Computer Aided Manufacturing Introduction • Computer Aided Manufacturing (CAM) can be defined as the use of computer systems to plan, manage and control the operations of a manufacturing plant through either direct or indirect computer interface with the plant’s production resources • In other words, the use of computer system in non-design activities but in manufacturing process is called CAM Types Of Manufacturing system Mass production system Batch production system Job shop Project Evolution Of CAM • The roots of CAD/CAM trail back to the beginning of civilization, when the engineers of the ancient civilizations such as Egyptians, Greeks and Romans acknowledged the importance of the graphical communication. • Later on, Leonardo Da Vinci developed technics, such as crosshatching and isometric views • The invention of computers and xerography made possible the creation of graphics and visualization (1991) • In the early 1950s, shortly after the World War II, the need for complex parts led to the invention of the Numerical Control (NC) that substituted the requirements for skilled human machine operators (Chang et al. 2006) • At the same time another invention, namely the digital computer, assisted the development of NC and provided the means for the creation of robots, computer aided design (CAD), computer-aided manufacturing (CAM) and flexible manufacturing systems (FMS) Benefit of CAM • The application of CAM in the production offers advantages to a company to develop capabilities by combining traditional economies of scale with economies of scope resulting in the desired flexibility and efficiency • Greater supervision of the production • Fast response to changes in market demand • Greater flexibility • Product variety • Small lot-sizes • Distributed processing capability • Reduced waste TECHNOLOGIESRELATEDTOCAM There are several constituent technologies in (CAM). Some of them are: • (i) Computer Numerical Control • (ii) CAM software • (iii) Robotics • (iv) Flexible manufacturing • (v) Computer Aided Process Planning • (vi) Enterprise resource planning • (vii) Product life cycle management Computer integrated Manufacturing - Introduction WHAT IS COMPUTER INTEGRATED MANUFACTURING (CIM) The term CIM comprises three words – computer, integrated and manufacturing. CIM is the application of computers in manufacturing in an integrated way. CIM is an attempt to combine computer technologies in order to manage and control the entire business and manufacturing. CIM is the computerization of design, manufacturing, distribution and financial/business function into one coherent system. Computer integrated Manufacturing - Introduction Definition CIM is complete integration an automation of all function of factory i.e. design ,manufacturing planning and control, manufacturing and business function Evolution of CIM • Concept of CIM has been involved since 1970,and starting devoting as a technology since 1980 . • With globalization of economy ,manufacturing industries starting cometing with each other all over the world • This has transformed market from seller driven to buyer driven and customer occupied in the center stage . • The customer demanding more product variety ,better product Quality and low cost product. • This has to led emergence of CIM Computer aided Manufacturing - Introduction Factor affected to the development of CIM Development and advancement of CNC,FMS and automation technologies. Development of cost –effective and high speed computer system Market Challenger - high labor cost, global computation ,buyer driven market Customer demands – product variety ,better product Quality and law cost product Computer‐Aided Manufacturing(CAM) Now Prof J. Ramkumar Micro-manufacturing Lab IIT Kanpur Evolution ofcycle Prof J. Ramkumar Micro-manufacturing Lab IIT Kanpur Manufacturingchanges Manufacturingchanges • Manufacturing industry affect all facet of our daily life • Companies constantly seek ways to optimize process and decrease cost – Manufacturing changes • 1990’s – quality was the driving force • 2000’s – safety • Today – environmental sustainability All lead to internal change in manufacturing industries • Automation ‐ old • Automation – new – machine size and operability cost decrease • Human’s out of blue collarjob Manufacturing change • Robotics have become common, easy to use and efficient • But still human isrequired • Insourcing Vs outsourcing • The primary variation between outsourcing and insourcing is the method in which work is divided between various companies or departments for strategic purposes. Assigning a project to a person or department within the company instead of hiring an outside person or company to do the work is considered insourcing • Outsourcing – shipping delay, quality problems and miscommunications – calling back of products • Area closer to home Top trends in manufacturing • Green manufacturing will replace existingmethodologies technology • Linear economy to circulareconomy Top trends in manufacturing technology Companies will turn to low‐cost marketing and funding solutions New technology can help manufacturers reach new markets and create new products. However, more companies are still looking for cost‐effective ways to develop and test prototypes, and social media and crowdfunding may be the solution. Most companies already have technologies in place to interact with customers, but crowdfunding and social media provides another channel for communication. Responsiveness Will Become Synonymous With Real Time. Manufacturers have always faced a battle with responsiveness. Business‐to‐business and omnichannel sales are making this challenge more difficult. However, greater visibility and speed in production are helping manufacturers create price quotes for new products and get products from the factory to the end user more quickly. Top trends in manufacturingtechnology More Off‐Site IT Investments Will Be Made. The days of in‐house IT departments are obsolescent. Cloud‐based technologies are replacing antiquated, legacy systems, and major manufacturers are planning to launch new investments into customer relationship management (CRM) tools. Avoiding the IIoT (Industrial Internet of Things) Will Be Impossible. Some companies have held out on implementing the IIoT in manufacturing for initial investment reasons, cyber security concerns or other issues. However, this will become an impossibility in 2017. Any type of new system purchased will have connectivity with the internet, provided the company has internet access Customization Will Replace Traditional Inventory Management. Traditional inventory management operations will change in 2017. Inventory management will become more reliant on advanced computer analytics systems to manage inventory in real time. This will eliminate shrink from theft, damages and errors during shipping, reducing overhead and improving operations Today’s new Termination 1. Flexible Manufacturing System 2. Variable Mission Manufacturing 3. Computerized Manufacturing System Product realizationprocess • The purpose of manufacturing is to produce a product. The product can be single component, such as screw, gear or it can be a complex assembly such as aeroplane or car. • Regardless of the complexity of the product, all products go through a common development activity: product realization process. Screw Gear Car assembly Product realization processcont… 1. Planning of productrealization 2. Customer related processes 1. Determination of requirements related to theproduct 4. Purchasing 1. Purchasing process 2. purchasing information 3. verification of purchased product 2. Review of requirements related tothe product 5. Production and service provision 3. Customer communication 1. control of production and serviceprovision 2. validation of processes for production and service provision 3. identification and traceability 4. customer property 5. preservation of product 3.Design and development 1. design and development planning 2. design and development inputs 3. design and development outputs 4. design and development review 5. design and development verification 6. design and development validation 7. control of design and developmentchanges 6. Control of monitoring and measuringdevices Engineering process for productrealization Product specification • After an initial design is completed, engineering analysis is carried out. An assembly may need kinematics analysis to ensure that the motion of the parts will achieve the desired functions. • For individual parts, stress and temperature properties under operational conditions may need to be determine. Design synthesis (design for X) Design representation Design analysis • A wide range of analytical and computational tool such as finite‐element analysis software and kinematics simulation tools are available. Design evaluation • Some of these tools have been integrated into CAD software, many others can import design data through a translator. Manufacturing planning • On the basis of the results of analysis, improvements to the design can be made to reduce the value of the targeted deign parameters. Manufacturing execution Inspection Evolution of productrealization Before we focus on the history of CAM, it is worthwhile to look at the historicaldevelopment of manufacturing Category Milestone Skeleton Hand tools: thousand of year to several thousands of years Muscle Machine tool: Industrial Revolution, 18th century, custom‐made product Smartness Gauges: Late 19th century, interchangeability Resource Manufacturing system: early 20th century Management Modern management transfer line pulltechnology Nerve Numerical control, robot (19500s, 1960s, 1970s),flexible manufacturing systems, sensor, vision Brain Computer‐aided manufacturing, intelligent manufacturing • • • • • The major manufacturing milestones that took place during the course of human civilization. It is said that what differentiates human being from other animals is our ability to use tools. Some animals do use tools to help them get their food. Human are the only species that know how to build (i.e. manufacture). Today manufacturing equipment is commonly control by digital devices through software programs Concept and Scope of CIM • CIM system Applied B computer and communication technology to completely integrated and automate for following four factore Design Manufacturing planning and control Manufacturing Business Functions CIM and CAD/CAM are very closely related but scope of CIM is Broder then CAD/CAM CAD/CAM covers only all Function Of factory Operation where CIM covers Business Function in Addition . Historical review of CAM/CIM • 1923 – Automatic transfer lines were introduced. • 1952 – Generation of punched paper tapes • 1954 – First NC Milling machine used. • 1959 – application of control using digital computer • 1960 – First NC Control Unimate Robot was installed. • 1963 – Sketchpad usage • 1965 – International business machines developed. • 1973 – CNC – DNC Concepts developed • 1980 - Concept of FMS established. • To meet Competitive pressures. • To coordinate and Organize data. • To eliminate paper and cost associated with its use. • To automate communication within a factory • To facilitate simultaneous engineering. Objectives The main aim is to use the advanced information processing technology into all areas of manufacturing industry More productive and efficient Increase product reliability Decrease the cost of production and maintenance Reduces the number of hazardous jobs Computerized Elements of system Impact of CIM on Personal • CIM has Affected all the company personnel from the lowest rank oprator to the CEO of a company • The Impact of CIM on the workforce is more then that on the technology itself Implementation Of CIM on Personnel Downsizing of workforce Requinto of change in skill set Specialist Need to generalize and Generalize Need to Special Culture change in management Role of Manufacturing Engineers in CIM • Manufacturing Engineer isVersatile in Nature • Due to continuous upgrade and modification manufacturing engineer must be closely interact with design engineer . • Manufacturing Engineer Need to understand design process, especially CAD Tool • Manufacturing Engineer must be developed certain degree of experty in the area of maintained of their own Machine . • Manufacturing Engineer must understand the various system machinetool like hydraulic system, pneumatic systems, electrical systems, and computer system. Role of Management • Development of businessmodel for factory to understand the problem • Develop a Functional model for the processes, function and activities • Develop an information model for system interfaces, database ,information Exchange ,etc • Develop a network model for communication and networking • Develop an organizational model for integrating various island of automation • Develop the implementation plan which takes into account special features of the business and operation.
