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By

Mr. T.Manokaran ME,MBA ASSISTANT PROFESSOR

DEPARTMENT OF MECHANICAL ENGINEERING SASURIE COLLEGE OF ENGINEERING

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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)

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 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 families-classification 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.

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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

2

1.2.

CAD system -

Hardware & Software. 3

1.3. Features of CAD packages. 4

1.3.1. Graphic Entities. 5

1.3.2. Graphic Utilities. 5

1.3.3. CAD – Drawing Editing Commands. 5

1.3.4. Graphic Transformations. 7

1.4. Geometric Modeling 8

1.4.1. Wireframe Modeling 9

1.4.2. Surface Modeling 10

1.4.3. Solid Modeling 10

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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

2.5.1. 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. 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

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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

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ME2402 COMPUTER INTEGRATED MANUFACTURING L T P C 3 0 0 3

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 families-classification 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.

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UNIT – I

COMPUTER AIDED DESIGN 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 two-dimensional (2D) space; or curves, surfaces, and solids in three-two-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.

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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 two-dimensional (2D) space; or curves, surfaces, and solids in three-two-dimensional (3D) space.

 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, * Line, * Arc, * Ellipse,

 Circle, *Polygon, *Spline, *Rectangle, etc., 1.3.2. 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, *Snap,, *Units, , *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, *Move, *Array, *Fillet, * Chamfer

*Mirror *Rotate, *Trim, *Copy *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

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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.

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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 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 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 object’s 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. car’s 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 aren’t 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 computer-aided 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) isn’t like a car in that you can use it pretty well even if you don’t 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 don’t 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;

Surface modeling is defining an object’s 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. car’s 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

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generally considered more difficult than solids modeling, but the models are more robust because the programs aren’t 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.

1.5. 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.

 EDGE CAM – site of CAM software for all your NC program needs such as turning, milling, EDM, free burn and advance surface machining.

UNIT – II

COMPONENTS OF CIM Pre Requisite Discussions:

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;

 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;

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

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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.

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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

There are several commonly used network topology or ways of routing the interconnections. It classified as Star, Ring, Bus topologies.

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 design (CAD)

 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)

 Computer-aided surgical simulation (CASS)

 Computational fluid dynamics (CFD)

 Component information system (CIS)

 Computer-integrated manufacturing (CIM)

 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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Pre Requisite Discussions:

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

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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:

 Volume of work to be done by the cell

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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. That’s 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 company’s 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.

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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.

Point to point

Multi drop UNIT – IV

SHOP FLOOR CONTROL AND INTRODUCTION TO FMS Pre Requisite Discussions:

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.

PC PC PC PC PC PC PC PC

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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 real-time 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

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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,

References

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