1. Computer-Integrated Manufacturing (CIM)
KR: Supplement B
Computer-Integrated Manufacturing (CIM)

2. Definition of Automation
Automation is a technology with the application of mechanical, electronic, and computer-based systems to operate and control production, this technology includes:
Automatic machine tools to process parts
Automatic assembly machines
Industrial robots
Automatic material handling and storage systems
Automatic inspection systems for quality control
Feedback control and computer process control
Computer systems for planning, data collection, and decision making to support manufacturing activities

3. Types of Automation Fixed automation Programmable automation
Flexible automation
Fixed Automation
Flexible Automation
Programmable Automation

4. Number of different parts
Programmable automation
High
Production variety
Medium
Flexible automation
Fixed
Automation
Manual methods
Low
Parts per year
Low
Medium
High
Production volume
. Three types of production automation as a function of production volume and product variety.

5. Basic Components of an NC System.
Program
Machine control unit
Processing equipment
Basic Components of an NC System.
FIGURE Basic components of an NC system.

6. General configuration of a direct numerical control (DNC)
Central
computer
Bulk
Memory
NC programs
Telecommunication lines
Machine tools
General configuration of a direct numerical control (DNC)

7. General configuration of a direct numerical control (CNC) system
Tape
Reader
for
initial program
entry NC
Program
storage
Microcomputer
(software
functions)
Computer-
hardware
interface
and
servosystem
General configuration of a direct numerical control (CNC) system

8. Robot and Its Standard Movements

9. Where Robots Are Better
Hazardous work environment for human beings
Repetitive work cycle
Difficult handling for human beings
Multishift operation
Infrequent changeovers
Part position and orientation are established

10. Possible Objectives for Installing an Automated Storage System in a Factory or Warehouse
Increase storage capacity
Increase floor space utilization
Recover space for manufacturing facilities
Improve security and reduce pilferage
Reduce labor cost in storage operations
Increase labor productivity in storage operations
Improve safety in storage function
Improve control over inventories
Increase stock rotation
Improve customer service

11. Flexible Manufacturing Systems
What is an FMS
A flexible manufacturing system consists of a group of processing stations (CNC), interconnected by means of an automated material handling and storage system, and controlled by an integrated computer system.
Components of an FMS
Processing stations
Material handling and storage
Computer control system

12. FMS

13. CIM Managerial Issues Cost-benefit analysis
Advantages
Cost justification
CIM and manufacturing strategy
Organizational and behavioral aspects
Lessons learned

14. Synergistic Effects of a CIM System
Benefits of data integration
CIM benefits
Benefits of each separate technology

15. Advantage of CIM Higher quality Shorter lead time Less inventory
Higher flexibility
Economy of scope
Less floor space
Less material handling

16. CIM and Manufacturing Strategy
Cost leadership vs. differentiation
Productivity vs. innovation
Efficiency vs. flexibility
Market segmentation
Fixed costs vs. variable costs
Break-even point
Barriers to entry

17. Flexible Manufacturing
Traditional Technology can be described by:
Economy of scale
Learning curve
Task specialization
Work as a social activity
Separable variable costs
Standardization
Expensive flexibility and variety
In contrast the CIM Factory is described by:
Economy of scope
Truncated product life cycle
Multimission facilities
Unmanned systems
Joint costs
Variety
Profitable flexibility and variety

18. Flexible Manufacturing
Leading to factories that exhibit characteristics of:
Traditional
CIM
Centralization
Large plants
Balanced lines
Smooth flows
Standard product design
Low rate of change and high stability
Inventory used as a buffer
“Focused factory” as an organizing concept
Job enrichment and enlargement
Batch systems
Decentralization
Disaggregated capacity
Flexibility
Inexpensive surge and turnaround ability
Many custom products
Innovation and responsiveness
Production tied to demand
Functional range for repeated reorganization
Responsibility tied to reward
Flow systems

19. Taking Advantage of CIM Capabilities
To effectively use the capabilities of CIM as a strategic weapon, a firm should:
Invest in flexibility of, not just equipment, but the organization as a whole.
Deliberately truncate the product life cycle by introducing new versions frequently; and thus not giving the competitors a chance to catch up.
Proliferate the range of products to the extent of customizing them one-by-one so that no customer has any reason to go to the competitors.
Deliberately fragment the market into segments so small that they cannot support a conventional production system.
Deliberately complicate the product so that it cannot be copied with the old manufacturing process and technology.

20. Organizational and Behavioral Aspects of CIM
Integration of functions
Flattening the organization structure
Changing role of supervisors
Impact on workers
Shift from direct to indirect workers
Increased skill requirements
Displacement of workers
Retraining and education

21. Lessons Learned Focus on a flexible business enterprise.
An automated mess is still a mess.
People make flexible automation work.
Provide an adequate funding.
Focus on potentials of new technology.
Understanding the emerging technologies.

22. CIM Examples
Toshiba
Toshiba’s computer factory in Ome is called an “intelligent works” because a snazzy computer network links office, engineering and factory operations, providing just-in-time information as well as just-in-time parts. Ome workers assemble nine different word processors on the same line and, on an adjacent one, 20 varieties of laptop computers. Usually they make a batch of 20 before changing models, but Toshiba can afford lot sizes as small as ten.
Workers on the lines have been trained to make each model but don’t need to rely on memory. A laptop at every post displays a drawing and instructions, which change when the model does. Product life cycles for low-end computers are measured in months these days, so the flexible lines allow the company to guard against running short of a hot model or overproducing one whose sales have slowed, Toshiba’s next goal: to get managers thinking about how to ship small lots fast and cheaply, with quicker feedback from stores, so sales and distribution are as flexible as the factories

23. CIM Examples
Fuji
Fuji Electric’s investment in FMS and the like soared starting in Fuji’s goal was to reduce lead time 30%, labor costs 70% , and work in-process inventory 50%.
When Fuji gets and order for an electric motor switch, 20% of the time the buyer wants-and gets 24 hour delivery. Another 40% must arrive within two days. Fuji didn’t narrow its product line: Those schedules are for customized work.

24. Variety Is Free Flexibility Through Manufacturing Technology
Ingersoll Milling Machine Company
The Ingersoll Co. uses an advanced CIM system that links design with manufacturing and process control. Ingersoll’s state-of-the-art computer-controlled manufacturing system will machine over 25,000 different prismatic parts used for specialized motor controls. Seventy percent of the production will occur in lot sizes of one. Half of the 25,000 will never be used again. Production cost is approximately the same as for a long run of a single standard part.

25. Variety Is Free Flexibility Through Manufacturing Technology
Vought Corporation
Vought Corporation’s $10 million flexible machining center began operations during the late 1980s. This advanced production technology allows the aerospace maker to produce some 600 different designs of specialized aircraft parts using the same equipment--even one design at a time in random sequence. It is expected to save Vought over $25 million annually in machine costs for these parts by performing 200,000 hours of work in less than 70,000 hours.