Dr Atul Sidola

Computer Integrated Manufacturing (CIM) System

Dr Atul Sidola

Contents Flexible manufacturing system

CIM

Dr Atul Sidola

A flexible manufacturing system (FMS) is a highlyautomated GT machine cell, consisting of a group orprocessing workstations (usually CNC machine tools),interconnected by an automated material handling andstorage system, and controlled by a distributed computersystem.

FMS can be viewed as computer assisted and controlledshop floor automation.

Flexible Manufacturing System(FMS)

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It is called flexible because it is capable ofprocessing a variety of different part stylessimultaneously at the various workstations, andthe mix of part styles and quantities of productioncan be adjusted in response to changing demandpatterns.

The FMS is most suited for the mid-variety, mid-volume production range

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Dr Atul Sidola

Flexibility Requirement of System

A manufacturing system must possess followingcharacteristics to be a flexible.1. The ability to identify and distinguish among

the different part styles processed by thesystem.

2. Quick changeover of operating instructions,and

3. Quick changeover of physical setup.

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A typical FMS system

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System Flexibility Check

To qualify as being flexible, a manufacturing system shouldsatisfy several criteria. The following are four reasonable testsof flexibility in an automated manufacturing system:1. Part variety test. Can the system process different part

styles in a non batch mode?2. Schedule change test. Can the system readily accept

changes in production schedule, and changes in eitherpart mix or production quantity?

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3. Error recovery test. Can the system recover quicklyfrom equipment breakdowns, so that theproduction is not completely disrupted?

4. New part test. Can new part designs be introducedinto the existing product mix with relative ease?

If the answer to all of these questions is YES for agiven manufacturing system, then the system can beconsidered flexible.

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Classification of Flexibility in Manufacturing

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Comparison of four Criteria of Flexibility in a Manufacturing System and the Seven Types of Flexibility

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Classification of FMS (basis: number of machines)

Flexible manufacturing systems can be distinguishedaccording to the number of machines in the system. Thefollowing are typical categories:1. Single machine cell2. Flexible manufacturing cell3. Flexible manufacturing system

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Single Machine Cell (SMC)

A single machine cell consists of one CNC machiningcenter combined with a parts storage system forunattended operation.

Completed parts are periodically unloaded from theparts storage unit, and raw workparts are loaded intoit

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Flexible Manufacturing Cell (FMC)

A flexible manufacturing cell consists of two or threeprocessing workstations (typically CNC machiningcenters) plus a part handling system.

The part handling system is connected to aload/unload station.

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Dr Atul Sidola

Flexible Manufacturing System (FMS)

A flexible manufacturing system has four or moreprocessing workstations connected mechanically by acommon part handling system and electronically by adistributed computer system.

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Dr Atul Sidola

Some of the distinguishing characteristics of the three categories offlexible manufacturing cells and systems are summarized as per figureshown.

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Flexibility Criteria Applied to the Three Types of Manufacturing Cells and Systems

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Classification of FMS (basis: Level of Flexibility

Another classification of FMS is according tothe level of flexibility designed into thesystem. Two categories are distinguishedhere: Dedicated FMS Random-order FMS

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A dedicated FMS is designed to produce a limited variety ofpart styles, and the complete universe of parts to be madeon the system is known in advance.

A random-order FMS is more appropriate when

1. The part family is large.

2. There are substantial variations in part configurations.

3. There will be new part designs introduced into thesystem and engineering changes in parts currentlyproduced, and

4. The production schedule is subjected to change fromday-to-day.

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A Comparison of Dedicated and Random-order FMS types

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Flexibility Criteria Applied to Dedicated FMS and Random-order FMS

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Components of FMS

There are several basic components of anFMS:1. Workstations.2. Material handling and storage systems.3. Computer control system.4. Human resource.

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Dr Atul Sidola

1. Workstations

The types of workstations typically found in an FMS:1. Load/Unload Stations.2. Machining Stations.3. Other processing Stations. (punching, shearing,

welding, etc.)4. Assembly Station.5. Other Stations and Equipment. (Inspection,

Vision, etc)

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2. Material Handling and Storage System

Functions of the Handling System1. Independent movement of workparts between

stations.2. Handle a variety of workpart configurations.3. Temporary storage.4. Convenient access for loading and unloading

workparts.5. Compatible with computer control.

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Material Handling Equipment

Automated material handling system (AMHS)

Automated guided vehicles (AGV)

Conveyors

Automated storage and retrieval systems (AS/RS)

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3. Computer Control System

The FMS includes a distributed computer system that is interfacedto the workstations, Material handling system, and Other hardware components.

A typical FMS computer system consists of a central computer andmicrocomputers. Microcomputers controlling the individual machines and other

components. The central computer coordinates the activities of the

components to achieve smooth overall operation of the system

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4. Human Resources Human are needed to manage the operations of the FMS.

Functions typically performed by human includes: Loading raw workparts into the system, Unloading finished parts (or assemblies) from the system, Changing and setting tools, Equipment maintenance and repair, NC part programming in a machining system, and Programming and operation the computer system.

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Applications of FMS

Metal-cutting (machining)

Metal forming

Assembly

Joining-welding (arc , spot), gluing

Surface treatment

Inspection

Testing

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Advantages of FMS1. To reduce set up and queue times

2. Improve efficiency

3. Reduce time for product completion

4. Utilize human workers better

5. Improve product routing

6. Produce a variety of Items under one roof

7. Improve product quality

8. Serve a variety of vendors simultaneously

9. Produce more product more quickly

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Disadvantage of using FMS 1. Limited ability to adapt to changes in product or product

mix (Ex: machines are of limited capacity and the

tooling necessary for products, even of the same family,

is not always feasible in a given FMS)

2. Substantial pre-planning activity

3. Expensive

4. Technological problems of exact component positioning

and precise timing necessary to process a component

5. Sophisticated manufacturing systems

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Computer Integrated Manufacturing (CIM)

CIM involves a fundamental strategy of integratingmanufacturing facilities and systems in an enterprisethrough the computer and its peripheral.

CIM system integrates the computer automation of FMSwith other computer assisted automation activities in afactory or a manufacturing organization.

CIM is the integration of total manufacturing enterprisethrough the use of integrated system and datacommunication mixed with new managerial philosophieswhich results in the improvement of personnel ororganizational efficiencies.

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Building Blocks of CIMS Computer aided design(CAD)

Computer aided manufacturing(CAM)

Flexible manufacturing system(FMS)

Business data processing system(BDPS)

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BDPS activities1. Sales order processing2. Marketing and forecasting3. Sales estimating4. Master scheduling5. MRP6. Budgeting7. Ledger keeping and

accounting8. Inventory management9. Stock control and forecasting

10. Purchasing11. Manufacturing costs12. Personal and payrolls 13. Plant maintenance14. Preparation of bill of material.15. Routines, time study, reports16. Shipping of products17. Etc.

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Benefits of CIMS1. Products quality

improvement.2. Shorter time in launching

new product in the market. 3. Flow time minimized. 4. Inventory level reduced. 5. Competitiveness increases. 6. Improved scheduling

performance. 7. Shorter vendor lead time.

8. Improved customer service.9. Increase in flexibility and

responsiveness. 10. Total cost minimized. 11. Long term profitability

increases. 12. Customers lead time

minimized. 13. Manufacturing productivity

increases. 14. Work in process inventory

decreases.

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Good Luck for Examination

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Type of flexibility Definition Depends on factors

1 Machine Capability to adopt a given machine (work station) in the systems to a wide range production operation and part styles. The greater the range of operations and part style s , the greater the machine flexibility.

2 Production The range or universe of part styles that can be produced on the system.

3 Mix Ability to change the product mix while maintaining the same total production quantity ; that is ,producing the same parts only on different proportions.