INTEGRATED MANUFACTURING SYSTEMS

Computer Integrated Manufacturing (CIM)

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Definition of CIM by the Computer and Automation Systems Association of the Society of manufacturing Engineers (CASA/SME):

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.

What is CIM?
CIM is the integration of all enterprise operations and activities around a common corporate data repository. It is the use of integrated systems and data communications coupled with new managerial philosophies.

What is CIM?
CIM is not a product that can be purchased and installed. It is a way of thinking and solving problems.

CIM Objectives
Simplify production processes, product designs, and factory organization as a vital foundation to automation and integration Automate production processes and the business functions that support them with computers, machines, and robots Integrate all production and support processes using computer networks, cross-functional business software, and other information technologies
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POTANTIAL BENEFITS OF CIM

Improved customer service Improved quality Shorter time to market with new products Shorter flow time Shorter vendor lead time Reduced inventory levels Improved schedule performance Greater flexibility and responsiveness Improved competitiveness Lower total cost Shorter customer lead time Increase in manufacturing productivity Decrease in work-in process inventory
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Computer-Integrated Manufacturing

CIM Systems
Computer-aided manufacturing (CAM) - automate the production process Manufacturing execution systems (MES) performance monitoring information systems for factory floor operations Process Control control ongoing physical processes Machine Control controls the actions of machines
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The Role of Computer in Manufacturing

The computer has had a substantial impact on almost all activities of a factory. Often, the introduction of the computer changed the organizational structure of a department and made necessary adoption of new management structures.

The Role of Computer in Manufacturing

The operation of a CIM system gives the user substantial benefits: Reduction of design costs by 15-30%; Reduction of the in-shop time of a part by 30-60%; Increase of productivity by 40-70%; Better product quality, reduction of scrap 20-50%.

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Information System
Information systems involve people, hardware, software, computer networks, and data used to manage daily and long-term operations.

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AGILE MANUFACTURING

Agility is the ability to grow and succeed in an environment of constant and unpredictable changes.
In recent years, the manufacturing paradigm has been changing from mass production to agile manufacturing.
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AGILE MANUFACTURING
Globalization of markets has put tremendous pressure on manufacturing enterprises to be competitive.
To cope with competitive pressures, a new paradigm in manufacturing known as AGILE MANUFACTURING is emerging.
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AGILE MANUFACTURING

The objective of agile manufacturing is to enable manufacturing enterprises to be competitive by dynamically reconfiguring software, equipment and organization structures.

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AGILE MANUFACTURING
The reasons of this trend change are: The strength of global competition is increasing; Mass markets are fragmenting to niche markets; Customers expect low volume, high quality; Short product life-cycles, development

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CHARACTERISTICS OF AGILE MANUFACTURING:

Greater product customization Rapid introduction of new or modified product Advanced interenterpise networking technology Upgradable products Increased emphasis on knowledgeable, highly trained workers Interactive customer relationship
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CHARACTERISTICS OF AGILE MANUFACTURING:

Dynamic reconfiguration of production processes Greater use of flexible production technologies Rapid prototyping An open systems information environment Innovative and flexible management structures Product pricing based on value to the customer Commitment to the bening operations and product designs

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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.

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Communication Networks
For example, sales and marketing can send customer requirements for new products to design engineering. A CAD generated bill of materials can then be transferred to material requirements planning(MRP) systems. Product design information can be transmitted to manufacturing for use in process planning.

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Types of Communication Networks

There 2 main types of communication networks:
1) Telecommunication Networks; 2) Computer communication Networks.

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Types of 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.

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Highlights in the History of Telecommunications

1844 1876 1877 1881 Morse sends the first public telegraph message Telephone patent issued to Alexander Graham Bell First telephone in private home First long-distance line, from Boston, MA, to Providence,RI 1890 Undersea telephone cable, England to France 1915 First transcontinental telephones call in U.S. 1929 Coaxial cable invented; Herbert Hoover becomes the first President with a phone on his desk.

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1947 Transistor invented 1951 Direct long-distance dialing 1960 First test of electronic switch 1963 Touch-tone service introduced 1970 Laser invented 1976 First digital electronic switch installed 1980 Divestiture of AT&T (Ma Bell and the baby bells) 1988 First transatlantic optical fiber cable 1989 First fiber-optic cable to the home field trial, Cerritos, CA 1990 Demonstration of 2000-km links using optical amplifiers without repeaters.

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Networks: 1980s-Decentralized - Isolated

Interaction is between a user and a system! No interaction between users and systems

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 Isolated users/computers/networks No common protocol (language)

Before the Internet

IBM Digital DECNET

SNA

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After 85-Decentralized - Networked

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Types of Communication Networks

Network Architectures & Protocols

A communication network consists of a number components such as hardware, software and media.
A network architecture describes the components, the functions performed, and the interfaces between the components of a network. It encompasses hardware, software, standards, data link controls, topologies and protocols.

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Computer Networks
Computer network connects two or more autonomous computers.

The computers geographically anywhere.

can be located

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Applications of Networks
Resource Sharing Hardware (computing resources, disks, printers) Software (application software) Information Sharing Easy accessibility from anywhere (files, databases) Search Capability (WWW) Communication Email, Message broadcast

Remote computing
Distributed processing (GRID Computing)
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Types of Communication Networks

Network Architectures & Protocols

It defines the functions of, and interactions between, three types of components.
Network hardware components Communication software modules Application programs that use the networks

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Types of Communication Networks

Network Architectures & Protocols PROTOCOL: Protocols in network architecture define the set of rules of information exchange between two devices(peers). Protocols specify the message format and the rules for interpreting and reacting to messages.

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Types of Communication Networks

Computer Network Reference Model

The OSI (Open Systems Interconnection) Reference Model is an architecture that enables different vendors systems, such as DECNET, SNA, TCP/IP and SINEC, to communicate by using a common set of protocols.

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Types of Communication Networks

The reference model is based on: The communication functions are divided into layers; The services to be provided by each layer are specified; Layer N+1, above layer N, uses the services of the latter to implement its functions; Communication between the layer N and the participating terminals is specified by the ISO protocols.

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Types of Communication Networks

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Layer Functionality
Departing airport
baggage (check) gates (load) runway takeoff airplane routing baggage (claim)

gates (unload)
runway landing airplane routing

intermediate air traffic sites

airplane routing airplane routing

airplane routing
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arriving airport

ticket (purchase)

ticket (complain)

Layering: physical communication

ODT data application transport network link physical application transport network link physical

Trk Telekom

network link physical

data application transport network link physical

application transport network link physical

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TYPES OF COMPUTER NETWORKS

Local Area Networks (LANs) Used to interconnect computers (wired or wireless) within the same building or organisation. A LAN typically operates at speeds ranging from 10 Mbps to 10 Giga bps, connecting several hundred devices over a distance of up to 5 to 10 km

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METU Wireless LAN Access Points (Green dots)

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Metropolitan Area Networks (MANs) - MANs are large LANs that cover a large city or suburb. Used to interconnect LANs within a metropolitan area. A typical MAN operates at a speed of several Gigabit per second (mostly wired but new wireless technologies are becoming popular, e.g. wimax)

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Wide Area Networks (WANs) Use common carrier facilities over long distances and are used to connect sites and facilities over the countries . Usually the speed between the cities can vary from 1 to 100Gbps. In a WAN, the cost of transmission is very high, and the network is usually owned and operated by a public network (e.g. TTNET)

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US Backbone

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Global Area Networks (GAN) these are networks connections between countries around the globe. A GANs speed ranges from 1.5Mbps to 100Gbps and its reach is several thousands of kilometres.

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enterprise level Globally link various plants/sites and interconnect corporations through electronic data interchange

COMMUNICATION HIERARCHY

plant level Connect departments inside plant

cell level Connect cells inside departments equipment/device level connect individual devices such as computers, robots and NC machines
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MANUFACTURING
Parallel with increasing needs for faster communications the needs of large data storage capacity and fast computers is increasing also. Now typical manufacturing environment, called also as CAD/CAM/CAE environment is composed of fast computers, centralized data storage units, CNC controlled machine centers, robots etc., all connected on the same network. On this networks either TCP/IP or specially designed manufacturing protocols like, MAP or TOP, are used.

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MANUFACTURING
MAP An initiative by General Motors of The United States has resulted in the selection of a set of protocols, all based on ISO standards, to achieve open system interconnection within an automated manufacturing plant.
The resulting protocols are knows as manufacturing automation protocols (MAPs).
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MANUFACTURING

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MANUFACTURING
TOP
In a similar way, an initiative by the Boeing Corporation (USA) has resulted in the selection of a set of ISO standards to achieve open system interconnection in a technical and office environment.

The selected protocols are known as technical and office protocols (TOPs).

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MANUFACTURING

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