computers. Some or all of the following subsystems may
be found in a CIM operation:
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Computer integrated manufacturing(CIM) is a broad term covering all technologies

and soft automation used to manage the resources for cost effective production of tangible
goods.
Integration capital, human, technology and equipment
CIM which orchestrates the factors of production and its management.
CIM is being projected as a panacea for Discrete manufacturing type of industry,
which produces 40% of all goods.
CIM is not applying computers to the design of the products of the company. That is
computer aided design (CAD)! It is not using them as tools for part and assembly analysis.
That is computer aided engineering (CAE)! It is not using computers to aid the development
of part programs to drive machine tools. That is computer aided manufacturing (CAM)!
It is not materials requirement planning (MRP) or just-in-time (JIT) or any other
method of developing the production schedule. It is not automated identification, data
collection, or data acquisition. It is not simulation or modeling of any materials handling or
robots or anything else like that. Taken by themselves, they are the application of computer
technology to the process of manufacturing. But taken by themselves they only crate the
islands of automation.
Definition of CIM:
It describes integrated applications of computers in manufacturing. A number of
observers have attempted to refine its meaning:
One needs to think of CIM as a computer system in which the peripherals, instead of
being printers, plotters, terminals and memory disks are robots, machine tools and other
processing equipment. It is a little noisier and a little messier, but its basically a computer
system.
CIM is a management philosophy, not a turnkey computer product. It is a philosophy
crucial to the survival of most manufacturers because it provides the levels of product design
and production control and shop flexibility to compete in future domestic and international
markets.
CIM is an opportunity for realigning your two most fundamental resources: people
and technology. CIM is a lot more than the integration of mechanical, electrical, and even
informational systems. Its an understanding of the new way to manage.
integrated systems and data communications coupled with new managerial philosophies that
improve organizational and personnel efficiency.
Concept or Technology
Some people view CIM as a concept, while others merely as a technology. It is
actually both. A good analogy of CIM is man, for what we mean by the word man
presupposes both the mind and the body. Similarly, CIM represents both the concept and the
technology. The concept leads to the technology which, in turn, broadens the concept.
The meaning and origin of CIM
The CIM will be used to mean the integration of business, engineering,
manufacturing and management information that spans company functions from marketing
to product distribution
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2.
Briefly Explain the CIM system?

The CIM system consists of Hardware & Software

Elements of CIM hardware;

Manufacturing equipment such as CNC machines, robots, DNC / FMS systems, work
holding and tool handling devices, Storage devices, sensors, shop floor data collection
devices, inspection machine etc.Computers ,Controllers, CAD /CAM systems,
workstations, data entry terminals, bar code readers, printers ,plotters, modems, cables,
connectors etc.
Elements of CIM software;
MIS- management information system
Sales, marketing, finance
Data base 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
Work flow automation,
Business process engineering, Network management
2. Explain the communication networks in CIM
Communication Networks;
A communication network is the backbone of an enterprise integration. Networks
help to unify a company by linking together all the computerized devices irrespective of their
physical location. Through networks the whole enterprise can be integrated, including
suppliers and customers.
For example, sales and marketing can send customer requirements for new products
to design engineering. A CAD generated bill of materials can then be transferred to material
requirements planning(MRP) systems. Product design information can be transmitted to
manufacturing for use in process planning.
There are wo main types of communication networks:
1) Telecommunication Networks;
2) Computer communication Networks.
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Telecommunication network is mainly used for voice communication. Computer

communication network is a system of interconnected computers and other devices capable
exchanging information.
Types of Computer networks;

The computer networks can be classified into four categories depending upon the
physical separations of the communication devices.
Miniature - <50m
Small - <500m
Medium - <1km
Local Area Network;
Local Area Network is intended to serve a number of users who are physically
located close together.
Wide Area Network;
Network Topologies.
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3. Explain the Seven Layers of OSI model?
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The physical layer

The data link layer
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The network layer

The transport layer
The session layer
The presentation layer
The application layer
4. Explain the various topologies in the communication in CIM?

Network Topologies;
Star topology
Ring topology
Bus topology
Tree topology
5. Explain the Basic Elements of Automation?

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Basic Elements of Automation;

An automation control system consist of three basic elements
1. Power to accomplish the process and operate the system
2. A program of instruction to direct the process
3. a control system to actuate the instructions.
The relationship amongst these elements is illustrated in below mentioned figure. All
the systems that quality as being automated includes these three basic elements in one form or
another.
Enterprise level
Manufacturing Support System
Quality Control
Systems
Manufacturing System
Automation and
Control technologies
Material Handling
Technologies
Manufacturing Processes and Assembly operations
automated system is used to operate some process, and power is required to drive the
process as well as the controls. The principal source of the power in automated system is
electrical power has many advantages in automated as well as no automated processes.
1) POWER FOR THE PROCESS
In production, the term process refers to the manufacturing operation that is
performed on a work unit. Most of the power in manufacturing plants is consumed by theses
kinds of operations. The "power form" indicated in the middle column of the table refers to
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the energy that is applied directly to the process. As indicated above, the power source for
each operation is often converted from electricity.
LOADING AND UNLOADING THE WORK UNIT:

Parts must be moved into the proper position and orientation for the process
to be performed, and power is required for this transport and placement function. at the
conclusion of the process, the work unit must similarly be removed. If the process is
completely automated, then some form of mechanized power is used. If the process is
manually operated or semi automated, then human power may be used to position and locate
the work unit.
MATERIAL TRANSPORT BETWEEN OPERATIONS:
In addition to loading and unloading at a given operation, the work unit must
be moved between operations.
2) POWER FOR AUTOMATION:
Above and beyond the basic power requirements for the manufacturing operation,
additional power is required for automation. The additional power is used for the following
functions:
CONTROLLER UNIT;
Modern industrial controllers are based on digital computers, which require electrical
power to read the program of instructions, make the control calculations, and execute the
instructions by transmitting the proper commands to the actuating devices.
POWER TO ACTUATE THE CONTROL SIGNALS;
The commands sent by the controller unit are carried out by means of
electromechanical devices, such as switches and motors called actuators. The commands are
generally transmitted by means of low-voltage control signals.
DATA ACQUISITION AND INFORMATION PROCESSING;
In most control systems, data must be collected from the process and used as
input to the control algorithms. In addition, a requirement of the process may include
keeping records of process performance or product quality. These data acquisition in modest
amounts.
\
2.) PROGRAM OF INSTRUCTIONS:The actions performed by an automated process are defined by a program of
instructions. Whether the manufacturing operation involves low, medium, or high
production. each part or product made in the operation requires one or more processing steps
that are unique to that part or product. These processing steps are performed during a work
cycle. A new part is completed during each work cycle. The particular processing steps for
the work cycle are specified in a work cycle program. Work cycle programs are called part
programs in numerical control
3) CONTROL SYSTEMS
The control element of the automated system executed the program of instructions,
the control system causes the process to accomplish is defined function, to carry out some
manufacturing operation. let us provide a brief introduction to control systems here.
The control systems in an automated system can be either closed loop or open loop. a
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closed loop control system, also known as feed back control system, is one in which the
output variables is compared with an input parameter, and any difference between the two is
used to drive the output into agreement with the input, as shown in below mentioned figure.
a closed loop control system consists of 6 basic elements.
Input parameter
Parameter
Controller
Output
Actuator
Process
Feed Back Sensor
7. Explain the advanced Automation function?

In addition to executing work cycle programs, an automated system may be capable
of executing advanced functions that are specific to a particular work unit. In general, the
functions are concerned with enhancing the safety and performance of the equipment.
Advanced automation functions include the following
(1) Safety monitoring,
(2) Maintenance and repair diagnostics, and
(3) Error detection and recovery.
automation functions are made possible by special subroutines included in the

program of instructions. In some cases, the functions provide information only and do not
involve any physical actions by the control systems, for example reporting a list of
preventive maintenance tasks that should be accomplished. Any actions taken on the basis of
this report are decided by the human operations and managers of the systems and not by the
system itself. In other cases, the program of instructions must be physically executed by the
control system using available actuators. A simple example of this case is a safety
monitoring system that sounds an alarm when a human worker gets dangerously close to the
automated equipment.
One of the significant reasons for automating a manufacturing operation is to remove
workers from a hazardous working environment. An automated system is often installed to
perform a potentially dangerous operation that would otherwise be accomplished manfully
by human workers. However, even in automated systems, workers are still needed to service
the system at periodic intervals if not full-time, accordingly, it is important that the
automated system be designed to operate safety when workers are in attendance. In addition,
it is essential that the automated system carry out it is process in a way that is not selfdestructive. Thus, there are two reasons for providing an automated system with a safety
monitoring capability:
(1) to product human workers in the vicinity of the system and
(2) to product the equipment associated with the system.
Safety monitoring means more than the conventional safety measures taken in a
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manufacturing operation, such a productive shield around the operation or the kinds of
manual devices that might be utilized by human workers such as emergency stop buttons.
Safety monitoring in an automated system involves the uses of sensors to track the systems
operation and identify conditions and events that are unsafe or potentially unsafe. The safety
monitoring system is programmed to respond to unsafe conditions in some appropriate way
.Possible responses to various hazards might include one more of the following:
1. completely stopping the automated system,
2. sounding an alarm
3. reducing the operating speed of the process,
4. Tacking corrective actions to recover from the safety violation.
This last response is the most sophisticated and is suggestive of an intelligent machine
performing some advanced strategy. This kind of response is applicable to a variety of
possible mishaps, not necessarily confined to safety issues, and is called error detection and
recovery
Sensors for safety monitoring range from very simple devices to highly sophisticated
systems. The following list suggests some of the possible sensors and their applications for
safety monitoring:
Limit switches to detect proper positioning of a part in a work holding devices so that
the processing cycle can begin.
Photoelectric sensors trigged by the interruption of a light beam; this could be used to
indicate that a part is in the proper positions or to detect the pressure of a human
intruder in the work cell.
Temperature sensors to indicate the metal work part is hot enough to proceed with
hot forging operations. if the work part is not sufficiently heated, then the metals
ductility might be too low, and the forging dies might be damaged during the
operations.
UNIT III GROUP TECHNOLOGY AND
Part - A (2 Marks)
1. Group technology (GT)
process route.
2. Part family
Design attributes:
Material type & Raw material state (casting, forging, bar stock, etc.)
Part manufacturing features:
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Batch sizes
Machine tools
Cutting tools
Processing times
3. General methods used for part families.

4. Production Flow analysis
Production Flow analysis (PFA) is a method for identifying part families and
associated machine groupings that uses the information contained on production route sheets
rather on part drawings.
5. Code structures used in GT application
Attribute codes (or polycodes or chain type structure).
Hierarchical codes (or monocodes or tree structure).
Decision-tree codes (or hybrid codes or mixed codes).
6. Coding systems.
1. Opitz classification system,
2. MICLASS system,
3. DCLASS system,
4. CODE system,
5. KK-3 system,and
6. CUTPLAN system.
7. Benefits of Group Technology
Group technology is a management strategy to help eliminate waste caused by
duplication of effort.
It affects all areas of a company, including:
Engineering
Equipment specification
Facilities planning
Process planning
Production control
Quality control
Tool design
Purchasing
Service
7. Cellular manufacturing
production of a part family.
8. Design considerations guiding the cell-formation.
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9. Process planning
10. Computer/Aided Process Planning
With the use of computers on the process planning one can reduce the routine
Also it provides the opportunity to generate rational, consistent and optimal

plans.
11. Process planning techniques used in the modern manufacturing technologies
Manual approach

12. CAPP;
clerical work of manufacturing engineers. It provides the opportunity to generate routings
which are rational, consistent and perhaps even optimal.
13. Retrieval type CAPP (Variant type) systems
files and then it is retrieved for new work parts which belong to that family. Because of the
alterations that are made in the retrieved process plan, the CAPP system is known as variant
system.
14. Generative CAPP system
process plan automatically without human assistance. The computer would employ a set of
algorithms to progress through the various technical and logical decisions toward a final
plan.
15. Role of process planning

1. Interpretation of product design data
2. Selection of machining processes.
3. Selection of machine tools.
4. Determination of fixtures and datum surfaces.
5. Sequencing the operations.
6. Selection of inspection devices.
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1. Explain the various benefits of GT?

Group technology is a manufacturing philosophy in which similar parts are
identified and grouped together to take the advantage of their similarities in manufacturing
and design. Similar parts are arranged in to part families.
Advantages of group technology
Product design benefits- 10 % reduction in the number of drawings
Tooling and setup benefits 69 % reduction of setup time.
Materials handling benefits
Production and inventory control benefits
-70 % reduction in production time
-62 % reduction in work in process inventories
-82 % reduction in overdue orders
Employee satisfaction
Process planning procedures
Group technology (GT);
process route.
Part family;
Design attributes:
Material type
Raw material state (casting, forging, bar stock, etc.)
Manufacturing attributes:
Batch sizes
Machine tools
Cutting tools
Processing times.
General methods used for part families;

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2. List out the Benefits of Group Technology?

Group technology, when successfully implemented, offers many benefits to industries.
GT benefits can be realized in a manufacturing organization in the following areas:
6. Production design
7. Tooling and setups
8. Materials handling
9. Production and inventory control
10. Process planning Management and employees.
1. Benefits in product Design
The main advantages of GT for product design come in cost and time savings,
because design engineers can quickly and easily search the database for parts that either
presently exist or can be used with slight modifications, rather than issuing new part
numbers.
A similar cost savings can be realized in the elimination of two or more identical parts
with different part numbers. Another advantage is the standardization of designs. Design
features such as corner radii, tolerances, chamfers, counter bores and surface finishes can be
standardized with GT.
2.Benefits in Tooling and Setups
In the area of tooling, group jigs and fixtures are designed to accommodate every
member of a part family. Also work holding devices are designed to use special adapters in
such a way that this general fixture can accept each part family member. Since setup times
are very short between parts in a family, a group layout can also result in dramatic reductions
in setup times.
3.Benefits in material handling:
GT facilitates a group layout of the shop. Since machines are arranged as cells, in a
group layout, the materials handling cost can be reduced by reducing travel and facilitating
increased automation.
4.Benefits in production and inventory Control
GT simplifies production and planning control. The complexity of the problem has
been reduced from a large portion of the shop to smaller groups of machines. The production
scheduling is simplified to a small number of parts through the machines in that cell.
5.Benefits in Process Planning
The concept of group technology parts classification and coding lead to an
automated process planning system. Grouping parts allows an examination of the various
planning/route sheets for all members of a particular family. Once this has been
accomplished, the same basic plans can be applied to other members, thereby optimizing the
shop for the group.
6.Benefits to Management and Employees
It is understood that GT simplifies the environment of the manufacturing firm, which
provides significant benefit to management.
Simplification reduces the cumbersome paper work.
Simplification also improves the work environment.
In the GT work environment, the supervisor has in depth knowledge of the work
performed and better control.
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3. Explain the Cellular manufacturing in CIM?

production of a part family. The machines in a multi station system with variable routing
may be manually operated, semi-automatic, or fully automated. When manually operated or
semi automatic the machine groups are often called machine cells, and the use of these cells
in a factory is called cellular manufacturing.
Design considerations guiding the cell-formation.;
Types of cell design
5. Single machine cell
6. Group machine cell with manual handling
7. Group machine cell with semi-integrated handling
8. Flexible manufacturing system
9. Explain the Computer Aided Process planning in CIM?
Role of process planning
1. Interpretation of product design data
2. Selection of machining processes.
3. Selection of machine tools.
4. Determination of fixtures and datum surfaces.
5. Sequencing the operations.
6. Selection of inspection devices.
7. Determination of production tolerances.
8. Determination of the proper cutting conditions.
9. Calculation of the overall times.
10. Generation of process sheets including NC data.
Process planning techniques;
Manual approach
Computer/Aided Process Planning;
With the use of computers on the process planning one can reduce the routine
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Also it provides the opportunity to generate rational, consistent and

optimal plans.
CAPP;
clerical work of manufacturing engineers. It provides the opportunity to generate routings
which are rational, consistent and perhaps even optimal.
Retrieval type CAPP (Variant type) systems;
files and then it is retrieved for new work parts which belong to that family. Because of the
alterations that are made in the retrieved process plan, the CAPP system is known as variant
system.
Generative CAPP system;
process plan automatically without human assistance.The computer would employ a set of
algorithms to progress through the various technical and logical decisions toward a final
plan.
10. Explain in detail the Generative and Variant approaches in process planning
and differentiate both approaches?
Generative approaches in Computer aided manufacturing process planning;
In the generative approach, an automatic computerized system is used to synthesize
or generate each individual process plan automatically and without reference to any prior
plan. The automatic computerized system normally consists of decision logic, formulas,
technology algorithms and geometry based data to uniquely determine the many processing
decisions required for generating process plans.
Unlike the retrieval CAPP no standard manufacturing plans are predefined or stored.
Instead, the computer automatically generates a unique operation/ route sheet whenever the
part is ordered.
Thus the generative CAPP system automatically generates the process plan based on
decision logics and pre-coded algorithms. The computer stores the rules of manufacturing
and the equipment capabilities (not any group of process plans).
When using a system, a specific process plan for a specific part can be generated
without any involvement of a process planner. The human role in running the system
includes
(i) inputting the GT code of the given part design, and (ii) monitoring the function.
Components of Generative CAPP system
The various components of a generative system are,
A part description, which identifies a series of component characteristics, including
geometric features, dimensions, tolerances and surface condition.
A subsystem to define the machining parameters for example using look up tables
and analytical results for cutting parameters.
A subsystem to select and sequence individual operations.
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Decision logic is used to associate appropriate operations with feautures of a

component, and heuristics and algorithms are used to calculate operation steps, times
and sequences.
A database of available machines and tooling.
A report generator which prepares the process plan report.
Advantages of Generative CAPP

The generative CAPP has the following advantages:
It can generate consistent process plans rapidly.
New components can be planned as easily as existing components.
It has potential for integrating with an automated manufacturing facility to provide
detailed control information.
Variant or Retrieval approaches in Computer aided manufacturing process planning;
A retrieval CAPP system, also called a variant CAPP system, has been widely used
in machining applications. The basic idea behind the retrieval CAPP is that similar parts will
have similar process plans.
In this system., a process plan for a new part is created by recalling., identifying and
retrieving an existing plan for a similar part, and making the necessary modifications for the
new part.
In fact, the variant CAPP is a computer assisted extension of the manual approach.
The computer assists by providing an efficient system for data management, retrieval ,
editing and high speed printing of the process plans. The retrieval CAPP system has the
capacity to alter an existing process plan. Thats why it is also known as variant CAPP
system.
Procedure for using Retrieval CAPP system
A retrieval CAPP system is based on the principles of group technology (GT) and
parts classification and coding. In this system, for each part family a standard process plan
(i.e., route sheet) is prepared and stored in computer files. Through classification and coding,
a code number is generated. These codes are often used to identify the part family and the
associated standard plan. The standard plan is retrieval and edited for the new part.
Variant CAPP system procedure.
Step 1 :Define the coding scheme
Adopt existing coding or classification schemes to label parts for the purpose of
classification. In some extreme cases, a new coding scheme maybe developed.
Step 2 :Group the parts into part families
Group the part families using the coding scheme defined in Step 1. based on some
common part features. A standard plan is attached to each part family (see step 3) . Often, a
number of part types are associated with a family, thereby reducing the total number of
standard process plan.
Step 3: Develop a standard process plan for each part family based on the common features
of the part types. This process plan can be used for every part type within the family with
suitable modifications.
Step 4.: Retrieve and modify the standard plan:
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When a new part enters the system, it is assigned to a part family based on the coding and
classification scheme. Then the corresponding standard process plan is retrieved and
modified to accommodate the unique features of the new part.
Advantages of Retrieval CAPP system:
Once a standard plan has been written, a variety of parts can be planned.
Comparatively simple programming and installation ( compare with generative
CAPP systems) is required to implement a planning system.
Efficient processing and evaluation of complicated activities and decisions, thus
reducing the time and labour requirements.
Standardized procedures by structuring manufacturing knowledge of the process
planners to companys needs.
Lower development and hardware costs.

Shorter development times.
The system is understandable, and the planner has control of the final plan.
It is easy to learn and easy to use.
Draw backs of Retrieval CAPP system
The components to be planned are limited to similar components previously planned.
Maintaining consistency in editing is difficult.
Experienced process planners are still required to modify the standard plan for the
specific component.
7. How parts are classified and coded in Group Technology? Illustrate the same for a
product.
Coding is the systematic process of establishing an alphanumeric value for parts on
selected part features. Classification is the grouping of parts based on code values. This
method is the most time consuming of the three methods, in parts classification and coding,
similarities among parts are identified and these similarities are related in a coding system.
Three categories of part similarities can be distinguished 1. Design attributes which
are concerned with part characteristics such as, geometry, size and material, and 2.
Manufacturing attributes consider the processing steps required to make a part.3.system
based on both attributes.
There are three basic coding structures
1. Hierarchical codes (or monocodes)
2. Attributes codes (or polycodes)
3. Decision tree codes (or hybrid codes)
Coding systems
Through more than 100 coding systems are available, the following coding systems are
widely recognizes in industries
1. Opitz classification system
6. CUTPLAN system
2. DCLASS system
7. COFORM
3. CODE system
8. RNC system
4. MICLASS system
9. Part analog system
5.KK-3 system
10. Brish system.
8.Explain in detail various Networking methods with necessary sketches?
Networking is a convenient technique for typing together the various islands of
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automations and in the process makes integration possible through high speed data exchange
between different automated segments.
Networking of computers was initially adopted successfully by service sectors like
banking, air lines and train reservation etc..,
Communication networks can be classified in four ways depending upon the physical
separation of communicating devices.
1. Miniature (<50m) such networks are concerned with the interconnection of multiple
computational elements.
2. Small (<500m) these are concerned with the interconnection of multiple computational
units.
3. Medium (<1km) these are concerned with the interconnection of multiple computational
units. These are connected through a local area network or internet.
4. Large (>1km) large networks involve connection of remote mainframes, networking of
mini computer systems to a remote mainframe or terminals etc. it can be city wide or country
wide or world wide. With internet becoming more and more popular, the intranet internet
extranet technologies have found favor with manufacturing companies.
Network Wiring methods;
There are two basic ways by which three or more nodes can be incorporated in a
network. These are point to point and multi drop.
PC
PC
PC
PC
PC
PC
PC
Point to point
Multi drop
PC
Network Topologies
There are several commonly used networks topologies or ways of routing the
interconnections
1. Star networks
2. Ring network
3. Bus network
4. Hybrid network.
1. Star network
PC
PC
PC
2.Ring network
PC
PC
PC
PC
PC
PC
3. Bus Network
PC
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PC
4. Hybrid network.
PC
PC
PC
PC
PC
PC
PC
PC
UNIT IV SHOP FLOOR CONTROL

AND INTRODUCTION TO FMS
Part - A (2 Marks)
1. Shop floor control.
schedule, capacity planning and materials requirement planning is called shop floor
control.
Shop floor control is defined as a method of controlling the work in process in the
factory.
2. Functions of shop floor control SFC;
3. Modules of SFC system;
Order release
Order scheduling
Order progress
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accompanies an order as it processed through the shop. These documents collectively
called as shop packets.
The order progress module performs the remaining three functions of
SFC.
Shop order status
Capacity control
4. Functions of a Data Management system;

User functions:
Project management
Utility functions:

Data transport
Data translation
Image services
System administration
5. Factory Data Collection System;


6. Purpose of data collection system;

The purpose of the data collection system in shop floor control is to provide
basic data for monitoring order progress.
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In computerized SFC system the data are submitted to the order progress
module for analysis and generation of work order status reports and exception
reports.
7. Types of data collected from the shop floor;
Machine data,
Operator data,
Tooling data,
Materials data,
Scheduling data,
Inspection data.
8. Data collection techniques in shop floor control;
Job traveler
Employee time sheet
9. Computer process monitoring (Computer assisted data collection systems)
Computer process monitoring is a data collection system in which the
computer is directly connected to the workstation and associated equipment for the
purpose of observing the operation.
10. Components used to build a computer process monitoring system
Multiplexers,
11. Configurations of computer assisted data collection systems
Multilevel scanning
12. Types of data collection systems
13. Data acquisition system ( DAS )
The data acquisition system that collects data from the various production
operations for direct communication to a central computer. Hence it is called as
online system.
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14. Automatic identification methods.

automatic or semi automatic acquisition of product data for entry into a computer
system.
15. Technologies available for automatic identification system
Bar codes,
Radio frequency systems,
Magnetic stripes,
Optical character recognition, and
Machine vision.
16. Classifications of bar codes according to the dimensions of width
High density
Medium density
Low density

17. Types of bar code readers

Fixed beam reader,
Moving beam reader.
18. Smart cards
They are of the size of a credit card and are embedded with one or
more microchips.
These have a 8 bit or higher level microprocessors and a storage
capacity of about 8kB-256kB. Personal identification numbers prevent
their unauthorized use.
19. Flexible manufacturing system FMS;

20. Components of FMS systems;
Processing stations.
Material handling and storage.
Computer control system.
21. Different FMS layout configurations
Inline configuration,
Loop configuration,
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Ladder configuration,
Open field configuration and
Robot centered cell.
22. Types of FMS

1.Explain the Concept of Shop floor control;
schedule, capacity planning and materials requirement planning is called shop floor control.
Shop floor control is defined as a method of controlling the work in process in the factory.
Functions of shop floor control SFC;
Phases Shop floor control
The three phases of shop floor control
4. Order release
5. Order scheduling
6. Order progress
accompanies an order as it processed through the shop. These documents collectively called
as shop packets.

The order progress module performs the remaining three functions of SFC.
Shop order status
Capacity control.
2.What are the Functions of a Data Management system in CIM?
User functions:
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Project management
Utility functions:
Data transport
Data translation
Image services
System administration.
Factory Data Collection System;

Purpose of data collection system;
The purpose of the data collection system in shop floor control is to provide basic
data for monitoring order progress.
In computerized SFC system the data are submitted to the order progress module for
analysis and generation of work order status reports and exception reports.
Types of data collected from the shop floor;

Machine data,
Operator data,
Tooling data,
Materials data,
Scheduling data,
Inspection data.
Data collection techniques in shop floor control?
Job traveler
Employee time sheet
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3. Explain the Computer process monitoring (Computer assisted data collection

systems);
Computer process monitoring is a data collection system in which the computer is
directly connected to the workstation and associated equipment for the purpose of observing
the operation.
Components used to build a computer process monitoring system
Multiplexers,
Configurations of computer assisted data collection systems
Multilevel scanning
On-line versus batch systems
Data input techniques
Job traveler
Employee time sheets
Operation tear strips
Prepunched cards
Providing key board based terminals
o One centralized terminal
o Satellite terminals
o Workstation terminals
Data acquisition system ( DAS );
The data acquisition system that collects data from the various production operations
for direct communication to a central computer. Hence it is called as online system.
Automatic identification methods;
automatic or semi automatic acquisition of product data for entry into a computer system.
Bar codes
Radio frequency systems
Magnetic stripe
Optical character recognition
Machine vision
Classifications of bar codes according to the dimensions of width
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High density
Medium density
Low density
Types of bar code readers;
Fixed beam reader,
Moving beam reader.
Smart cards
They are of the size of a credit card and are embedded with one or more microchips.
These have a 8 bit or higher level microprocessors and a storage capacity of about 8kB256kB. Personal identification numbers prevent their unauthorized use.
5.Explain the Flexible manufacturing system (FMS) in CIM?

Components of FMS systems;
Workstations
Material handling and storage
Computer control system
Human resources
1.Workstations
Load/unload stations
Machining stations
Other processing stations
Assembly
2.Material handling and storage systems
Primary material handling
Secondary material handling
The material handling function in a FMS is often shared between two systems:
5. Primary handling system - establishes the basic layout of the FMS and is responsible
for moving workparts between stations in the system.
6. Secondary handling system - consists of transfer devices, automatic pallet changers,
and similar mechanisms located at the workstations in the FMS.
3.Computer control system
Workstation control
Distribution of control instructions to workstations
Production control
Traffic control
Shuttle control
Workpiece monitoring
Tool control
Performance monitoring and reporting
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Diagnostics
4.Human resources
For loading and unloading the materials in the machines and for the maintenance works the
human resource are required in the flexible manufacturing system.
Benefits of FMS
Higher machine utilization
Reduced work in process
Lower manufacturing lead time
Greater flexibility in production scheduling.
Types of FMS;
6.What makes the FMS flexible? Define the types of flexibility and explain its
dependent factors?
FMS Flexibility:
The three capabilities that a manufacturing system must process in order to the flexible
1. The ability to identify and distinguish among the different incoming part or product styles
processed by the system.
2. Quick changeover of operating instructions.
3. Quick changeover of physical setup. Flexibility is an attribute that applies to both manual
and automated systems. In manual systems the human workers are often the enables of the
systems flexibility.
Types of flexibility;
The flexibility allows a mixed model manufacturing system to cope with level of
variation in part or product style without interruptions in production for changeover between
models. It is generally a desirable feature of a manufacturing system.
The feature of flexibility is broadly classified in to following ways

1. Machine flexibility
2. Part flexibility
3. Route flexibility
4. Volume flexibility
5. Man flexibility.
FMS technology is approaches to simultaneously manufacture different parts in the
shortest time possible, with the highest quality and at the lowest costs possible. To do this a
maximum of management of management information must be available for the FMS host to
work with. When this is achieved there are several types of flexibility available; to an FMS
user.
The first area is that in which the FMS user is interested. This most important area.
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The available flexibilities are provided for the FMS user to be able to satisfy the demands of
their customers.

The second type of flexibility concerns the method of applying FMSs.this is of
extreme interest to the FMS host supplier. Every FMS applications different, and no. of
FMS supplier can start from scratch to supply a FMS host solution every time for each new
FMS user. A suppliers solution need to be flexible enough to integrate the different machine
types in to different FMS configurations and layouts for different product mixes.
7.What are the 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 function. Following is the list of
varied tasks one might expect to accomplish in a CIM environment.
1.Designing assemblies and performing tolerance analysis on those assemblies.
2. Preparing production drawings of assemblies, invidual parts, tooling, fixtures and other
manufacturing facilities.
3. Creating analytical models of parts for structural, kinematics and thermal analysis (FEM,
MeM etc., )
4. Calculating weights, volumes, centres of gravity (mass properties) and costs of
manufacturing (cost estimation). Classifying existing parts according to shape, function and
the process by which they are manufactured and retrieving these pans from the parts library
on demand (Group technology and coding).
1. Preparing parts lists and bill of materials (BOM).
2. Preparing process plans for individual part manufacture and assembly (Variant or
Generative).
3. Programming CNC machines for processing complete parts (CAM).
4. Designing work cells and programming the movement of components in those cells
using work handling devices like robots, conveyors, AGVS/ RGVs, etc., (Cellular
manufacture).
5. Controlling engineering changes and maintaining associativity between design and
manufacturing (concurrent associativity).
6. Preparing programs to handle components or manipulate production equipment (like
welding torches or robots).
7. Preparing inspection programs including programs for CNC co-ordinate measuring
machines {CNC- CMMS}.
The exchange of graphic information has been advanced with increasing acceptance
of Initial Graphics Exchange Specification (IGES) and STEP.
8. Explain the Barcode Technology in automatic data collection system?
A bar code (often seen as a single word, barcode) is the small image of lines (bars)
and spaces that is affixed to retail store items, identification cards, and postal mail to identify
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a particular product number, person, or location. The code uses a sequence of vertical bars
and spaces to represent numbers and other symbols. A bar code symbol typically consists of
five parts: a quiet zone, a start character, data characters (including an optional check
character), a stop character, and another quiet zone.
barcode symbol
A barcode is an optical machine-readable representation of data relating to the object
to which it is attached. Originally barcodes systematically represented data by varying the
widths and spacings of parallel lines, and may be referred to as linear or one-dimensional
(1D). Later they evolved into rectangles, dots, hexagons and other geometric patterns in two
dimensions (2D). Although 2D systems use a variety of symbols, they are generally referred
to as barcodes as well. Barcodes originally were scanned by special optical scanners called
barcode readers. Later, scanners and interpretive software became available on devices
including desktop printers and smartphones.
An early use of one type of barcode in an industrial context was sponsored by the
Association of American Railroads in the late 1960s. Developed by General Telephone and
Electronics (GTE) and called KarTrak ACI (Automatic Car Identification), this scheme
involved placing colored stripes in various combinations on steel plates which were affixed
to the sides of railroad rolling stock. Two plates were used per car, one on each side, with the
arrangement of the colored stripes representing things such as ownership, type of equipment,
and identification number. The plates were "read" by a trackside scanner located, for
instance, at the entrance to a classification yard while the car was moving past The project
was abandoned after about ten years because the system proved unreliable after long-term
use in the field.
Barcodes became commercially successful when they were used to automate supermarket
checkout systems, a task for which they have become almost universal. Their use has spread
to many other tasks that are generically referred to as automatic identification and data
capture (AIDC). The very first scanning of the now ubiquitous Universal Product Code
(UPC) barcode was on a pack of Wrigley Company chewing gum in June 1974.
Other systems have made inroads in the AIDC market, but the simplicity, universality and
low cost of barcodes has limited the role of these other systems until the 2000s (decade),
over 40 years after the introduction of the commercial barcode, with the introduction of
technologies such as radio frequency identification, or RFID.
Barcode Reader
A barcode reader is used to read the code. The reader uses a laser beam that is
sensitive to the reflections from the line and space thickness and variation. The reader
translates the reflected light into digital data that is transferred to a computer for immediate
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action or storage. Bar codes and readers are most often seen in supermarkets and retail
stores, but a large number of different uses have been found for them. They are also used to
take inventory in retail stores; to check out books from a library; to track manufacturing and
shipping movement; to sign in on a job; to identify hospital patients; and to tabulate the
results of direct mail marketing returns.
Very small bar codes have been used to tag honey bees used in research. Readers
may be attached to a computer (as they often are in retail store settings) or separate and
portable, in which case they store the data they read until it can be fed into a computer.
There is no one standard bar code; instead, there are several different bar code
standards called symbologies that serve different uses, industries, or geographic needs. Since
1973, the Uniform Product Code (UPC), regulated by the Uniform Code Council, an
industry organization, has provided a standard bar code used by most retail stores. The
European Article Numbering system (EAN), developed by Joe Woodland, the inventor of
the first bar code system, allows for an extra pair of digits and is becoming widely used.
POSTNET is the standard bar code used in the United States for ZIP codes in bulk mailing.
The following table summarizes the most common bar code standards.
Barcode Scanning Technology
Scanning technology is constantly evolving and providing industries with more
choices in data capture solutions. Two competing data capture devices: the laser scanner and
the digital imager have many businesses facing a tough decision. Deciding which scanning
technology is right for your application can be a difficult task. Knowing the advantages and
applications in which these two technologies are used is the first step to success.
The key to deciding between these two technologies is determining which fits the
requirements and budget of your business most accurately.
2D Data Matrix Code

Both laser scanners and digital images are programmed to decode specific
symbologies, or the language, of barcodes. The symbology used in the application can
help determine which scanning technology will provide the most benefit. The use of 2dimensional (2D) symbologies is on the rise in many markets, making digital imagers a
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better choice. However, for applications that dont require reading 2D barcodes, laser
scanners are a cost-effective option.
UNIT V COMPUTER AIDED PROCESS PLANNING

AND CONTROL AND COMPUTER MONITORING.
Part - A (2 Marks)
1. Production Planning and control
Production planning and control may be defined as the direction as the
direction and coordination of a firms material and physical facilities towards the
attainment of pre specified Production of goods, with production efficiency.
2. Production planning
Deciding which products to make, how many of each, and when
they should be completed.
Planning the manpower and equipment resources needed to
accomplish the production plan.
Scheduling the production and delivery of the parts and products ;
3. Production control
Production control is concerned with determining whether the necessary
resources to implement the production plan have been provided or not.
4. Activities of production control.
Shop floor control;
Inventory control;
Manufacturing resource planning (MRP II); and
Just-in-time manufacturing systems.
5. MRP - Function of MRP
It is a planning technique. It translates the master production schedule (MPS)
of end products into a detailed schedule for the raw materials and parts used in those end
products.
6. BOM
The bill of materials (BOM) designates what itemsand how many of each are used to
make up a specified final product.
7. Benefits of MRP
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The benefits of implementing MRP system are:

Reduced inventory levels.
Better Production scheduling
Reduced production lead time.
Better machine utilization.
Improved product quality.
8. Material requirements planning (MRP)
It is a production planning and inventory control system used to manage
to customers.
9. Agile manufacturing
It is a term applied to an organization that has created the processes, tools, and
training to enable it to respond quickly to customer needs and market changes while still
controlling costs and quality.
10. Inventory Control
It is the supervision of supply, storage and accessibility of items in order to ensure an
adequate supply without excessive oversupply. It can also be referred as internal control an accounting procedure or system designed to promote efficiency or assure the
implementation of a policy or safeguard assets or avoid fraud and error etc.
11.Inventory control may refer to:
In economics, the inventory control problem, which aims to reduce overhead cost
without hurting sales
In the field of loss prevention, systems designed to introduce technical barriers to
shoplifting
12.Inventory
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Inventory or stock refers to the goods and materials that a business holds for the
ultimate purpose of resale (or repair).
Inventory management is a science primarily about specifying the shape and percentage
of stocked goods. It is required at different locations within a facility or within many
locations of a supply network to precede the regular and planned course of production and
stock of materials.
13.Lean manufacturing,
Lean manufacturing, Lean Enterprise, or lean production, often simply, "lean", is a
production philosophy that considers the expenditure of resources in any aspect other than
the direct creation of value for the end customer to be wasteful, and thus a target for
elimination. Working from the perspective of the client who consumes a product or service,
"value" is any action or process that a customer would be willing to pay for.
Basically, lean manufacturing technique consists of four steps. First step is to realize
that there are wastes in the system to be removed. Although this seems like a crazy idea, this
is the step which creates the requirement for the movement towards lean manufacturing.
Many organizations do not realize that they have tons of hidden wastes with them. Therefore
they do not have the requirement to remove them from the system. So they will have their
problems forever and they will try to find solutions for these problems forever.
14.Direct digital control (DDC)
It is the automated control of a condition or process by a digital device (computer).
A very early example of a DDC system meeting the above requirements was
completed by the Australian business Midac in 1981-1982 using R-Tec Australian designed
hardware.
15.Inventory Management;
Inventory management is a science primarily about specifying the shape and
percentage of stocked goods. It is required at different locations within a facility or within
many locations of a supply network to precede the regular and planned course of production
and stock of materials.
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1.Explain the Inventory management in CIM?

Definition - Inventory
The overseeing and controlling of the ordering, storage and use of components that a
company will use in the production of the items it will sell as well as the overseeing and
controlling of quantities of finished products for sale. A business's inventory is one of its
major assets and represents an investment that is tied up until the item is sold or used in the
production of an item that is sold. It also costs money to store, track and insure inventory.
Inventories that are mismanaged can create significant financial problems for a business,
whether the mismanagement results in an inventory glut or an inventory shortage.
Inventory or stock refers to the goods and materials include that a business holds for
the ultimate purpose of resale (or repair).
Inventory management is a science primarily about specifying the shape and percentage of
stocked goods. It is required at different locations within a facility or within many locations
of a supply network to precede the regular and planned course of production and stock of
materials.
The scope of inventory management concerns the fine lines between replenishment
lead time, carrying costs of inventory, asset management, inventory forecasting, inventory
valuation, inventory visibility, future inventory price forecasting, physical inventory,
available physical space for inventory, quality management, replenishment, returns and
defective goods, and demand forecasting. Balancing these competing requirements leads to
optimal inventory levels, which is an ongoing process as the business needs shift and react to
the wider environment.
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Inventory management involves a retailer seeking to acquire and maintain a proper

merchandise assortment while ordering, shipping, handling, and related costs are kept in
check. It also involves systems and processes that identify inventory requirements, set
targets, provide replenishment techniques, report actual and projected inventory status and
handle all functions related to the tracking and management of material. This would include
the monitoring of material moved into and out of stockroom locations and the reconciling of
the inventory balances. It also may include ABC analysis, lot tracking, cycle counting
support, etc. Management of the inventories, with the primary objective of
determining/controlling stock levels within the physical distribution system, functions to
balance the need for product availability against the need for minimizing stock holding and
handling costs.
Definition - Inventory management
2.explain the Material requirements planning (MRP) in CIM?

It is a production planning, scheduling, and inventory control system used to manage
to customers.
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History Of MRP
Prior to MRP, and before computers dominated industry, Reorder point (ROP) /
reorder-quantity (ROQ) type methods like EOQ (Economic Order Quantity) had been used
in manufacturing and inventory management.
In 1964, as a response to the Toyota Manufacturing Program, Joseph Orlicky
developed Material Requirements Planning (MRP). The first company to use MRP was
Black & Decker in 1964, with Dick Alban as project leader. Orlicky's book Material
Requirements Planning has the subtitle The New Way of Life in Production and Inventory
Management (1975). By 1975, MRP was implemented in 700 companies. This number had
grown to about 8,000 by 1981.
In 1983 Oliver Wight developed MRP into manufacturing resource planning (MRP
II). In the 1980s, Joe Orlicky's MRP evolved into Oliver Wight's manufacturing resource
planning (MRP II) which brings master scheduling, rough-cut capacity planning, capacity
requirements planning, S&OP in 1983 and other concepts to classical MRP. By 1989, about
one third of the software industry was MRP II software sold to American industry ($1.2
billion worth of software).[2]
[1]
Functions of MRP;
The basic functions of an MRP system include: inventory control, bill of material
processing, and elementary scheduling. MRP helps organizations to maintain low inventory
levels. It is used to plan manufacturing, purchasing and delivering activities.
"Manufacturing organizations, whatever their products, face the same daily practical
problem - that customers want products to be available in a shorter time than it takes to make
them. This means that some level of planning is required."
Companies need to control the types and quantities of materials they purchase, plan
which products are to be produced and in what quantities and ensure that they are able to
meet current and future customer demand, all at the lowest possible cost. Making a bad
decision in any of these areas will make the company lose money. A few examples are given
below:
If a company purchases insufficient quantities of an item used in manufacturing (or

the wrong item) it may be unable to meet contract obligations to supply products on
time.
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If a company purchases excessive quantities of an item, money is wasted - the excess

quantity ties up cash while it remains as stock and may never even be used at all.
Beginning production of an order at the wrong time can cause customer deadlines to
be missed.
MRP is a tool to deal with these problems. It provides answers for several questions:
What items are required?

How many are required?
When are they required?...
MRP can be applied both to items that are purchased from outside suppliers and to subassemblies, produced internally, that are components of more complex items.
3.Explain the Manufacturing Shop Floor Control
Definition
Shop floor control is responsible for the detailed management of activities and the flow
of materials inside the plant, including employees, materials, machines, and production time.
Shop floor control activity typically begins after planning (e.g., with MRP, ERP); once
Planned orders
Order confirmations
Order settlement
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Shop floor control may also include identifying and assessing vulnerabilities and risks due to
the shop floor environment, employees, process, and the technologies employed at the shopfloor level. Based on the assessment of these factors, shop floor control initiates measures to
keep risk at an acceptable minimum level.
specifications.
equipment.
4.Explain the Agile and Lean manufacturing in CIM?

larger downstream effects. It is a general proposition of manufacturing that the cost of
correcting quality issues increases as the problem moves downstream, so that it is cheaper to
correct quality problems at the earliest possible point in the process.
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at the earliest possible point in the process. Agile manufacturing is seen as the next step after
Lean manufacturing in the evolution of production methodology. The key difference
between the two is like between a thin and an athletic person, agile being the latter. One can
be neither, one or both. In manufacturing theory, being both is often referred to as leagile.
According to Martin Christopher, when companies have to decide what to be, they
have to look at the Customer Order Cycle (the time the customers are willing to wait) and
the leadtime for getting supplies. If the supplier has a short lead time, lean production is
possible. If the COC is short, agile production is beneficial.
Lean manufacturing or lean production, often simply "lean", is a systematic
method for the elimination of waste ("Muda") within a manufacturing process. Lean also
takes into account waste created through overburden ("Muri") and waste created through
unevenness in work loads ("Mura"). Working from the perspective of the client who
consumes a product or service, "value" is any action or process that a customer would be
willing to pay for.
Essentially, lean is centered on making obvious what adds value by reducing

everything else. Lean manufacturing is a management philosophy derived mostly from the
Toyota Production System (TPS) (hence the term Toyotism is also prevalent) and identified
as "lean" only in the 1990s TPS is renowned for its focus on reduction of the original Toyota
seven wastes to improve overall customer value, but there are varying perspectives on how
this is best achieved. The steady growth of Toyota, from a small company to the world's
largest automaker, has focused attention on how it has achieved this success.
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5.Explain the Production systemin CIM?

The term production system may refer to:
In operations management and industrial engineering, a production system comprises

both the technological elements (machines and tools) and organizational behavior
(division of labor and information flow) needed to produce something.
In computer science, a production system (or production rule system) is a computer
program typically used to provide some form of artificial intelligence.
Toyota Production System, organizes manufacturing and logistics at Toyota
The Computer Animation Production System (CAPS) is a proprietary collection of
software, scanning camera systems, servers, networked computer workstations, and
custom desks developed by The Walt Disney Company together with Pixar in the
late-1980s.
Subsea Production Systems are typical wells located on the sea floor, shallow or deep
water.
Production control is the activity of monitoring and controlling any particular

production or operation. Production control is often run from a specific control room or
operations room
Role of Production Control in the Production Cycle.

Basic Process Control Strategies
In a simple control system, a process variable (PV) is measured and compared with a
setpoint value (SP). A manipulated variable (MV, or output) signal is generated by the
controller and sent to a final control element, which then influences the process variable to
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achieve stable control. The algorithm by which the controller develops its output signal is
typically PID (Proportional-Integral-Derivative), but other algorithms may be used as well:
This form of simple control may be improved upon and expanded for a greater range
of process applications by interconnecting multiple controllers and/or redirecting
measurement and control signals in more complex arrangements. An exploration of some of
the more common control system configurations is the subject of this chapter.
6.Explain the Direct digital control (DDC)in CIM?
It is the automated control of a condition or process by a digital device
(computer).[1][2] DDC is considered by many to be a more modern, granular and responsive
update to older HVAC control systems based upon PLC technologies. In those older PLC
based systems, each zone was self-sufficient and contained all of the instrumentation and
control elements needed to consider analog and digital inputs and then take actions
according to rules. The complexity came from the desire to expand these 'zones' from a few
dozen points and a handful of controlled elements to much broader building-wide systems.
Connecting PLCs together becomes complex, and the creation of rules which would be
loaded individually into each PLC impractical.
DDC on the other hand takes a more centralized network-oriented approach. All
instrumentation is gathered by various analog and digital converters which use the network
to transport these signals to the central controller. The centralized computer then follows all
of its production rules (which may incorporate sense points anywhere in the structure) and
causes actions to be sent via the same network to valves, actuators, and other HVAC
components that can be adjusted.
Central controllers and most terminal unit controllers are programmable, meaning the
direct digital control program code may be customized for the intended use. The program
features include time schedules, setpoints, controllers, logic, timers, trend logs, and alarms.
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The unit controllers typically have analog and digital inputs, that allow measurement
of the variable (temperature, humidity, or pressure) and analog and digital outputs for control
of the medium (hot/cold water and/or steam). Digital inputs are typically (dry) contacts from
a control device, and analog inputs are typically a voltage or current measurement from a
variable (temperature, humidity, velocity, or pressure) sensing device.
Digital outputs are typically relay contacts used to start and stop equipment, and
analog outputs are typically voltage or current signals to control the movement of the
medium (air/water/steam) control devices. Usually abbreviated as "DDC".
*** END ***

** ALL THE VERY BEST **
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ME 2402 Computer Integrated Manufacturing (CIM) WITH QB

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A Course Material on

Computer Integrated Manufacturing

This is to certify that the e-course material

: Computer Integrated Manufacturing.

: IV Year Mechanical Engineering.

Signature of the Author

COMPUTER INTEGRATED MANUFACTURING

GROUP TECHNOLOGY AND COMPUTER AIDED PROCESS

COMPUTER AIDED PLANNING AND CONTROL AND COMPUTER

UNIT I - COMPUTER AIDED DESIGN

CAD system - Hardware & Software.

Features of CAD packages.

CAD Drawing Editing Commands.

Solid Modeling Vs Surface Modeling.

Advantages and Applications of CAD packages

UNIT II - COMPONENTS OF CIM

Concept or Technology of CIM.

CIM System Hardware & Software

CIM Wheel Elements.

Computer Communication in CIM

Communication Network in CIM.

Types of Communication Network in CIM.

ISO / OSI model 7 layers of OSI model.

UNIT III - GROUP TECHNOLOGY AND

Concept of Group Technology.

Benefits of G.T. in CIM.

Methods for Part Family.

Computer Aided Process Planning.

Variant or Retrieval approach.

UNIT IV - SHOP FLOOR CONTROL AND

Functions of shop floor control SFC

Factory Data Collection System

Automatic identification methods

Barcode Technology in automatic data collection system

Flexible manufacturing system FMS

Components of FMS systems;

UNIT V - COMPUTER AIDED PROCESS PLANNING AND

Production Planning and control

Inventory management in CIM

Material requirements planning (MRP) in CIM

Shop Floor Control.

Agile and Lean manufacturing in CIM

Direct digital control (DDC)

COMPUTER INTEGRATED MANUFACTURING

COMPUTER INTEGRATED MANUFACTURING

COMPUTER AIDED PLANNING AND CONTROL AND COMPUTER

1. Mikell. P. Groover Automation, Production Systems and Computer Integrated

SCE 2015-16 MECHANICAL ENGINEERING

COMPUTER INTEGRATED MANUFACTURING

SCE 2015-16 MECHANICAL ENGINEERING

COMPUTER INTEGRATED MANUFACTURING

1.2. CAD system;

1.3...Features of CAD Packages;

SCE 2015-16 MECHANICAL ENGINEERING

COMPUTER INTEGRATED MANUFACTURING

Computer-aided design (CAD) is the use of computer systems to assist in the

1.3.1.. Drawing entities;

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COMPUTER INTEGRATED MANUFACTURING

*Screen size, * Line type,

1.3.3.. Editing commands in CAD;

Various Edit and Inquiry commands in CAD;

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Screen size, Line type,