COMPUTER INTEGRATED MANUFACTURING LABORATORY
(BND43403)
Chapter 1 (Part 1)
INTRODUCTION TO
COMPUTER INTEGRATED MANUFACTURING
Ts Dr Amirul Syafiq bin Sadun
amirul@uthm.edu.my
October 2023
Malaysia Manufacturing Sector
Production Systems
• A production system is a collection of people, equipment, and
procedures organized to perform the manufacturing operations
of a company.
Production Systems
Two major components:
 Facilities : The physical facilities of the production
system include the equipment, the way of the
equipment is laid out and the factory in which the
equipment is located
 Manufacturing support system : These are procedures
used by the company to manage production and to
solve the technical and logistics problems encountered
in ordering materials, moving the work through the
factory and ensuring that products meet quality
standards. Product design and certain business
functions are included in the manufacturing support
systems
 Direct labor people (blue-collar workers) are
responsible for operating the facilities, and professional
staff people (white-collar workers) are responsible for
manufacturing support systems
Facilities
• The facilities in the production system consist of
the factory, production machines and tooling,
material
handling
equipment,
inspection
equipment, and computer systems that control the
manufacturing operations.
• Include the plant layout, which is the way the
equipment is physically arranged in the factory. The
equipment is usually organized into manufacturing
systems, which are the logical groupings of
equipment and workers that accomplish the
processing and assembly operations on parts and
products made by the factory.
• Manufacturing systems can be individual work cells
consisting of a single production machine and a
worker assigned to that machine. More complex
manufacturing systems consist of collections of
machines and workers, for example, a production
line.
Facilities (cont’d)
Manual Work Systems
Worker-Machine Systems
Automated Systems
• Three basic categories of human participation
1. Manual Work Systems
A manual work system consist of one or more workers performing one or more tasks
without the aid of powered tools (Using Hand).
Production tasks commonly require the use of hand tolls, such as screwdrivers and
hammers
Examples:
- A machinist using a file to round the edges of a rectangular part that has just been milled
- A quality control inspector using a micrometer to measure the diameter of a shaft
- A material handling worker using a dolly to move cartons in a warehouse
- A team of assembly workers putting together a piece of machinery using hand tools
Facilities (cont’d)
2. Worker-Machine Systems
In a worker-machine system, a human worker operates powered equipment,
such as a machine tool or other production machine (most widely used
manufacturing systems)
Worker-machine systems include combinations of one or more workers and one
or more pieces of equipment.
Examples:
- A machinist operating an engine lathe to fabricate a part for a product
- A fitter and industrial robot working together in an arc-welding work cell
- A crew of workers operating a rolling mill that converts hot steel slabs into flat
plates
- A production line in which the products are moved by mechanized conveyor and
the workers at some of the stations use power tools to accomplish their
processing or assembly tasks
Humans vs Machines
Facilities (cont’d)
3. Automated Systems
 An automated system is one in which a process is performed by a machine
without the direct participation of a human worker
 Automation is implemented using a program of instructions combined with a
control system that executes the instructions
 Power is required to drive the process and to operate the program and control
system
 Two levels of automation:
1)
SEMIAUTOMATED
 A portion of the work cycle under some form of program control, and a
human worker tends to the machine for the remainder of the cycle, by
loading and unloading it, or by performing some other task each cycle
2)
A FULLY AUTOMATED MACHINE
 Operate without human attention for an extended period of time. Extended
period of time means longer than one work cycle; a worker is not required to
be present during each cycle.
 Instead, the worker may need to tend the machine every tenth cycle or every
hundredth cycle. Example of this operation is found in many injection
molding plants, where the molding machines run on automatic cycles, but
periodically the molded parts at the machine must be collected by a worker.
Facilities (cont’d)
(a) Manual Work System, (b) Worker-Machine System and (c) Fully
Automated System
Manufacturing Support System
• Manufacturing Support System is a people and
procedures by which a company manages its production
operations. Most of these support systems do not
directly contact the product, but they plan and control
its progress through the factory
Manufacturing Support System
• The activities
• Business functions (sales and marketing, sales
forecasting, order entry and customer billing)
• Product Design ( customer’s product design,
manufacturer’s product design, product
development and design)
• Manufacturing Planning ( information and
documentations of product design flows into
the manufacturing planning function that
includes process planning, master scheduling,
material requirements planning and capacity
planning)
• Manufacturing Control ( managing and
controlling the physical operations in the
factory to implement the manufacturing plans.
The flow of information is from planning to
control that includes shop floor control,
inventory control and quality control)
Sequence of information processing activities
Automation in production systems
Production system are likely to be
automated, whereas others will be
operated manually or clerically.
SME Mostly manual
The automated elements of the
production system:
1. Automation of the manufacturing
systems in the factory
2. Computerization of the
manufacturing support systems
REFRESH
Automation
Element
TASK 1 : First Grouping Task
Find examples of manual work processes, semiautomated processes, and fully automated
processes. Record and submit a video via Google
Form.
Video Format:
i. Find any social media video for each process
type, with a length not exceeding 10 minutes
each.
ii. Record a 1-minute presentation in which you
briefly explain each video, highlighting the
significant parts only.
Submission Link:
COMPUTER INTEGRATED MANUFACTURING LABORATORY
(BND43403)
Chapter 1 (Part 2)
INTRODUCTION TO
COMPUTER INTEGRATED MANUFACTURING
Ts Dr Amirul Syafiq bin Sadun
amirul@uthm.edu.my
October 2023
Video Pengalaman Kerja Kilang
Sumber : ML Studios
Video Reflection:
1. How do you relate to the
experiences
and
challenges
discussed in the video?
2. If you could ask the woman in
the video for one piece of career
advice, what would it be?
3. What key lessons or insights can
you draw from her experience as
an engineer?
REFRESH
REFRESH
REFRESH
Type of Processes with Automated Systems
(a) Manual Work System, (b) Worker-Machine System and (c) Fully
Automated System
REFRESH
REFRESH
THIS IS AN ESTABLISH SYSTEM,
BUT WHAT MORE CAN BE DONE TO IMPROVE>??
REFRESH
IMAGINE A 24 HOURS RUNNING FACTORY
WHAT IF
1. We can reduce barriers between all the
functions within an operation
2. All departments are able to work closely
throughout the processes:
 Marketing,
 Order entry,
 Accounting,
 Design,
 Manufacturing,
 Quality control,
 Shipping
REFRESH
Automation
Element
THIS IS WHERE
CIM IS
INTROUDUCE
INTERGRATION
Departments and Relation to CIM
1.
Design and Engineering: Use CIM for CAD and CAE.
2.
Production and Manufacturing: Integrate automation for efficiency.
3.
Inventory and Materials Management: Track materials and manage stock.
4.
Quality Control and Assurance: Automate inspections.
5.
Supply Chain Management: Coordinate with suppliers and customers.
6.
Maintenance and Equipment Management: Predict maintenance needs.
7.
Information Technology: Implement and maintain CIM systems.
8.
Human Resources: Train staff for CIM.
9.
Research and Development: Use CIM for virtual testing.
10.
Sales and Customer Service: Improve customer service.
11.
Finance and Accounting: Analyze costs and budgets.
12.
Environmental and Health & Safety (EHS): Monitor compliance.
13.
Marketing and Product Management: Use CIM data for analysis.
14.
Logistics and Transportation: Optimize logistics.
15.
Legal and Compliance: Ensure regulatory compliance.
16.
Facility Management: Manage facilities and energy consumption.
How the Office in the Factory Looks
REASONS FOR AUTOMATING
Increase
Increase labour productivity
Reduce
Reduce labour cost
Mitigate
Reduce or
eliminate
Improve
Mitigate the effect of labour shortages
Reduce or eliminate routine manual and clerical tasks
Improve worker safety
Improve
Improve product quality
Reduce
Reduce manufacturing lead time
Accomplish
Avoid
Accomplish process that cannot done manually
Avoid the high cost of not automating
Manual Labour in Factory Operation
REMEMBER :
NOT EVERY
PROCESS CAN
BE
AUTOMATED
• Task is technologically difficult to automate (e.g.
Inspection, handling flexible or fragile materials)
• Short product life cycle
• Customized product (unique features)
• Ups and downs in demand
• Need to reduce risk of product failure
• Lack of capital
Labour in Manufacturing Support System
• Equipment maintenance
• Programming and computer operation
• Engineering project work
• Plant management
Automation
Principles
Understand
• U : Understand the existing Process
• operation chart, flow process chart,
mathematical model
Simplify
• S : Simplify the Process
• ten strategies for automation and process
improvement
Automate
• A : Automate the process
• an automation migration strategy
Automation
Migration
Strategy
Three types of automation relative to
production quantity and product variety
Lab Activity 1 (Lab 1)
• https://drive.google.com/file/d/1L4URZDnZErbRl1BMqmVRWatcpKJBNvv/view?usp=
sharing