S.K.P. Engineering College, Tiruvannamalai.

VII Sem

SKP Engineering College

Tiruvannamalai – 606611

A Course Material
on
Computer Integrated Manufacturing
System

By

Mr.C.Muthazhagan, Mr.M.Thirumurugan, Mr.S.Sathishkumar,

Mr.N.Sarankumar
Assistant Professor
Mechanical Engineering Department

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Quality Certificate

This is to Certify that the Electronic Study Material

Subject Code: ME 6703

Subject Name: Computer Integrated Manufacturing Systems

Year/Sem: IV / VII

Being prepared by me and it meets the knowledge requirement of the University

curriculum.

Signature of the Author

Name: Mr.C.Muthazhagan

Mr. M.Thirumurugan,

Mr.S.Sathishkumar

Mr.N.Sarankumar

Designation: Assistant Professor

This is to certify that the course material being prepared by Mr.C.Muthazhagan,

Mr.M.Thirumurugan, Mr.S.Sathishkumar, Mr.N.Sarankumar is of the adequate quality.
He has referred more than five books and one among them is from abroad author.

Signature of HD Signature of the Principal

Name: Dr.J.Kuberan Name: Dr.V.Subramania Bharathi

Seal: Seal:

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CONTENTS

S.No Particulars Page

1 Unit – I 7

2 Unit – II 22

3 Unit – III 44

4 Unit – IV 65

5 Unit – V 89

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ME 6703-COMPUTER INTEGRATED MANUFACTURING SYSTEMS

Lecture : 3hrs/Week Internal Assessment: 20 Marks
Tutorial : 0 hrs/week Final Examination: 80 Marks
Practical : - Credits: 3
TYPE OF COURSE: Required course
ASSESSMENT METHOD: 2 internal tests, 1 Model examination and Course end university
examination.
PREREQUISITE:
 CAD/CAM,
 Manufacturing Technology
COURSE OBJECTIVES:
 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.
COURSE OUTCOMES: Upon completion of this course the student will be able to:

CO1 Familiar with usage of CAD/CAM system and will acquire concepts of CAD
Packages
CO2 Understand the data transmission methods in CIM.
CO3 Acquire the basic knowledge in grouping of manufacturing processes and
machines.
CO4 Apply the integration of manufacturing activities to ease factory floor
management.
CO5 Implement the computer aided planning, control and monitoring.

CO-PO MAPPING

CO/PO PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12

CO1 3 2 1
CO2 3 1 1 2 2
CO3 1 1 2 1 1 2
CO4 1 2 2 2 2 3 1
CO5 2 2 1 3 1 1 1 1 1

SYLLABUS

UNIT I INTRODUCTION 9
Brief introduction to CAD and CAM – Manufacturing Planning, Manufacturing control-
Introduction to CAD/CAM – Concurrent Engineering-CIM concepts – Computerised
elements of CIM system –Types of production - Manufacturing models and Metrics –
Mathematical models of Production Performance – Simple problems – Manufacturing
Control – Simple Problems – Basic Elements of an Automated system – Levels of
Automation – Lean Production and Just-In-Time Production.

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UNIT II PRODUCTION PLANNING AND CONTROL AND COMPUTERISED

PROCESS PLANNING 10
Process planning – Computer Aided Process Planning (CAPP) – Logical steps in
Computer Aided Process Planning – Aggregate Production Planning and the Master
Production Schedule – Material
Requirement planning – Capacity Planning- Control Systems-Shop Floor Control-
Inventory Control –Brief on Manufacturing Resource Planning-II (MRP-II) & Enterprise
Resource Planning (ERP) -Simple Problems.
UNIT III CELLULAR MANUFACTURING 9
Group Technology(GT), Part Families – Parts Classification and coding – Simple
Problems in Opitz Part Coding system – Production flow Analysis – Cellular
Manufacturing – Composite part concept –Machine cell design and layout – Quantitative
analysis in Cellular Manufacturing – Rank Order Clustering Method - Arranging
Machines in a GT cell – Hollier Method – Simple Problems.
UNIT IV FLEXIBLE MANUFACTURING SYSTEM (FMS) AND AUTOMATED
GUIDED VEHICLE SYSTEM (AGVS) 8
Types of Flexibility - FMS – FMS Components – FMS Application & Benefits – FMS
Planning and Control– Quantitative analysis in FMS – Simple Problems. Automated
Guided Vehicle System (AGVS) – AGVS Application – Vehicle Guidance technology –
Vehicle Management & Safety.
UNIT V INDUSTRIAL ROBOTICS 8
Robot Anatomy and Related Attributes – Classification of Robots- Robot Control
systems – End Effectors – Sensors in Robotics – Robot Accuracy and Repeatability -
Industrial Robot Applications – Robot Part Programming – Robot Accuracy and
Repeatability – Simple Problems.

TOTAL: 45 PERIODS
CONTENT BEYOND SYLLABUS

 Various models of GT and FMS systems in different industries and corporates

 Fit and tolerance.
LEARNINGRESOURCES:

TEXT BOOKS:
1. Mikell. P. Groover ―Automation, Production Systems and Computer
IntegratedManufacturing‖, Pearson Education 2001.
REFERENCES:
1. Mikell. P. Groover and Emory ZimmersJr.,―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. YoremKoren, ― Computer Integrated Manufacturing‖, McGraw Hill, 2005.
6. P N Rao, ― CAD/CAM Principles and Applications‖, TMH Publications, 2007.

WEB RESOURCES:
1. en.wikipedia.org/wiki/Computer-integratedmanufacturing

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2. www.technologystudent.com/rmprp07/intman1.html
ADDITIONAL RESOURCES :

1. NPTEL TUTORIALS (Internal Server)

2. Online Objective Questions
3. Videos Materials if any (You tube)

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UNIT – I

INTRODUCTION

Part - A (2 Marks)

1. Define CAD.(even 2016)

Computer aided design can be defined as any design that involves the effective use
of computers to create, modify or document an engineering design.

2. Explain CAD system(even 2016)

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 modelling,
- Application software for design, analysis and synthesis.

3. Write the Various phases of CAD.(even 2015)

The design process in a CAD system consists of 4 stages / phases, they are;

Geometric modelling,
Design analysis and optimization,
Design review and evaluation,
Documentation and drafting.

4. Drawing entities;(even 2015)

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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;

Point, * Line, * Arc, * Ellipse,

*Rectangle,
Circle, *Polygon, *Spline, etc.,

5. Drawing Utilities;(odd 2015)

Drawing utilities include several functions to have the creation and storage of
drawings. Common utilities are;

*Screen
size, * Line type, * Scaling * Layers,

*file utilities,
*Grid, *Snap,, *Units, , etc.,

6. Explain Editing commands in CAD? (odd 2015)

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

-Erase,move,array,mirror,rotate,trim,copy,fillet,chamfer,copy,etc.,

7. Define Geometric modelling;(even 2014)

Geometric modelling 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.

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8. What are the Geometric modelling techniques?(even 2014)

These are various types of geometric models used in CAD,

Based on the dimensioning, - Two dimensional modelling, - Three

dimensional
modelling.
Based on the modelling,
-Wire frame modelling,

-Surface modelling,

-Solid modelling.

9. Distinguish between 2D and 3D.”(odd 2014)

2D models are best utilized for design problems, such as flat objects and layouts of
building.

3D models are capable of modelling 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.

10. Write the Advantages of CAD.(odd 2014)

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,

Part - B (16 Marks)

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1. Explain the Computer Aided Design in manufacturing?(even 2016)

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-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
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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)
 Electronic design automation (EDA)

2. Explain the Geometric modelling in CAD?(even 2016)

Geometric modelling is a branch of applied mathematics and computational

geometry that studies methods and algorithms for the mathematical description of
shapes.

The shapes studied in geometric modelling 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 modelling 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

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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.

3. Explain the Solid modelling technique in CAD?(odd 2015)

Solid modelling (or modelling) is a consistent set of principles for

mathematical and computer modelling of three-dimensional solids. Solid modelling
is distinguished from related areas of geometric modelling and computer graphics
by its emphasis on physical fidelity.[1] Together, the principles of geometric and solid
modelling 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 modelling 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 modelling. More
recently, the range of supported manufacturing applications has been greatly

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expanded to include sheet metal manufacturing, injection molding, welding, pipe

routing etc.

Beyond traditional manufacturing, solid modelling 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. 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 modelling research and
development has effectively addressed many of these issues, and continues to be a
central focus of computer-aided engineering.

4. Explain the Wire-frame modelling technique in CAD?(odd 2015)

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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 modelling 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 chansolids 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. 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

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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 modelling consists of only lines, points and curves
defining the edges of an object

5. Write the differences between the Solids vs. Surface Modelling? What and
why you need to know?(even 2015)

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 modelling 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.

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The easiest way to understand the difference between surface and solids
modelling is to think of a water balloon; the water in the balloon would be solids
modelling, while the latex skin would be surface modelling. Need more of an
explanation? No problem.

Solids modelling

Solids modelling is defining an object with geometric mass. Solids modelling

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 modelling programs are Solidworks, CATIA, and

ProEngineer. It was originally developed for machine design, and is used heavily for
engineering with large part assemblies, digital testing and rapid prototyping.

Surface modelling

Surface modelling 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).

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It was developed for the aerospace and automotive industries in the late 70s.
Rhinoceros 3D and Alias Studio Tools are examples of a surface modelling
programs. It is

generally considered more difficult than solids modelling, 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.

6. Write the functions of various Edit and Inquiry commands in CAD?(even 2015)

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 :

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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

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.

The OOPS command restores only the most recently erased objects.

Copying and Moving :

The commands available are :

MOVE, COPY, ROTATE, SCALE, MIRROR, STRETCH and ARRAY

The MOVE and COPY commands are for recreating the object at another place.

The COPY command retains a copy in the original place while the MOVE command
does not.

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.

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.
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Changes, Cuts and Constructions : These commands allow you to change

color, layer,etc.) and modify objects by

roper of objects (like trimming

/extending their cutting sections out of them. They can also be

ends, and 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: colour, elevation, layer, line type,
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.

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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.

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.

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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 two points.
AREA : finds are of specified enclosure.

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UNIT – II
PRODUCTION PLANNING AND CONTROL AND COMPUTERISED
PROCESS PLANNING

Part - A (2 Marks)

1. Define CIM?(even 2016)

Computer-integrated manufacturing (CIM) is the manufacturing approach of

using computers to control the entire production process.

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.

2. What is the main objective of CIM?(odd 2015)

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;

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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

3. Define Automation.(odd 2015)

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.

4. Explain ‘Islands of automation(even 2015)

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.

5. Difference between CAD, CAM AND CIM(even 2015)

CAD/CAM involves the use of computers to make Design and

Manufacturing more profitable.

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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.

6. What is Computer-aided technologies?(odd 2014)

Computer-aided technologies (CAx) is a broad term that means the use of

computer technology to aid in the design, analysis, and manufacture of
products.

Advanced CAx tools merge many different aspects of the product lifecycle
management (PLM), including design, finite element analysis (FEA),
manufacturing,

production planning, product

Computer-aided design (CAD)

Computer-aided engineering (CAE)

Computer-aided industrial design (CAID)

Computer-aided manufacturing (CAM)

Computer-aided requirements capture (CAR)

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Computer-aided rule definition (CARD)

Computer-aided rule execution (CARE)

Computer-aided software engineering (CASE)

Computer-assisted surgery (CAS)

Computer-aided surgical simulation (CASS)

Computational fluid dynamics (CFD)

Component information system (CIS)

Computer-integrated manufacturing (CIM)

7. Explain CIM system – Hardware & Software.(odd 2014)

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.
8. Discuss about CIM Wheel or CIM Components.(even 2014)

Distinct components of CIM wheel

Manufacturing / Human resource management

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Marketing

Strategic planning

Finance

Product and process design and planning

Manufacturing planning and control

Factory automation

9. Computer communication network in CIM(even 2014)

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.

10. What are the various communication needs of CIM?(even 2013)

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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Part - B (16 Marks)

1. Explain the CIM system.(even 2016)

Computer-integrated manufacturing (CIM) is the manufacturing approach of

using computers to control the entire production process. This integration allows
individual processes to exchange information with each other and initiate actions.
Through the integration of computers, manufacturing can be faster and less error-
prone, although the main advantage is the ability to create automated manufacturing
processes. Typically CIM relies on closed-loop control processes, based on real-
time input from sensors. It is also known as flexible design and manufacturing.

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:

Computer integrated manufacturing(CIM) is a broad term covering all

technologies and soft automation used to manage the resources for cost effective
production of tangible goods.

Integration – capital, human, technology and equipment

CIM – which orchestrates the factors of production and its management.

CIM is being projected as a panacea for Discrete manufacturing type of

industry, which produces 40% of all goods.

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―CIM is not applying computers to the design of the products of the company.
That is computer aided design (CAD)! It is not using them as tools for part and
assembly analysis. That is computer aided engineering (CAE)! It is not using
computers to aid the development of part programs to drive machine tools. That is
computer aided manufacturing (CAM)!

It is not materials requirement planning (MRP) or just-in-time (JIT) or any

other method of developing the production schedule. It is not automated
identification, data collection, or data acquisition. It is not simulation or modelling of
any materials handling or robots or anything else like that. Taken by themselves,
they are the application of computer technology to the process of manufacturing.
But taken by themselves they only crate the islands of automation.‖

Definition of CIM:

It describes integrated applications of computers in manufacturing. A number

of observers have attempted to refine its meaning:

One needs to think of CIM as a computer system in which the peripherals, instead of

being printers, plotters, terminals and memory disks are robots, machine tools and
other processing equipment. It is a little noisier and a little messier, but it‘s basically
a computer

system.

CIM is a management philosophy, not a turnkey computer product. It is a

philosophy crucial to the survival of most manufacturers because it provides the
levels of product design and production control and shop flexibility to compete in
future domestic and international markets.
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CIM is an opportunity for realigning your two most fundamental resources: people

and technology. CIM is a lot more than the integration of mechanical, electrical, and
even informational systems. It‘s an understanding of the new way to manage.

―CIM is the integration of the total manufacturing enterprise through the use of

integrated systems and data communications coupled with new managerial

philosophies that improve organizational and personnel efficiency.‖

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. Briefly Explain the CIM system?(even 2015)

The CIM system consists of Hardware & Software

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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

Modelling and design

Analysis, simulation, communications

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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

2. Explain the communication networks in CIM(even 2015)

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

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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.

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.

Wide Area Network;

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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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3. Explain the Seven Layers of OSI model?(odd 2015)

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

4. Explain the various topologies in the communication in CIM?(odd 2015)

Network Topologies;
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Star topology

Ring topology

Bus topology

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 o

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 designa

destination station.

Bus network communication

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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.

5. Explain the Basic Elements of Automation?(even 2014)

Basic Elements of Automation;

An automation control system consist of three basic elements

1. Power to accomplish the process and operate the system

2. A program of instruction to direct the process
3. a control system to actuate the instructions.

The relationship amongst these elements is illustrated in below

mentioned figure. All the systems that quality as being automated includes these
three basic elements in one form or another.

Enterprise level

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Manufacturing Support System

Manufacturing System

Automation and Material Handling

Control technologies Technologies

Manufacturing Processes and Assembly operations

automated system is used to operate some process, and power is

required to drive the process as well as the controls. The principal source of the
power in automated system is electrical power has many advantages in
automated as well as no automated processes.

1) POWER FOR THE PROCESS

In production, the term process refers to the manufacturing

operation that is performed on a work unit. Most of the power in manufacturing
plants is consumed by theses kinds of operations. The "power form" indicated in
the middle column of the table refers to the energy that is applied directly to the
process. As indicated above, the power source for each operation is often
converted from electricity.
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LOADING AND UNLOADING THE WORK UNIT:

Parts must be moved into the proper position and orientation for the
process to be performed, and power is required for this transport and placement
function. at the conclusion of the process, the work unit must similarly be removed.
If the process is completely automated, then some form of mechanized power is
used. If the process is manually operated or semi automated, then human power
may be used to position and locate the work unit.

MATERIAL TRANSPORT BETWEEN OPERATIONS:

In addition to loading and unloading at a given operation, the work unit

must be moved between operations.

2) POWER FOR AUTOMATION:

Above and beyond the basic power requirements for the manufacturing
operation, additional power is required for automation. The additional power is used
for the following functions:

CONTROLLER UNIT;

Modern industrial controllers are based on digital computers, which require

electrical power to read the program of instructions, make the control calculations,
and execute the instructions by transmitting the proper commands to the actuating
devices.

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POWER TO ACTUATE THE CONTROL SIGNALS;

The commands sent by the controller unit are carried out by means of
electromechanical devices, such as switches and motors called actuators. The
commands are generally transmitted by means of low-voltage control signals.

DATA ACQUISITION AND INFORMATION PROCESSING;

In most control systems, data must be collected from the process and
used as input to the control algorithms. In addition, a requirement of the process
may include keeping records of process performance or product quality. These data
acquisition in modest amounts.

2.) PROGRAM OF INSTRUCTIONS:-

The actions performed by an automated process are defined by a program of

instructions. Whether the manufacturing operation involves low, medium, or high
production. each part or product made in the operation requires one or more
processing steps that are unique to that part or product. These processing steps are
performed during a work cycle. A new part is completed during each work cycle.
The particular processing steps for the work cycle are specified in a work cycle
program. Work cycle programs are called part programs in numerical control

3) CONTROL SYSTEMS

The control element of the automated system executed the program of

instructions, the control system causes the process to accomplish is defined

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function, to carry out some manufacturing operation. let us provide a brief

introduction to control systems here.

The control systems in an automated system can be either closed loop or open loop. a

closed loop control system, also known as feed back control system, is one in which
the output variables is compared with an input parameter, and any difference
between the two is used to drive the output into agreement with the input, as shown
in below mentioned figure. a closed loop control system consists of 6 basic
elements.

Outpu
Input parameter t

Parameter

Controller Actuator Process

Feed Back Sensor

7. Explain the advanced Automation function?(even 2014)

In addition to executing work cycle programs, an automated system may be

capable of executing advanced functions that are specific to a particular work unit.
In general, the functions are concerned with enhancing the safety and performance
of the equipment. Advanced automation functions include the following
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(1) Safety monitoring,

(2) Maintenance and repair diagnostics, and
(3) Error detection and recovery.
automation functions are made possible by special subroutines included in the
program of instructions. In some cases, the functions provide information only and
do not involve any physical actions by the control systems, for example reporting a
list of preventive maintenance tasks that should be accomplished. Any actions taken
on the basis of this report

are decided by the human operations and managers of the systems and not by the
system itself. In other cases, the program of instructions must be physically
executed by the control system using available actuators. A simple example of this
case is a safety monitoring system that sounds an alarm when a human worker gets
dangerously close to the automated equipment.

One of the significant reasons for automating a manufacturing operation is to

remove workers from a hazardous working environment. An automated system is
often installed to perform a potentially dangerous operation that would otherwise be
accomplished manfully by human workers. However, even in automated systems,
workers are still needed to service the system at periodic intervals if not full-time,
accordingly, it is important that the automated system be designed to operate safety
when workers are in attendance. In addition, it is essential that the automated
system carry out it is process in a way that is not self-destructive. Thus, there are
two reasons for providing an automated system with a safety monitoring capability:

(1) to product human workers in the vicinity of the system and

(2) to product the equipment associated with the system.

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Safety monitoring means more than the conventional safety measures taken in a

manufacturing operation, such a productive shield around the operation or the kinds
of manual devices that might be utilized by human workers such as emergency stop
buttons. Safety monitoring in an automated system involves the uses of sensors to
track the systems operation and identify conditions and events that are unsafe or
potentially unsafe. The safety monitoring system is programmed to respond to
unsafe conditions in some appropriate way

.Possible responses to various hazards might include one more of the following:

1. completely stopping the automated system,

2. sounding an alarm

3. reducing the operating speed of the process,

4. Tacking corrective actions to recover from the safety violation.

This last response is the most sophisticated and is suggestive of an intelligent

machine performing some advanced strategy. This kind of response is applicable to
a variety of possible mishaps, not necessarily confined to safety issues, and is
called error detection and recovery

Sensors for safety monitoring range from very simple devices to highly
sophisticated systems. The following list suggests some of the possible sensors and
their applications for safety monitoring:

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Limit switches to detect proper positioning of a part in a work holding devices

so that the processing cycle can begin.

Photoelectric sensors trigged by the interruption of a light beam; this could be

used to indicate that a part is in the proper positions or to detect the pressure
of a human intruder in the work cell.

Temperature sensors to indicate the metal work part is hot enough to

proceed with hot forging operations. if the work part is not sufficiently
heated, then the metals ductility might be too low, and the forging dies
might be damaged during the operations.

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UNIT – III – CELLULAR MANUFACTURING

Part - A (2 Marks)

1. What is Group technology (GT)(even 2016)

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.

2. Define Part family(even 2016)

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 & Raw material state (casting, forging, bar stock, etc.)

Part manufacturing features:

Operations and operation sequences (turning, milling, etc.)

Batch sizes

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Machine tools
Cutting tools
Work holding devices
Processing times
3. What are the General methods used for part families.(odd 2015)
Visual inspection,

Parts classification and coding system, and

Production flow analysis.

4. What is Production Flow Analysis?(odd 2015)

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.

5. What are the Code structures used in GT application(even 2015)

Attribute codes (or polycodes or chain type structure).

Hierarchical codes (or monocodes or tree structure).

Decision-tree codes (or hybrid codes or mixed codes).

6. Define Coding systems.(even 2015)

1. Opitz classification system, 2. MICLASS system,

3. DCLASS system, 4. CODE system,

5. KK-3 system,and 6. CUTPLAN system.

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7. What is the Benefits of Group Technology(odd 2014)

Group technology is a management strategy to help eliminate waste

caused by duplication of effort.

It affects all areas of a company, including:

Engineering
Equipment specification
Facilities planning
Process planning
Production control
Quality control
Tool design
Purchasing
Service

7. What is Cellular manufacturing(odd 2014)

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.

8. What are Design considerations guiding the cell-formation.(even 2014)

Parts/products to be fully completed in the cell.

Higher operator utilization.

9. What is Process Planning?(even 2014)

Process Planning is the systematic determination of the methods by which

a product is to be manufactured, economically and competitively.

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10. Explain Computer/Aided Process Planning(even 2013)

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.

Part - B ( 16 Marks)

1. Explain the various benefits of GT?(even 2016)

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

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Employee satisfaction
Process planning procedures

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.

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
Raw material state (casting, forging, bar stock, etc.)
Manufacturing attributes:

Operations and operation sequences (turning, milling, etc.)

Batch sizes
Machine tools
Cutting tools
Work holding devices
Processing times.
General methods used for part families;

1. Visual inspection,
2. Parts classification and coding system, and
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3. Production flow analysis.

2. List out the Benefits of Group Technology?(even 2016)

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

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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 planning/route sheets for all members of a particular family. Once this

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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. Explain the Cellular manufacturing in CIM?(even 2015)

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.

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Fewer operations than equipment.

Balanced equipment utilization in the cell.

Types of cell design

5. Single machine cell

6. Group machine cell with manual handling

7. Group machine cell with semi-integrated handling

8. Flexible manufacturing system

9. Explain the Computer Aided Process planning in CIM?(odd 2015)

Process Planning is the systematic determination of the methods by which a

product is to be manufactured, economically and competitively.

Role of process planning

1. Interpretation of product design data

2. Selection of machining processes.

3. Selection of machine tools.

4. Determination of fixtures and datum surfaces.

5. Sequencing the operations.

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6. Selection of inspection devices.

7. Determination of production tolerances.

8. Determination of the proper cutting conditions.

9. Calculation of the overall times.

10. 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

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.

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Also it provides the opportunity to generate rational, consistent and

optimal plans.

CAPP;

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.

4. Explain in detail the Generative and Variant approaches in process

planning and differentiate both approaches?(even 2014), (odd 2014)

Generative approaches in Computer aided manufacturing process planning;

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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.
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A subsystem to select and sequence individual operation

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.

Variant or Retrieval approaches in Computer aided manufacturing process planning;

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.

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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

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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.

Shorter development times.

The system is understandable, and the planner has control of the final plan.

It is easy to learn and easy to use.

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.

7. How parts are classified and coded in Group Technology? Illustrate the
same for a product.(even 2014)

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, 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,
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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

CUTPLAN
1. Opitz classification system 6. system

2. DCLASS system 7. COFORM

3. CODE system 8. RNC system

Part analog
4. MICLASS system 9. system

5.KK-3 system 10. Brish system.

8.Explain in detail various Networking methods with necessary sketches?

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..,

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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.

PC

PC PC PC

PC PC

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PC

Point to point

PC Multi drop

Network Topologies

There are several commonly used networks topologies or ways of

routing the interconnections

1. Star networks
2. Ring network
3. Bus network

4. Hybrid network.
1. Star network

P
C

PC

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P
PC C

2.Ring network

PC

P
C PC

PC

PC

3. Bus Network

PC

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PC

4. Hybrid network.

PC
P
PC C

PC

PC

PC

PC PC

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UNIT – IV
FLEXIBLE MANUFACTURING SYSTEM (FMS) AND AUTOMATED
GUIDED VEHICLE SYSTEMS (AGVs)

Part - A (2 Marks)

1. What is Shop floor control?(even 2015)

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.

2. What are Functions of shop floor control – SFC(even 2015)

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.

3. Explain the Modules of SFC system;(even 2015)

Order release

Order scheduling

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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

Capacity control

4. What are the Functions of a Data Management system;(odd 2015)

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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

5. Discuss about Factory Data Collection System;(odd 2015)

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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.

6. Explain Purpose of data collection system;(even 2014)

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.

7. What are the Types of data collected from the shop floor;(even 2014)

Machine data,

Operator data,

Tooling data,

Data relating to jobs to be done,

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Materials data,

Materials handling data,

Scheduling data,

Process planning data, and

Inspection data.

8. Explain Data collection techniques in shop floor control;(odd 2014)

Job traveler

Employee time sheet

Operation tear strips or punched cards included with shop packet

Centralized shop floor terminals

Individual work centre terminals

9. What is Computer process monitoring (Computer assisted data collection

systems)(odd 2014)

Computer process monitoring is a data collection system in which the computer is

directly connected to the workstation and associated equipment for the purpose of
observing the operation.

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10. What are the Components used to build a computer process monitoring system(even
2013)

Transducers and sensors,

Analog to digital converters (ADC),

Multiplexers,

Real time clocks, and

Other electronic devices

Part - B ( 16 Marks)

1.Explain the Concept of Shop floor control;(even 2016, even 2013)

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.

Functions of shop floor control – SFC;

Priority control and assignment of shop orders

Maintain information on work in process for MRP.

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Monitor shop order status information.

Provide production output data for capacity control processes.

Phases Shop floor control

The three phases of shop floor control

4. Order release

5. Order scheduling

6. 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.

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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

Capacity control.

2.What are the Functions of a Data Management system in CIM?(odd 2013, odd 2011,
even 2012)

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
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Data translation

Image services

System administration.

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.
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Types of data collected from the shop floor;

Machine data,

Operator data,

Tooling data,

Data relating to jobs to be done,

Materials data,

Materials handling data,

Scheduling data,

Process planning data, and

Inspection data.

Data collection techniques in shop floor control?

Job traveler

Employee time sheet

Operation tear strips or punched cards included with shop packet

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Centralized shop floor terminals

Individual work centre terminals

3. Explain the Computer process monitoring (Computer assisted data

collection systems);(even 2016)

Computer process monitoring is a data collection system in which the

computer is directly connected to the workstation and associated equipment for the
purpose of observing the operation.

Components used to build a computer process monitoring system

Transducers and sensors,

Analog to digital converters (ADC),

Multiplexers,

Real time clocks, and

Other electronic devices

Configurations of computer assisted data collection systems

Or (Automated data collection system)?

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Data logging systems

Data acquisition systems

Multilevel scanning

Types of data collection systems;

On-line data collection systems

Off-line data collection systems

Factory Data Collection System

On-line versus batch systems

Data input techniques

Job traveler

Employee time sheets

Operation tear strips

Prepunched cards

Providing key board based terminals

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o One centralized
terminal o Satellite
terminals

o Workstation terminals

Data acquisition system ( DAS );

The data acquisition system that collects data from the various production
operations for direct communication to a central computer. Hence it is called as
online system.

Automatic identification methods;

Automatic identification is a term that refers to various technologies used in

automatic or semi automatic acquisition of product data for entry into a computer
system.

Automatic identification methods

Bar codes

Radio frequency systems

Magnetic stripe

Optical character recognition

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Machine vision

Classifications of bar codes according to the dimensions of width

High density : X dimension is 0.010 in. or less.

Medium density : X dimension is between 0.010 and 0.030 in.

Low density : X dimension is 0.030 in. or greater.

Types of bar code readers;

Fixed beam reader,

Moving beam reader.

Smart cards

Smart cards are made of plastic.

They are of the size of a credit card and are embedded with one or more microchips.

These have a 8 bit or higher level microprocessors and a storage capacity of about
8kB-256kB. Personal identification numbers prevent their unauthorized use.

4.Explain the Flexible manufacturing system (FMS) in CIM?(odd 2013)

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A flexible manufacturing system consists of a group of processing stations,

interconnected by means of a automated material handling and storage systems,
and controlled by an integrated computer system.

Components of FMS systems;

Workstations

Material handling and storage

Computer control system

Human resources

1.Workstations

Load/unload stations

Machining stations

Other processing stations

Assembly

2.Material handling and storage systems

Primary material handling

Secondary material handling

The material handling function in a FMS is often shared between two systems:
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5. Primary handling system - establishes the basic layout of the FMS and is
responsible for moving workparts between stations in the system.

6. Secondary handling system - consists of transfer devices, automatic pallet

changers, and similar mechanisms located at the workstations in the FMS.

3.Computer control system

Workstation control

Distribution of control instructions to workstations

Production control

Traffic control

Shuttle control

Workpiece monitoring

Tool control

Performance monitoring and reporting

Diagnostics

4.Human resources

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For loading and unloading the materials in the machines and for the maintenance
works the human resource are required in the flexible manufacturing system.

Benefits of FMS

Higher machine utilization

Reduced work in process

Lower manufacturing lead time

Greater flexibility in production scheduling.

Types of FMS;

Flexible manufacturing module (FMM)

Flexible manufacturing cell (FMC)

Flexible manufacturing group (FMG)

Flexible fabrication-machining-assembly system (FFMAS)

5.What makes the FMS flexible? Define the types of flexibility and explain its
dependent factors?(odd 2015, even 2012)

FMS Flexibility:

The three capabilities that a manufacturing system must process in order to the flexible

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1. The ability to identify and distinguish among the different incoming part or product
styles processed by the system.

2. Quick changeover of operating instructions.

3. Quick changeover of physical setup. Flexibility is an attribute that applies to both

manual and automated systems. In manual systems the human workers are often
the enables of the systems flexibility.

Types of flexibility;

The flexibility allows a mixed model manufacturing system to cope with level
of variation in part or product style without interruptions in production for changeover
between models. It is generally a desirable feature of a manufacturing system.

The feature of flexibility is broadly classified in to following ways

1. Machine flexibility
2. Part flexibility
3. Route flexibility
4. Volume flexibility
5. Man flexibility.

FMS technology is approaches to simultaneously manufacture different parts

in the shortest time possible, with the highest quality and at the lowest costs
possible. To do this a maximum of management of management information must
be available for the FMS host to work with. When this is achieved there are several
types of flexibility available; to an FMS user.

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1. FMS user flexibility

2. FMS supplier flexibility.
1. FMS user flexibility
The first area is that in which the FMS user is interested. This most important area.

The available flexibilities are provided for the FMS user to be able to satisfy the
demands of their customers.

2. FMS supplier flexibility.

The second type of flexibility concerns the method of applying FMSs.this is of

extreme interest to the FMS host supplier. Every FMS application‘s different, and
no. of

FMS supplier can start from scratch to supply a FMS host solution every time for each new

FMS user. A supplier‘s solution need to be flexible enough to integrate the different machine

types in to different FMS configurations and layouts for different product mixes.

6.What are the database requirements of CIM?(even 2014, odd 2014)

A major challenge facing the implementation of CIM is to establish the type of

data needed to bridge the mechanical design and manufacturing function. Following
is the list of varied tasks one might expect to accomplish in a CIM environment.

1.Designing assemblies and performing tolerance analysis on those assemblies.

2. Preparing production drawings of assemblies, invidual parts, tooling, fixtures and

other manufacturing facilities.

3. Creating analytical models of parts for structural, kinematics and thermal analysis
(FEM, MeM etc., )
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4. Calculating weights, volumes, centres of gravity (mass properties) and costs of

manufacturing (cost estimation). Classifying existing parts according to shape,
function and the process by which they are manufactured and retrieving these pans
from the parts library on demand (Group technology and coding).

1. Preparing parts lists and bill of materials (BOM).

2. Preparing process plans for individual part manufacture and assembly

(Variant or Generative).

3. Programming CNC machines for processing complete parts (CAM).

4. Designing work cells and programming the movement of components in

those cells using work handling devices like robots, conveyors, AGVS/ RGVs,
etc., (Cellular manufacture).

5. Controlling engineering changes and maintaining associativity between

design and manufacturing (concurrent associativity).

6. Preparing programs to handle components or manipulate production

equipment (like welding torches or robots).

7. Preparing inspection programs including programs for CNC co-ordinate

measuring machines {CNC- CMMS}.

The exchange of graphic information has been advanced with increasing

acceptance of Initial Graphics Exchange Specification (IGES) and STEP.

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7. Explain the Barcode Technology in automatic data collection system?(even

2013,odd 2014, even 2012)

A bar code (often seen as a single word, barcode) is the small image of lines
(bars) and spaces that is affixed to retail store items, identification cards, and postal
mail to identify

a particular product number, person, or location. The code uses a sequence of

vertical bars and spaces to represent numbers and other symbols. A bar code
symbol typically consists of five parts: a quiet zone, a start character, data
characters (including an optional check character), a stop character, and another
quiet zone.

barcode symbol

A barcode is an optical machine-readable representation of data relating to

the object to which it is attached. Originally barcodes systematically represented
data by varying the widths and spacings of parallel lines, and may be referred to as
linear or one-dimensional (1D). Later they evolved into rectangles, dots, hexagons
and other geometric patterns in two dimensions (2D). Although 2D systems use a
variety of symbols, they are generally referred to as barcodes as well. Barcodes
originally were scanned by special optical scanners called barcode readers. Later,
scanners and interpretive software became available on devices including desktop
printers and smartphones.

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An early use of one type of barcode in an industrial context was sponsored

by the Association of American Railroads in the late 1960s. Developed by General
Telephone and Electronics (GTE) and called KarTrak ACI (Automatic Car
Identification), this scheme involved placing colored stripes in various combinations
on steel plates which were affixed to the sides of railroad rolling stock. Two plates
were used per car, one on each side, with the arrangement of the colored stripes
representing things such as ownership, type of equipment, and identification
number. The plates were "read" by a trackside scanner located, for instance, at the
entrance to a classification yard while the car was moving past The project was
abandoned after about ten years because the system proved unreliable after long-
term use in the field.

Barcodes became commercially successful when they were used to automate

supermarket checkout systems, a task for which they have become almost
universal. Their use has spread to many other tasks that are generically referred to
as automatic identification and data capture (AIDC). The very first scanning of the
now ubiquitous Universal Product Code (UPC) barcode was on a pack of Wrigley
Company chewing gum in June 1974.

Other systems have made inroads in the AIDC market, but the simplicity,
universality and low cost of barcodes has limited the role of these other systems
until the 2000s (decade), over 40 years after the introduction of the commercial
barcode, with the introduction of technologies such as radio frequency identification,
or RFID.

Barcode Reader

A barcode reader is used to read the code. The reader uses a laser beam
that is sensitive to the reflections from the line and space thickness and variation.
The reader translates the reflected light into digital data that is transferred to a
computer for immediate

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action or storage. Bar codes and readers are most often seen in supermarkets and
retail stores, but a large number of different uses have been found for them. They
are also used to take inventory in retail stores; to check out books from a library; to
track manufacturing and shipping movement; to sign in on a job; to identify hospital
patients; and to tabulate the results of direct mail marketing returns.

Very small bar codes have been used to tag honey bees used in research.
Readers may be attached to a computer (as they often are in retail store settings) or
separate and portable, in which case they store the data they read until it can be fed
into a computer.

There is no one standard bar code; instead, there are several different bar
code standards called symbologies that serve different uses, industries, or
geographic needs. Since 1973, the Uniform Product Code (UPC), regulated by the
Uniform Code Council, an industry organization, has provided a standard bar code
used by most retail stores. The European Article Numbering system (EAN),
developed by Joe Woodland, the inventor of the first bar code system, allows for an
extra pair of digits and is becoming widely used. POSTNET is the standard bar code
used in the United States for ZIP codes in bulk mailing. The following table
summarizes the most common bar code standards.

Barcode Scanning Technology

Scanning technology is constantly evolving and providing industries with

more choices in data capture solutions. Two competing data capture devices: the
laser scanner and the digital imager have many businesses facing a tough decision.
Deciding which scanning technology is right for your application can be a difficult
task. Knowing the advantages and applications in which these two technologies are
used is the first step to success.

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The key to deciding between these two technologies is determining which fits
the requirements and budget of your business most accurately.

2D Data Matrix Code

Both laser scanners and digital images are programmed to decode specific
symbologies, or the ―language,‖ of barcodes. The symbology used in the application
can

help determine which scanning technology will provide the most benefit. The use of
2-dimensional (2D) symbologies is on the rise in many markets, making digital
imagers a better choice. However, for applications that don‘t require reading 2D
barcodes, laser

scanners are a cost-effective option.

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UNIT – V

INDUSTRIAL ROBOTICS

Part - A (2 Marks)

1. Production Planning and control(even 2016)

Production planning and control may be defined as the direction as the

direction and coordination of a firm‘s material and physical facilities towards the

attainment of pre specified Production of goods, with production

efficiency.

2. Discuss about Production planning(even 2016)

Deciding which products to make, how many of each, and when

they should be completed.

Planning the manpower and equipment resources needed to

accomplish the production plan.

Scheduling the production and delivery of the parts and products ;

3. explain Production control(odd 2015)

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Production control is concerned with determining whether the necessary

resources to implement the production plan have been provided or not.

4. What are the Activities of production control.(odd 2015)

Shop floor control;

Inventory control;

Manufacturing resource planning (MRP II); and

Just-in-time manufacturing systems.

5. MRP - Function of MRP(even 2015,odd 2012)

It is a planning technique. It translates the master production schedule (MPS)

of end products into a detailed schedule for the raw materials and parts used in
those end products.

6. what is BOM(odd 2014)

The bill of materials (BOM) designates what itemsand how many of each are
used to make up a specified final product.

7. Benefits of MRP(odd 2014)

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The benefits of implementing MRP system are:

Reduced inventory levels.

Better Production scheduling

Reduced production lead time.

Better machine utilization.

Improved product quality.

8. What is Material requirements planning (MRP)(even 2014)

It is a production planning and inventory control system used to manage

manufacturing processes. Most MRP systems are software-based, while it is
possible to conduct MRP by hand as well.

An MRP system is intended to simultaneously meet three objectives:

Ensure materials are available for production and products are available for
delivery to customers.

Maintain the lowest possible material and product levels in store

Plan manufacturing activities, delivery schedules and purchasing activities.

9. Define Agile manufacturing(even 2014)

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It is a term applied to an organization that has created the processes, tools,

and training to enable it to respond quickly to customer needs and market changes
while still controlling costs and quality.

10. explain Inventory Control(even 2013)

It is the supervision of supply, storage and accessibility of items in order to

ensure an adequate supply without excessive oversupply. It can also be referred
as internal control - an accounting procedure or system designed to promote
efficiency or assure the implementation of a policy or safeguard assets or avoid
fraud and error etc.

Part - B ( 16 Marks)

1.Explain the Inventory management in CIM?(even 2015)

Definition - Inventory

Inventory management is primarily about specifying the size and placement

of stocked goods. Inventory management is required at different locations within a
facility or within multiple locations of a supply network to protect the regular and
planned course of production against the random disturbance of running out of
materials or goods.

The scope of inventory management also concerns the fine lines between
replenishment lead time, carrying costs of inventory, asset management, inventory
forecasting, inventory valuation, inventory visibility, future inventory price
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forecasting, physical inventory, available physical space for inventory, quality

management, replenishment, returns and defective goods and demand forecasting
and also by replenishment Or can be defined as the left out stock of any item used
in an organization. inventory is liabilities of a business.

The overseeing and controlling of the ordering, storage and use of

components that a company will use in the production of the items it will sell as well
as the overseeing and controlling of quantities of finished products for sale. A
business's inventory is one of its major assets and represents an investment that is
tied up until the item is sold or used in the production of an item that is sold. It also
costs money to store, track and insure inventory. Inventories that are mismanaged
can create significant financial problems for a business, whether the
mismanagement results in an inventory glut or an inventory shortage.

Inventory or stock refers to the goods and materials include that a business
holds for the ultimate purpose of resale (or repair).

Inventory management is a science primarily about specifying the shape and

percentage of stocked goods. It is required at different locations within a facility or
within many locations of a supply network to precede the regular and planned
course of production and stock of materials.

The scope of inventory management concerns the fine lines between

replenishment lead time, carrying costs of inventory, asset management, inventory
forecasting, inventory valuation, inventory visibility, future inventory price
forecasting, physical inventory, available physical space for inventory, quality
management, replenishment, returns and defective goods, and demand forecasting.
Balancing these competing requirements leads to optimal inventory levels, which is
an ongoing process as the business needs shift and react to the wider environment.

Inventory management involves a retailer seeking to acquire and maintain a

proper merchandise assortment while ordering, shipping, handling, and related
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costs are kept in check. It also involves systems and processes that identify
inventory requirements, set targets, provide replenishment techniques, report actual
and projected inventory status and handle all functions related to the tracking and
management of material. This would include the monitoring of material moved into
and out of stockroom locations and the reconciling of the inventory balances. It also
may include ABC analysis, lot tracking, cycle counting support, etc. Management of
the inventories, with the primary objective of determining/controlling stock levels
within the physical distribution system, functions to balance the need for product
availability against the need for minimizing stock holding and handling costs.

Definition - Inventory management

Inventory management is primarily about specifying the size and placement

of stocked goods. Inventory management is required at different locations within a
facility or within multiple locations of a supply network to protect the regular and
planned course of production against the random disturbance of running out of
materials or goods.

The scope of inventory management also concerns the fine lines between
replenishment lead time, carrying costs of inventory, asset management, inventory
forecasting, inventory valuation, inventory visibility, future inventory price
forecasting, physical inventory, available physical space for inventory, quality
management, replenishment, returns and defective goods and demand forecasting
and also by replenishment Or can be defined as the left out stock of any item used
in an organization. inventory is liabilities of a business.

2.explain the Material requirements planning (MRP) in CIM?(even 2015)

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It is a production planning, scheduling, and inventory control system used to

manage manufacturing processes. Most MRP systems are software-based, while it
is possible to conduct MRP by hand as well.

An MRP system is intended to simultaneously meet three objectives:

Ensure materials are available for production and products are available for
delivery to customers.
Maintain the lowest possible material and product levels in store

Plan manufacturing activities, delivery schedules and purchasing activities.

History Of MRP

Prior to MRP, and before computers dominated industry, Reorder point

(ROP) / reorder-quantity (ROQ) type methods like EOQ (Economic Order Quantity)
had been used in manufacturing and inventory management.

In 1964, as a response to the Toyota Manufacturing Program, Joseph Orlicky

developed Material Requirements Planning (MRP). The first company to use MRP
was Black & Decker in 1964, with Dick Alban as project leader. Orlicky's book
Material Requirements Planning has the subtitle The New Way of Life in Production
and Inventory

Management (1975). By 1975, MRP was implemented in 700 companies. This

number had grown to about 8,000 by 1981.

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In 1983 Oliver Wight developed MRP into manufacturing resource planning

(MRP II).[1] In the 1980s, Joe Orlicky's MRP evolved into Oliver Wight's
manufacturing resource planning (MRP II) which brings master scheduling, rough-
cut capacity planning, capacity requirements planning, S&OP in 1983 and other
concepts to classical MRP. By 1989, about one third of the software industry was
MRP II software sold to American industry ($1.2 billion worth of software).[2]

Functions of MRP;

The basic functions of an MRP system include: inventory control, bill of

material processing, and elementary scheduling. MRP helps organizations to
maintain low inventory levels. It is used to plan manufacturing, purchasing and
delivering activities.

"Manufacturing organizations, whatever their products, face the same daily

practical problem - that customers want products to be available in a shorter time
than it takes to make them. This means that some level of planning is required."

Companies need to control the types and quantities of materials they purchase,
plan which products are to be produced and in what quantities and ensure that they
are able to meet current and future customer demand, all at the lowest possible
cost. Making a bad decision in any of these areas will make the company lose
money. A few examples are given below:

If a company purchases insufficient quantities of an item used in

manufacturing (or the wrong item) it may be unable to meet contract
obligations to supply products on time.
If a company purchases excessive quantities of an item, money is wasted -
the excess quantity ties up cash while it remains as stock and may never
even be used at all.

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Beginning production of an order at the wrong time can cause customer

deadlines to be missed.

MRP is a tool to deal with these problems. It provides answers for several questions:

What items are required?

How many are required?

When are they required?...

MRP can be applied both to items that are purchased from outside suppliers and to
sub-assemblies, produced internally, that are components of more complex items.

3.Explain the Manufacturing Shop Floor Control(odd 2015, even 2013)

Definition

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.

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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

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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.

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.

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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.Explain the Agile and Lean manufacturing in CIM?(odd 2015,even 2013)

Agile manufacturing is a term applied to an organization that has created

the processes, tools, and training to enable it to respond quickly to customer needs
and market changes while still controlling costs and quality.

An enabling factor in becoming an agile manufacturer has been the

development of manufacturing support technology that allows the marketers, the
designers and the production personnel to share a common database of parts and
products, to share data on production capacities and problems — particularly where
small initial problems may have larger downstream effects. It is a general
proposition of manufacturing that the cost of correcting quality issues increases as
the problem moves downstream, so that it is cheaper to correct quality problems at
the earliest possible point in the process.

Agile manufacturing is a term applied to an organization that has created the

processes, tools, and training to enable it to respond quickly to customer needs and
market changes while still controlling costs and quality.

An enabling factor in becoming an agile manufacturer has been the

development of manufacturing support technology that allows the marketers, the
designers and the production personnel to share a common database of parts and
products, to share data on production capacities and problems — particularly where
small initial problems may have larger downstream effects.

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It is a general proposition of manufacturing that the cost of correcting quality

issues increases as the problem moves downstream, so that it is cheaper to correct
quality problems at the earliest possible point in the process. Agile manufacturing is
seen as the next step after Lean manufacturing in the evolution of production
methodology. The key difference between the two is like between a thin and an
athletic person, agile being the latter. One can be neither, one or both. In
manufacturing theory, being both is often referred to as leagile.

According to Martin Christopher, when companies have to decide what to be,

they have to look at the Customer Order Cycle (the time the customers are willing to
wait) and the leadtime for getting supplies. If the supplier has a short lead time, lean
production is possible. If the COC is short, agile production is beneficial.

Lean manufacturing or lean production, often simply "lean", is a

systematic method for the elimination of waste ("Muda") within a manufacturing
process. Lean also takes into account waste created through overburden ("Muri")
and waste created through unevenness in work loads ("Mura"). Working from the
perspective of the client who consumes a product or service, "value" is any action or
process that a customer would be willing to pay for.

Essentially, lean is centered on making obvious what adds value by reducing

everything else. Lean manufacturing is a management philosophy derived mostly
from the Toyota Production System (TPS) (hence the term Toyotism is also
prevalent) and identified as "lean" only in the 1990s TPS is renowned for its focus
on reduction of the original Toyota seven wastes to improve overall customer value,
but there are varying perspectives on how this is best achieved. The steady growth
of Toyota, from a small company to the world's largest automaker, has focused
attention on how it has achieved this success.
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5.Explain the Production systemin CIM?(even 2014, odd 2012)

The term production system may refer to:

In operations management and industrial engineering, a production system

comprises both the technological elements (machines and tools) and
organizational behavior (division of labor and information flow) needed to
produce something.

In computer science, a production system (or production rule system) is a

computer program typically used to provide some form of artificial
intelligence.

Toyota Production System, organizes manufacturing and logistics at Toyota

The Computer Animation Production System (CAPS) is a proprietary

collection of software, scanning camera systems, servers, networked
computer workstations, and custom desks developed by The Walt Disney
Company together with Pixar in the late-1980s.

Subsea Production Systems are typical wells located on the sea floor,
shallow or deep water.

Production control is the activity of monitoring and controlling any particular

production or operation. Production control is often run from a specific control room
or operations room

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Role of Production Control in the Production Cycle.

Basic Process Control Strategies

In a simple control system, a process variable (PV) is measured and

compared with a setpoint value (SP). A manipulated variable (MV, or output) signal
is generated by the controller and sent to a final control element, which then
influences the process variable to

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achieve stable control. The algorithm by which the controller develops its
output signal is typically PID (Proportional-Integral-Derivative), but other
algorithms may be used as well:

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This form of simple control may be improved upon and expanded for
a greater range of process applications by interconnecting multiple
controllers and/or redirecting measurement and control signals in more
complex arrangements. An exploration of some of the more common control
system configurations is the subject of this chapter.

6.Explain the Direct digital control (DDC)in CIM?(odd 2014, even 2012)

It is the automated control of a condition or process by a digital device

(computer).[1][2] DDC is considered by many to be a more modern, granular
and responsive

update to older HVAC control systems based upon PLC technologies. In

those older PLC based systems, each zone was self-sufficient and
contained all of the instrumentation and control elements needed to consider

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analog and digital inputs and then take actions according to rules. The
complexity came from the desire to expand these 'zones' from a few dozen
points and a handful of controlled elements to much broader building-wide
systems. Connecting PLCs together becomes complex, and the creation of
rules which would be loaded individually into each PLC impractical.

DDC on the other hand takes a more centralized network-oriented

approach. All instrumentation is gathered by various analog and digital
converters which use the network to transport these signals to the central
controller. The centralized computer then follows all of its production rules
(which may incorporate sense points anywhere in the structure) and causes
actions to be sent via the same network to valves, actuators, and other
HVAC components that can be adjusted.

Central controllers and most terminal unit controllers are

programmable, meaning the direct digital control program code may be
customized for the intended use. The program features include time
schedules, setpoints, controllers, logic, timers, trend logs, and alarms The
unit controllers typically have analog and digital inputs, that allow
measurement of the variable (temperature, humidity, or pressure) and
analog and digital outputs for control of the medium (hot/cold water and/or
steam). Digital inputs are typically (dry) contacts from a control device, and
analog inputs are typically a voltage or current measurement from a variable
(temperature, humidity, velocity, or pressure) sensing device.

Digital outputs are typically relay contacts used to start and stop
equipment, and analog outputs are typically voltage or current signals to

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control the movement of the medium (air/water/steam) control devices.

Usually abbreviated as "DDC".

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