Sub: Computer Aided Design Unit 1: Introduction to Computer Graphics and Database

Introduction
Production Planning is a managerial function which is mainly concerned with the following important issues:
What production facilities are required?
How these production facilities should be laid down in the space available for production? and
How they should be used to produce the desired products at the desired rate of production?
Broadly speaking, production planning is concerned with two main aspects: (i) routing or planning work tasks (ii)
layout or spatial relationship between the resources. Production planning is dynamic in nature and always remains
in fluid state as plans may have to be changed according to the changes in circumstances.

Production control is a mechanism to monitor the execution of the plans. It has several important functions:
Making sure that production operations are started at planned places and planned times.
Observing progress of the operations and recording it properly.
Analyzing the recorded data with the plans and measuring the deviations.
Taking immediate corrective actions to minimize the negative impact of deviations from the plans.
Feeding back the recorded information to the planning section in order to improve future plans.
A block diagram depicting the architecture of a control system is shown in Figure1. Important functions covered
by production planning and control (PPC) function in any manufacturing system are shown in Table1along with
the issues to be covered.

Types of Production Systems

A production system can be defined as a transformation system in which a saleable product or service is created
by working upon a set of inputs. Inputs are usually in the form of men, machine, money, materials etc. Production
systems are usually classified on the basis of the following:
Type of product,
Type of production line,
Rate of production,
Equipments used etc.
They are broadly classified into three categories:

Job shop production

Batch production
Mass production

Job Production
In this system products are made to satisfy a specific order. However that order may be produced-
only once
or at irregular time intervals as and when new order arrives
or at regular time intervals to satisfy a continuous demand
The following are the important characteristics of job shop type production system:
Machines and methods employed should be general purpose as product changes are quite frequent.
Planning and control system should be flexible enough to deal with the frequent changes in product
requirements.
Man power should be skilled enough to deal with changing work conditions.
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Schedules are actually nonexistent in this system as no definite data is available on the product.
In process inventory will usually be high as accurate plans and schedules do not exist.
Product cost is normally high because of high material and labor costs.
Grouping of machines is done on functional basis (i.e. as lathe section, milling section etc.)
This system is very flexible as management has to manufacture varying product types.
Material handling systems are also flexible to meet changing product requirements.

Batch Production
Batch production is the manufacture of a number of identical articles either to meet a specific order or to meet a
continuous demand. Batch can be manufactured either-
only once
or repeatedly at irregular time intervals as and when demand arise
or repeatedly at regular time intervals to satisfy a continuous demand
The following are the important characteristics of batch type production system:
As final product is somewhat standard and manufactured in batches, economy of scale can be availed to
some extent.
Machines are grouped on functional basis similar to the job shop manufacturing.
Semi automatic, special purpose automatic machines are generally used to take advantage of the similarity
among the products.
Labor should be skilled enough to work upon different product batches.
In process inventory is usually high owing to the type of layout and material handling policies adopted.
Semi automatic material handling systems are most appropriate in conjunction with the semi automatic
machines.
Normally production planning and control is difficult due to the odd size and non repetitive nature of
order.

Mass Production
In mass production, same type of product is manufactured to meet the continuous demand of the product. Usually
demand of the product is very high and market is going to sustain same demand for sufficiently long time.
The following are the important characteristics of mass production system:
As same product is manufactured for sufficiently long time, machines can be laid down in order of
processing sequence. Product type layout is most appropriate for mass production system.
Standard methods and machines are used during part manufacture.
Most of the equipments are semi automatic or automatic in nature.
Material handling is also automatic (such as conveyors).
Semi skilled workers are normally employed as most of the facilities are automatic.
As product flows along a pre defined line, planning and control of the system is much easier.
Cost of production is low owing to the high rate of production.
In process inventories are low as production scheduling is simple and can be implemented with ease.

Manufacturing Systems Types

Let us first look at the essential components of Manufacturing Systems:
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The process of designing a manufacturing system therefore must engage upon the design of each of the above
four components AND their integration.

Physical Systems refer to all physical aspects of a manufacturing system, including the factories, including the
facilities, machines, tools etc., the raw materials, the material handling systems, the work in process, as well as
the products.
Product based: These are manufacturing systems that are designed specifically for a fixed product (or product
type). The underlying principles are those of interchangeability, and division of labour. These systems may be
highly automated or human-labour intensive. However, in every case, they must operate at relatively high
throughput rates.
Further divided into:
Continuous production (e.g. chemicals, food processing etc.)

Discrete part production.

Further divided into:
Assembly lines
Transfer Lines
Process-based: these are facilities where machines of the same type are grouped together physically. Some
examples may be seen in job shops, workshops, prototype makers, tool makers.
Flexible Manufacturing systems may loosely be categorized as highly automated versions of process-based
systems.
Cellular: Cells are formed using GT, and typical cells are small clusters of a mixed bunch of machines that can
handle a particular family of products. Such layouts are used when the batch sizes of orders are not large, but
throughput times required are lower.
Fixed position: For single units of a large item (e.g. construction project, MTR line, ship building etc.)

The Operation refers to all aspects of decision structures that determine how the system functions. For example,
does it use a Toyota style pull production, or does it depend on an MRP II system with forecasts driven
production? How does the plant manager determine the size and sequence of the jobs to be done on each machine,
on each day?
Once we have a physical system all installed, we need to worry about the operational aspects. This includes,
among other things, Production Control. Several important things here include:
Lot sizing;
Scheduling;
Process Planning;
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When we design the physical systems, we are concerned with the capability to produce the designed part. When
studying the operational aspects, we are more concerned with the efficiency at which we are working. Therefore,
it is essential for us to know our goals, when we make operational decisions. Some typical descriptors used for
Manufacturing Systems include:
WIP (Work in Process): The number of parts that are currently in the shop floor, either being worked upon by a
machine/operator, or waiting at a buffer or in a queue.
Production rate: number of finished parts being produced by the system in unit time.
Throughput time: the time that a part spends in the system from the moment it is released from the inventory to
the time it leaves the system.
Usually, we would like to make operational plans that are "good". That means we should know what we mean by
"good", especially since often, different desirable objectives tend to be conflicting [which is what gave rise to teh
famous saying: Good, Cheap, Fast. Pick any two.].

The Information in a manufacturing system refers to all data that will be accessed by some
function/person/decision-maker/software etc., and whose value may be used deciding upon an action. Examples
include design data, machine data, tool data, inventory status, process data, vendors, clients, personnel data and so
on. It is likely that for any MS of reasonable complexity, one will need automated data handling facilities, e.g. a
DBMS. I will also loosely include in this definition, mechanisms that are required for the flow of information,
that is, Information Technology (IT). This includes communication protocols (such as MAP, TOP, ISO-OSI), etc.

Humans refers to all personnel, vendors, customers, etc. Personnel related issues include: what is the capability
level of available labour, what is the working culture (1-shift, 2-shift availability), how many do we need to hire
for a given MS, what is the level of training needed, what policies will lead to better working environment etc.
Customers are another essential human element in the design of MS.
In the Human part, we will look at two important aspects:
What are the conditions under which the workers perform the best? How can this information be used to
design the work pattern of workers, and working system of manufacturing systems (team oriented
systems)?
Why is the customer an important part of the operations of the MS? What implications does this
participation of the customer have on the operation and organisation of the MS.

Manufacturing system: classification

Manufacturing systems: classification in the horizontal direction: Various types of
1. Enterprise manufacturing system: a system that has its own independent management.
2. Shop floor manufacturing system: a sub-system of an enterprise where manufacturing activities are
carried out.
3. Cell or line manufacturing system: a group of machines that produce a part.
4. Machine manufacturing system: a single entity that changes the input material
Examples of the different types of machine manufacturing system are: lathe, milling, drilling, etc.
Machining Operations and Machine Tools
1. Turning & Related Operations
Turning a machining process in which a single-point tool remove material from the surface of a rotating work
piece. (Lathe)
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Operations related to Turning

Work Holding

Mounting between two centers (Dog & Live center) Chuck

Collet
Face plate
Other Lathes & Turning Machine
Engine Lathe
Tool room Lathe and Speed Lathe
Turret Lathe: The tailstock is replaced with a turret
Chucking Machines No tailstock

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Automatic Bar Machine Similar to chuck machine but with a collet
A single- and multiple-spindle bar machines
NC Lathe

2. Drilling & Related Operations

Geometry of Twist drill
Shank, Neck and Drill body
Helix angle, Point angle, Flute, cutting edge, Chisel edge, Margin
Machine Tool for drilling
Drill press
Upright drill
Bench drill
Radial drill
Gang drill - 2-6 drills together
NC drill
Vice, Jig and fixture

3. Milling
Milling A machine operation in which a work part is fed past a rotating cylindrical tool with multiple edges.
(Milling machine)
Types
Peripheral milling
Slab, slotting, side and straddle milling
Up Milling (Conventional) & down milling (Climb)
Facing milling
Conventional face, Partial face, End, Profile, Pocket & contour millings.
Milling Machines
Knee-and-column Milling Machine
Horizontal and Vertical types
Universal and Ram types
Bed-type Mill
Planer-type Mills the largest category
Tracer (profile) Mill reproduce an irregular part geometry
CNC Milling machine

Machining Centers
Machining center highly automated machine tool capable of performing multiple machining operations under
CNC control.
Automatic tool changer
Pallet shuttles
Automatic workpart positioning

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CNC turning center
Other Machining Operations
Shaping and planing
A single-point tool moves linearly relative to the work part
Shaping - A tool moves
Planing A workpart moves
Broaching
Performed by a multiple-tooth cutting tool by moving linearly relative to the work in the direction of the tool
axis.
Sawing
Hacksawing, Bandsawing, and Circular sawing

Computer-integrated manufacturing
Computer-integrated manufacturing (CIM) is the manufacturing approach of using computers to control the entire
production process.
Components of CIMS (Computer Integrated Manufacturing Systems)
Management Information System:
Management information system (MIS) plays an important role in the companys information system. It manages
business processes and information based on market strategy, sales predictions, business decisions, order
processing, material supply, nance management, inventory management, human resource management, company
production plan, and so on. The aims of MIS are to shorten delivery time, reduce cost, and help the company to
make rapid decision to react to market change.
Basic Concept of ERP In balancing manufacturing, distribution, nancial, and other business functions to
optimize company productivity, ERP systems are considered to be the backbone of corporate infrastructure. The
ERP system thus provides more exibility and ability to the company in business process reengineering,
integration with customers, and integration with material suppliers as well as product dispatchers.
Manufacturing Resource Planning The basis of MRPII is MRP (material requirements planning), which dates
back to the 1940s. MRPII uses computer-enhanced materials ordering and inventory control methods. It enhances
speed and accuracy in issuing raw materials to factory work-stations.
Just-in-Time Another method that has received much attention for production planning and control is just-in-time
theory. In contrast to MRPII, which is push oriented, the JIT philosophy of management is pull oriented
that is, it calls for something to be manufactured only when there is a rm order for it. JIT is a productivity
enhancer based on the simple proposition that all waste in the manufacturing process must be eliminated.
CAD/CAPP/CAM Systems
CAD/CAPP/CAM stands for computer-aided design/ computer-aided process planning/computer-aided
manufacturing. The system is sometimes called the design automation system, meaning that CAD/CAPP/CAM is
used to promote the design automation standard and provide the means to design high-quality products faster.
Manufacturing Automation System
Manufacturing automation system is a value-added system. The material ow and information ow come together
in MAS. For a discrete manufacturing company, MAS consists of a number of manufacturing machines,
transportation systems, high-bay stores, control devices, and computers, as well as MAS software. The whole
system is controlled and monitored by the MAS software system. For the process industry, MAS consists of a
number of devices controlled by DCS, the monitor system, and the control software system. The objectives of

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MAS are to increase productivity, reduce cost, reduce work-in-progress, improve product quality, and reduce
production time.
Computer-Aided/Quality-Management-System
Since the 1970s, quality has become an extremely important factor for a company to win market competition.
Customers always want higher product quality for their investment. The computer-aided quality-management
system of CIMS is a system used to guarantee the product quality. It covers a wide range, from product design to
material supply to production quality control. The International Standards Organization (ISO) has established a
series of quality assurance standards, such as ISOs 9000, 9001, 9002, 9003, and 9004. The computer-aided
quality-management system has also been called the integrated quality system.
Computer Network and Database Management Systems
Computer network and database management systems are supporting systems for CIMS. The computer network
consists of a number of computers (called nodes in the network) and network devices, as well as network
software. It is used to connect different computers together to enable the communication of data between different
computers. The computer network can be classied as a local area network (LAN) or a wide area network
(WAN). LAN normally means a restricted area network, such as in a building, factory, or campus. WAN means a
much wider area network, across a city or internationally. Network technology is developing rapidly. The Internet
concept has changed manufacturing companies operation method greatly. Global manufacturing, agile
manufacturing, and network-based manufacturing paradigms have seen rapid development. A computer network
is the infrastructure for these new manufacturing paradigms to be realized in a cost-effective way.

Functions of Computer in CIMS

Machine Control CNC
Micro Computer Feed Back
NC Hardware (interface &
(Software Function
Programming Servo)
&NC Program Storage) Machine center
Direct Numerical Control (DNC)
A manufacturing system in which a number of m/c are controlled by a computer through direct connection & in
real time.
Consists of 4 basic elements: Central computer, Bulk memory (NC program storage), Telecommunication line, an
Machine tools (up to 100).

Central Bulk
Computer Memory

Satellite Bulk
Minicomput Memory
Tele communication lines

m/c m/c Up to 100 m/c tools

Production Control
This function includes decision on various parts onto the system.
Decision is based on:

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red production rate/day for the various parts
Number of raw work parts available
Number of available pallets
Traffic & Shuttle Control
Refers to the regulations of the primary & secondary transportation systems which move parts between
workstation.
Work Handling System Monitoring
The computer must monitor the status of each cart & /or pallet in the primary & secondary handling system.
Tool Control
Keeping track of the tool at each station
Monitoring of tool life
System Performance Monitoring & Reporting
The system computer can be programmed to generate various reports by the management on system performance.
Utilization reports - summarize the utilization of individual workstation as well as overall average
utilization of the system.
Production reports - summarize weekly/daily quantities of parts produced from a CIMS (comparing
scheduled production vs. actual production)
Status reports - instantaneous report "snapshot" of the present conditions of the CIMS.
Tool reports - may include a listing of missing tool, tool-life status etc.
Manufacturing data base
Collection of independent data bases
Centralized data base
Interfaced data base
Distributed data base
CIMS data files
To control the operation of the manufacturing system, the computer relies on data contained in files. The principal
data files required are of the following six types:
1. Part program file: The part program for each workpart processed on the system is maintained in this file.
For any given workpart, a separate program is required for each station that performs operations on the
part.
2. Routing file: This file contains the list of workstations through which each work part must be processed. It
also contains alternate routings for the parts. If a machine in the primary routing is down for repairs or
there is a large backlog of work waiting for the machine, the computer will select an alternate routing for
the part to follow. In the special system, where the routings would be identical or similar and the parts
proceed through the system in an in-line flow, the importance of the routing file is substantially reduced.
3. Part production file: A file of production parameters is maintained for each work part. It contains data
relative to production rates for the various machines in the routing, allowances for in-process inventory,
inspections required, and so on. These data are used for production control purposes.
4. Pallet reference file: A given pallet may be fixture only for certain parts. The pallet reference file is used to
maintain a record of the parts that each pallet can accept. Each pallet in the CIMS is uniquely identified
and referenced in this file.
5. Station tool file: A file is kept for each workstation, identifying the codes of the cutting tools stored at that
station. This file is used for tool control purposes.

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6. Tool-life file: This data file keeps the tool-life value for each cutting tool in the system. The cumulative
machining time of each tool is compared with its life value so that a replacement can be made before
complete failure occurs.

System reports
The data collected during monitoring can be summarized for preparation of performance reports. These reports
are tailored to the particular needs and desires of management. The following categories are typical:
1. Utilization reports: These are reports that summarize the utilization of individual workstations as well as
overall average utilization for the system.
2. Production reports: Management is interested in the daily and weekly quantities of parts produced from
the CIMS. This information is provided in the form of production reports which list the required schedule
together with actual production completions.
3. Status reports: Line supervision can call for a report on the current status of the system at any time. A
status report can be considered an instantaneous "snapshot" of the present condition of the CIMS. Of
interest to supervision would be status data on work parts, machine utilization, pallets, and other system
operating parameters.
4. Tool reports: These reports relate to various aspects of tool control. Reported data might include a listing
of missing tools at each workstation. Also, a tool-life status report can be prepared at the start of each
shift.

Computer Integrated Manufacturing Dept of IEM, SIT