Computer Aided

Manufacturing
Presented by: Dr. Somesh Kumar Sharma
Mechanical Engg.Deptt.
National Institute of Technology Hamirpur

Fundamental truth
If you cannot do the basic
things right,
all the technology in the
world won't help you.

Gain of Competitive Advantage Through

Technology

Have a strategic vision

Plan for a distant time horizon
Have a focused product line and know the product
and customer
Tie strong internal technical capabilities to the
strategy
Build learning organizations that can effectively
implement the changes necessary for constructive
use of technology

Major themes of this lecture

The definition of CAM

Problems during developing and

implementing formal systems

Technology involved in CAM system

Why Use CAM?

Responsiveness to Rapid Changes in Market

Demand and Product Modification.
Better Use of Materials, Machinery, Personnel,
Reduction in Inventory.
Better Control of Production and Management of
the Total Manufacturing Operation.
The Manufacture of High-Quality Products at
Low Cost.

Think of the big picture of CAM

The role of technology in the

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

What is CAM?
CIM is not a product that can be purchased and
installed.
It is a way of thinking and solving problems.

What is CIM?
CIM is the integration of all enterprise operations and
activities around a common corporate data repository.
It is the use of integrated systems and data
communications coupled with new managerial
philosophies.

POTENTIAL BENEFITS OF CAM

Greater flexibility and responsiveness

Improved competitiveness
Lower total cost
Shorter customer lead time
Increase in manufacturing productivity
Decrease in work-in process inventory

Major Applications of CAM

Computer numerical control

Adaptive control
Industrial robots
Automated handling of materials
Automated and robotic assembly systems
Computer-aided process planning
Just-in-time production
Group technology
Artificial intelligence

The Role of Computer in

Manufacturing

The computer has had a substantial impact on almost

all activities of a factory. Often, the introduction of
the computer changed the organizational structure of
a department and made necessary adoption of new
management structures.

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.

Communication Networks

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.

Computer-Aided Design and

Manufacturing

Computer-Aided Design (CAD)

A computerized process for designing new

products, modifying existing ones, or simulating
conditions that may affect the designs.

Computer-Aided Manufacturing (CAM)

A computerized process for planning and

programming production processes and
equipment.

Computer-Aided Manufacturing
(CAM)

Use of computer systems to

plan, manage, and control
manufacturing operations
Direct or indirect computer
interface with the plants
production resources
Numerical control of machine
tools
Programming of robots

Computer-Aided Manufacturing (CAM)

Refers to the use of specialized computer

programs to direct and control
manufacturing equipment

Benefits of CAM
Product quality
Shorter design time
Production cost reductions
Database availability
New range of capabilities
Reduces need for similar parts

Software Components

CAD software allows the designer to create

and manipulate a shape interactively and
store it
CAM software plans, manages and controls
the operations of a manufacturing site
CAE software analyzes design geometry,
allowing designer to study product
behavior

ProductionTechnology involved in
CAM

Numerically controlled machines

Numerical control
Computer numerical control
Direct numerical control

Process control
Vision systems
Robots
Automated storage and retrieval systems
Automated guided vehicles
Flexible manufacturing systems

Numerical Control

Numerical control (NC) - machine can be

controlled electronically
Computer Numerically Controlled (CNC) machine actually has its own
microprocessor and memory
Direct Numerical Control (DNC) - wired to
a central computer

Computer Numerical Control

Use Control Microcomputer as an Integral

Part
Can be Repeated at a Remote Site by the
Programmer
May Incorporate Information From
Drafting Software

Advantages of CNC

Increased Flexibility
Greater Accuracy
More Versatility

Adaptive Control

Research Began in Early 1950s

A Logical Extension of CNC
Operator Parameter Adjust Themselves to
Fit in New Circumstances
It Is a Feedback System Basically

Basic Functions on AC

Determine Operating Conditions of Process

Configure the Process Control in Response
to the Operating Conditions
Continue to Monitor the Process

Sensors, oftenControl
analog devices,
collect data
Process
- Operation
Analog devices read data on some periodic basis, perhaps
once a minute or once a second
Measurements are translated into digital signals, and
transmitted to a digital computer
Computer programs read the file (the digital data) and
analyze the data
Output may be a: message on printer or console, signal to
a motor to change a value setting, warning light or horn,
process control chart, etc.

Photo

Vision Systems

Combine video and computer technology

Often used in inspection roles
Consistently accurate, do not become
bored, of modest cost

Industrial Robots

The Word Robot was Converted from the

Czech Work Robota Which Means
Worker
Research Began in Early 1960s
A Mechanism Including Several Degrees
of Freedom
Having One or Several Arms
Controlled by A Memorizing Device

Robots

Machines that hold,

move, or grasp items
Perform monotonous or
dangerous tasks
Used when speed,
accuracy, or strength are
needed

1984-1994 T/Maker Co.

Types of Robots

Large articulated robot

Cartesian
(rectilinear)

Cylindrical

Spherical
(polar)

Articulated
(revolute, jointed,
anthropomorphic)

Major Applications of Industrial

Robots

Material Handling
Spot Welding Utilizes Automobile and Truck
bodies
Deburring, Grinding and Polishing
Applying Adhesives and Sealants
Spray Painting
Automated assembly
Inspection and gaging

Automated Storage and Retrieval

System
(ASRS)
Provide for automatic placement and
withdrawal of parts and products into and
from designated places in a warehouse.

Automated Handling of Materials

Manual Handling is Very Costly

Working Process and Environment Could
Be Danger to Human Being
Automated Handling Can Minimized the
Risk of Getting Injured
More Efficient and Accurate
Reduction in Cost

Automatic
Guided Vehicles (AGV)
Material handling

machines
Used to move parts &
equipment in
manufacturing
May be used to deliver
mail & meals in
service facilities

1984-1994 T/Maker Co.

Automated & Robotic Assembly

Cost of Manual Assembly is Very High

Automated & Robotic Assembly Reduce
the Cost of Production

Computer-Aided Process
Planning (CAPP)

Tradition Process Planning is very Time

consuming and not efficient
CAPP is especially good for small volume,
High Variety Parts Production

Cost Savings of CAPP

Reduction in process planning effort

Saving in direct labor
Saving in material
Saving in scrap
Saving in tooling
Reduction in work-in-process

Benefits of CAPP

Reduced Process Planning and Production Lead-Time

Greater Process Plans Consistency
Improved Cost Estimating Procedures F Calculation
Errors
More Complete and Detailed Process Plans
Improved production scheduling and capacity
utilization.
Improved Ability to Introduce New Manufacturing
Technology

Group Technology

First Developed In Europe in Early 1900s

Parts Can Be Grouped and Produced By
Classifying into Families
Seek Advantage of Design and Processing
Similarities

Introduction

Group technology was introduced by Frederick

Taylor in 1919 as a way to improve productivity.

One of long term benefits of group technology is

it helps implement a manufacturing strategy
aimed at greater automation.

What is group technology?

Group technology (GT) is a manufacturing
philosophy that seeks to improve
productivity by grouping parts and
products with similar characteristics into
families and forming production cells with
a group of dissimilar machines and
processes.

Group Technology

Group technology implementation can be broken

down into 3 different phases:

Actions on the manufacturing process

Changes to the production process
Results for the organization

Examples of the impacts group technology has

had on the production process.

Implementation Phases
Group technology has the
following actions on the
manufacturing process:

Part Simplification

Process Standardization

Production Control

Implementation Phases
The changes group technologies can have on the
production process.

Tighter Parts Control

Close physical layout of machine groups

Orderings tied to production

Implementation Phases
The results that group technologies have at the
organizational level.

Systematic design and redesign

High-quality level

Less process planning time and setup time

Impacts of Group Technology

Different impacts group technology has on the
production process:

Reduced purchasing cost

Accurate cost estimation

A more efficient process

Quicker design changes

Less redundant purchases.

Standardized Parts

Improved customer service

Classification builds customer relationships

A Classification Scheme
Coding Structures for Purchasing

GT coding is the process of assigning

symbols, numerics, and letters to a particular
attribute of a particular item

There are 3 different coding structures

Monocodes
Polycodes
Hybrid(mixed-mode) codes

Improving Quality
The production-oriented approach can be divided
into two phases:

A design phase

The number of completely new designs can be kept to a

minimum
Workers are more familiar with the parts.
Quality can be maintained at a high level by using proper
design

A manufacturing phase

The grouping of parts based on similar characteristics

Geometric features
Processing Requirements

Managerial Benefits
The Benefits of Group Technology
Classification:
1.

Reduced Purchasing Cost Through Volume

Purchasing

2.

Faster Lead Time

3.

Can purchase fewer different items at higher volumes

Can quickly identify the materials or materials needed

Better Negotiation Leverage

Value Analysis

Managerial Benefits
The Benefits of Group Technology
Classification (cont.):
4.

Accurate Cost Estimation

5.

Quicker Reaction to Design Changes

6.

Estimate the future price range with a standard cost database

Quickly identify newer material or parts that conform to newer
designs and specifications

Better Communication Between the Buyer and the Supplier

Eliminate the human errors with GT classification

Potential Obstacles
The Obstacles of Group Technology
Classification:
1.

Management Resistance to Change

2.

Extensive Data Requirements

3.

Unwilling to devote the time and energy

The proper identification needs detailed item descriptions
extensive purchase records/data

High Start-Up Cost

Item characteristics are not available without the aid of

automated information storage and retrieval systems which
usually incur high expenses until GT is in place

Summary
There are many benefits and obstacles toward the
use of group technology in an organization.
All things considered, GT is viewed as:

An essential step in the move toward factory

automation.
A necessary step in maintaining a high quality level
and profitable production.

Flexible Manufacturing Systems

Flexible Manufacturing System (FMS)

The organization of groups of production

machines that are connected by automated
materials-handling and transfer machines, and
integrated into a computer system for the purpose
of combining the benefits of made-to-order
flexibility and mass-production efficiency.

Automation

The automatic operation of a system, process, or

machine.

Flexible Manufacturing Systems

(FMS)

Using automated
machines (DNC) &
materials handling
equipment together
Often connected to
centralized computer
Also called automated
work cell

Auto Tool
Chg.
Machine 1
Robot
or AGV
Computer
Auto Tool
Chg.
Machine 2

Flexible Manufacturing Systems

General
purpose

Products

1000

Work cells

CIM
Flexible
Manufacturing
System

100

Focused
automation

10

Dedicated
automation

1
1

10

100

1000

10000

Volume

100000

1000000

FMS
- Pros & Cons
Advantages

Faster, lower-cost changes from one part to another

Lower direct labor costs
Reduced inventory
Consistent, and perhaps better quality

Disadvantages

Limited ability to adapt to product or product mix changes

Requires substantial preplanning and capital
expenditures
Technological problems of exact component positioning and
precise timing
Tooling and fixture requirements

Conclusions &Recommendations

Higher Efficiency in Manufacturing

Changing of Human Beings Role in
Manufacturing and Process
Decline in Number of Machine Tool
Operators
Increase in Computer Technicians
Need More Through Analysis and Tests

THANK
YOU!