CIM Lab Manual

MMCOE, Dept. of Mechanical Engg.
CIM
Marathwada Mitra Mandal's

COLLEGE OF ENGINEERING, PUNE
Department of Mechanical Engineering
Computer Integrated Manufacturing
Prepared by,
Prof. M. P.Pandagale
Prof. S. S. Raut
Prof. P. D. Bhambure
BE Mech
Academic Year 2023-24

MMCOE, Dept. of Mechanical Engg. CIM
Table of Contents
Practical
Title
Number
Modelling of Mechanical Component using any 3D CAD software, Preparing CNC

1 part program
using any CAM software, and execute it on CNC Turning.
Modelling of Mechanical Component using any 3D CAD software, Preparing CNC

2 part program
using any CAM software, and execute it on CNC Milling.
Generate Bill of Material (BOM) from Assembly and other data using CAD
3
Software.
4 Use MRP (Material Resource Planning) Software for CIM and Assembly.
Study FMS system from Video clip and identify various elements of FMS and its
5 controlling by
computer.
6 Modeling and Simulation of Computer Integrated Manufacturing System.
7 Machine vision based quality control
8 Remote Monitoring and Operation of a Computer Integrated Manufacturing System.

Practical Number: 01 Date:
Practical Name: Tool path generation and simulation for Turning – Grooving and Threading
with help of suitable software.
Aim: To generate CNC code for Turning, Grooving and threading Operation
Mastercam Procedure:
Double click on Mastercam X5
Following window will occur
Press F9
Click on Line on Sketcher Toolbar
Create Profile in Second Quadrant as per dimensions
Click on Solid Tab
Click on Revolve
Select the Line for revolve
As shown in figure
Click on OK in Chain Toolbar

Select the Axis as shown
Click on Revolve chain option
Enter 3600 angle-click OK.
Geometry will appear as in following figure.

Go to Machine Type in main Menu
Select Lathe-Default
Go to Properties on Operation Manager
Click on Stock Setup

Into stock tab click on properties
Click on make from 2 points
Tick on Use Margin Button

Input the Margin on OD, Right & Left side.
Click on Preview lathe boundaries-Enter.

Click on Chuck Jaws Properties.
Select the chuck from given chucks – click on make from 2 points.
Select starting and ending points from stock and little outside in the space.
Chuck will look as in following picture.

Go to Tool paths
Select Face Operation-click ok.
Select Right hand Rough Tool

Click on Face Parameters
Click on Select Points
Select the Point from where we want to start machining.

Also select second point as origin.
Turn Rough Step over option to ON put the value as 1.0 or 2.0
Click OK.
Tool path will be generated.
Click on Verify Selected Operations

Click OK.
This will give you 3D View of operation.
Now Go to Tool Path-Select Rough
Chaining window will appear

Select the chain as shown in following Figure
Click OK
Select Right Hand Tool as shown
Click on Rough Parameters Tab
Input Depth of Cut and Select the option Use Stock on Outer Diameter. Click OK.
Following path will be generated.
In this way we have completed with the Turning Operation.
For Grooving Operation:
Press F9
Draw the geometry as per the dimensions.
Go to Solid- Revolve the Geometry.

Go to Machine Type in main Menu
Select Lathe-Default
Go to Properties on Operation Manager
Click on Stock Setup
Into stock tab click on properties

Click on make from 2 points
Tick on Use Margin Button
Input the Margin on OD, Right & Left side.

Click on Preview lathe boundaries-Enter.
Draw Chuck as shown.
Perform facing operation up to the origin Point.
Perform Turning operation up to the origin Point.

Go to toolpaths – Groove-Select Chain – OK.
Select Chain as shown in Following Figure

Select Groove Parameters as shown in following Figure
Groove Shape Parameters as shown in following Figure
Groove Rough Parameters as shown in following Figure

Groove Finish parameters as shown in following figure
Click OK.
Tool path for Grooving is generated.
Check the operation as shown in following figure.

Hence Grooving Operation is performed.
Threading Operation:
Go to tool paths select thread.
Select the threading tool as shown in following figure

Click on Thread Shape Parameters Tab
Select start point and End Point on the outer diameter of the geometry.
Select Major Diameter and Minor diameter as per requirement.

Click Ok
Finally click on Machine Group-Click on G1 Button – Program will be Generated.

Practical Number: 02
Practical Name: Tool path generation and simulation for Milling – Facing, Pocketing,
Contouring and drilling, etc. with help of suitable software.
Aim: To generate CNC code for Milling – Facing, Pocketing, Contouring and Drilling
Mastercam Procedure:
Facing and Contour:
Double Click on Mastercam X5
Press F9
Click on create rectangle tool
Selected Centered Rectangle.
Enter Dimensions – Press Enter.
Go to Machine Type- Select Mill-Default
Following Tree will Occur

Go to Stock Set Up in Tree- select Rectangular Shape-Enter the Stock Dimensions in Yellow
boxes-Enter the extra Margin in X=, Y= & Z= tab-OK.
Go to Toolpaths –Select Face
Give the Chaining as shown in Figure(Start point and End Point Should be Same). Select Toolpath
Type as Facing.
Go to Cut Parameters –Depth Cuts-Enter Maximum Rough Over-Finish Steps.

Go to Linking Parameters select all Systems to Absolute- Enter the depth. (It’s from Extra Material to
the point upto which we want to machine in Z Direction) If it is below Z axis then it should be input
Negative.
Click OK.
Select Facing-Click on Verify Selected Operations
Following toolpath will be generated.

Facing is accomplished.
Go to Toolpaths-Contour.
Select the outer Lines of the geometry. Loop Should be Closed in Chaining.
Click OK.
Select Cut Parameters-Depth Cuts- Input Maximum Rough Stepover

Select Break Through
Input Number of passes in Multipass.

Select Linking Parameters- Set all systems to Absolute. Enter Depth in Z direction.
Click OK.
Following path will be generated.

Verify Selected Operation
Go to Toolpaths- Select Pocket
Select the Inner Rectangle for Pocketing (Loop should be completed in chaining).
Select toolpath Type
Select Cut parameters- Cutting Methods- choose a method. Go to linking parameters- set all systems
to Absolute-Input the depth in Z Direction.
Click OK. Following path will be generated.
Verify selected operation.

Pocketing is achieved.
Drill:
Go to Tool paths- Drill.
Select the Center point of the drill.
Enter the linking parameters.
Click ok.
Drilling will be achieved.
Select Machine Group – Verify all selected operations – Press G1 Button the Program will be
generated.
Practical No: 3
Aim: Generate Bill of Material (BOM) from Assembly and other data using CAD Software.
Objectives
❖ Learn how to manage bills of materials within AutoCAD
❖ Learn how to share the BOM with others
❖ Learn about the benefits of using AutoCAD Mechanical
❖ Learn how to utilize Vault Professional for BOM management
Theory
The bill of materials (BOM) is a list of things. In manufacturing, it is the recipe ingredients for
producing (and repairing) equipment and machinery. It lists the raw material, parts, sub- assemblies,
purchased items, and everything else that goes into the product.
The BOM acts as a key communication piece between departments. It contains the items designed by
engineering. A BOM provides the list of items to be purchased and the items that must be
manufactured. It contains the identifiers (part numbers, stock numbers), the descriptions, quantities,
purchasing details, manufacturer information, costs, and other key attributes.
The BOM is the single source of truth between so many systems. From sales (CRM) to engineering
(PDM), production (ERP, MRP), and product lifecycle management (PLM).
It is the most important piece of information in manufacturing. I’ve seen it multiple times where the
material is ordered, received, assembled, and shipped to the customer all without the drawing being
opened one time.
AutoCAD Bills of Materials
AutoCAD has no tools to manage bills of materials! right? Well… maybe sort of? AutoCAD does not
have dedicated BOM tools, but there are enough to fake it.
What tools am I talking about? How about the Count feature? Or the Data Extraction tools? And
Blocks with attributes are essentially the same as 3D models with meta-property data.
Blocks and Attributes

AutoCAD Blocks group objects into a single entity. As a singular object, it is easier to select,
manipulate, and share across drawings. Using blocks leads to consistency and standardization as the
same symbol is used across all drawings. Attributes provide the ability for variable text metadata
across your blocks. Each instance of a block definition can contain different attribute text content.
Creating blocks is easy. Use the BLOCK command to set the name, select the objects (including
attribute definitions), and set the insertion point. By selecting the attribute definitions they
automatically become part of the block, ready for use on the first insertion.
Figure 1: Building a Block
How does this help with bills of materials? It allows you to take unrelated 2D objects, group them into
a singular named object, and specify descriptive metadata. So instead of lines, arcs, and circles you
now have countable objects representing the items you manufacture and purchase.
Counting Blocks
AutoCAD’s COUNT is sort of a BOM tool, but mostly a tool to quickly extract the count of things.
With this feature, AutoCAD quickly counts the instances of any object type within the drawing,
including blocks. Insert a field with the count data or a table listing the blocks, both updating with
changes to the drawing.
Start by selecting the objects to count. This initiates the count environment, with the Count toolbar
along the top of the drawing area. Use this toolbar for a quick reference to the number of objects, to
navigate between the objects in the count, to insert the count field, and to end the counting process.
When selecting a single object, all objects of that type and configuration are automatically selected.
When selecting multiple objects, AutoCAD looks for identical instances of the same object
combination.
Figure 2: Using the Count Toolbar
Use the List All Blocks option for the Count palette – a list of blocks. This includes the number of
instances contained with the drawing. Select a block within the palette to drill into the selection. It’s in
the right-click menu where you’ll find the option of inserting a Count Field. Use the palette option to
insert a table.
Figure 3: Insert a Count Table
What about blocks with varying attribute information? Within the Count palette, expand the block by
property or attribute value. This allows you to see instances group by common properties.
Figure 4: Expanding the Block Count
The Verdict? Count is sort of a bill of materials tool.

Although it provides the block name, count, and one subsequent property, you need to provide the
descriptions and other details. Do not dismiss this tool though, it provides a quick and easy method to
get quantities - say to figure out purchasing details.
Data Extraction
For AutoCAD bills of materials, the creme-la-creme is Data Extraction.This wizard extracts
information from objects, including block attributes and drawing properties. Send the information to
an external document or insert it as a table into the drawing.
The process:
1. Create new or select an existing Data Extraction

2. Specify the data source(s)
3. Select the objects
4. Select the properties
5. Refine the properties
6. Choose the output
The data extraction (.dxe) is the saved configuration. It only needs to be created once as you can use
this as a template as opposed to re-establishing the settings each time.
The data source is a portion of a drawing, the active drawing, or a selection of drawings. You choose
to include blocks and/or to include objects from xrefs.
Figure 5: Define the Data Source
When selecting objects, use the filtering options to quickly select only the blocks with attributes. A
key feature is the option of adjusting display names, allowing for the merging of like objects (with
different names). For example, blocks representing different views of an item (front, top, side, etc).
Figure 6: Select Objects
For a bill of materials hide the name column (unless the name represents an important property) and
enable Combine identical rows.
Figure 7: Refine the Data
Note, externally exported data extractions do not auto-update with changes to the drawing. You will
need to re-export the details.
Figure 8: Choose the Output
With changes to the drawing use Update All Data Links, to update the data extraction and associated
tables.
Sharing the Data with Others
To share the BOM information with others the best method is via a table. Why?
1. Anyone who can view the drawing can view the BOM table
2. Tables can be exported (via the right-click menu) to be shared via a spreadsheet
3. Data Extraction allows for the direct export to a spreadseet
Managing Bills of Materials in AutoCAD… the Verdict
As you can see, AutoCAD provides basic bill-of-material-like-tools for the presentation of
components represented in your drawings. Count provides a quick and convenient method to extract
the number of instances, useful for ordering. Data extraction creates a more traditional bill of
materials, listing the component’s description, part number, and other key attributes.
With the lack of true BOM tools within AutoCAD, there are limitations. There is no eloquent method
of ballooning tieing the balloon item number to the parts list, there is only a single view of the BOM,
and AutoCAD provides no BOM integration with Vault or PLM. The setup of blocks is time-
consuming as you need to ensure each block definition uses the same set of attributes. Without this,
there is no way to extract the bill of materials.
AutoCAD Mechanical Bills of Materials
Autodesk initially released AutoCAD Mechanical (ACM) as an addition for AutoCAD 2014. In the
initial release it simply added a toolbar of extra mechanical focused functionality. Autodesk then
acquired German based Genius and the fun began. AutoCAD Mechanical is a member of the
AutoCAD One toolset as well various Autodesk suites and collections.
AutoCAD Mechanical is AutoCAD! It is based on AutoCAD, meaning everything you can do in

AutoCAD, you can do in AutoCAD Mechanical.
Bill of Materials, Parts Lists, and Balloons
The Bill of Materials (BOM) is a collection of Part References and their metadata. The BOM is live
- as the drawing changes, the BOM automatically updates. The metadata represents any and all data
you want to track on your components, including descriptions, material, and vendor.
Create Balloons manually or automatically from any Part Reference. The format managed by the
active standard, the item numbers managed by the BOM.
Parts Lists are the BOM representations inserted into the drawing. They do not need to contain all of
the information contained within the BOM and they can be filtered to only show the desired content.
What’s great about these features is that any drawing, whether it contains AutoCAD Mechanical
content or not can have Part References inserted to define your components. Any drawing with Part
References will have a Bill of Material and any Part Reference can be ballooned. This means that
even a drawing of lines, arcs, and circles can contain intelligent information that is organized,
ballooned, and displayed in the fashion you want on the drawing.
Part References
Use Part References to tag geometry as parts and assemblies.
Place Part References into the drawing to create components with no geometry. Select an object to
associate the Part Reference. As the geometry moves, so does the reference.
Associate a Part Reference with a block to count all instances of the block in the quantity. Part
References nested within blocks behave as assemblies.
As you add references, AutoCAD Mechanical prompts for

the component information. The available fields are managed
via the AutoCAD Mechanical Options.
Copying a Part Reference increments the quantity of the

component within the BOM. Changing one reference
automatically updates all instances to match. To create a new
reference, utilizing an existing reference, use the Part
Reference Copy option.
The typical workflow is creating the part reference first, thus

building the BOM. However, you can generate Part
References from BOM rows.
Figure 9: Populating the Part Reference
Bill of Materials (AMBOM)
The Bill of Materials (BOM) contains the information about the parts in the drawing. From the BOM
you generate Parts Lists and Balloons. Because parts lists and balloons are derived from the BOM, the
BOM must exist before you can use those features.
When a BOM is created, all Part References are included. As you create more references or edit
existing, the BOM updates automatically.
The BOM dialog provides tools for working with the bill of materials. This includes adjusting the
component data, editing multiple cells, and copying-and-pasting information. Additionally sort the
entire BOM or selected rows (with up to three sort criteria), increment the Item value, add (or remove)
BOM-only items, add columns (properties), and export the BOM.
Balloons
With the ACM toolset create single or multiple balloons at a time. With multiple balloon placement
you decide the alignment: horizontally, vertically, at an angle, or distributed around a rectangular area.
When ballooning, the leaders automatically snap to the center of the part references. Use the Collect
feature to merge several balloons under one leader.
AM:Standards
Like all things in AutoCAD Mechanical, the format of the Component Properties, BOM, Parts List,
and Balloons are controlled by the active Standard, but can be overridden after insertion (on the fly).
Figure 10: AM:Standards Dialog
AutoCAD Mechanical Structure
Structure could really be a class on its own, just because of the features and functionality and the
workflows possible. ACM Structure is like blocks on steroids, a combination of blocks and groups, to
define components. Although just 2D geometry the components defined by ACM are both parts and
assemblies defining the structure of the assembly you are building. The BOM is automatically built as
the structure is defined.
From the ACM help… “Mechanical Structure offers all the advantages of both Blocks and Layer
Groups and more. Since mechanical structure is designed for the explicit purpose of organizing a
drawing. The features go beyond visibility enhancements (offered by layer groups), reuse of
geometry, and automatic BOM updates (offered by blocks).”
AutoCAD Mechanical, Vault Professional, and Beyond
Vault Items
Autodesk Vault Professional provides the Item Master. Items representing the parts and assemblies
you manage, manufacture, assemble, purchase, and sell. An item will contain the bill of material
recipe to produce that item.
Figure 11: Item BOM
Although AutoCAD drawings can be linked to an item, it cannot generate a BOM. However, an
AutoCAD Mechanical drawing containing Part References or Structure Components will generate an
Item BOM.
An important step is mapping your Vault properties to the corresponding AutoCAD Mechanical
component properties. This way as you assign items, Vault extracts the metadata from the ACM
BOM, populating the items.
As Vault Items participate in lifecycle, not only can you revision manage your drawings but also the
items and their associated BOMs.The lifecycle state of an item tracks the state of the item through the
manufacturing process. This shows the state from the item creation (inception) to when the item is no
longer required (retirement)
The Vault Item Master provides the medium for sharing BOM information with other people,
departments, and other systems including ERP and PLM.
Item BOM Management
Not all components listed in the BOM have to originate in the attached file. Use the Add New Row
button to add an existing item to the BOM.
The proper quantities of the items are generated automatically using the same units and quantities
from the CAD file. There are times where it may be desired to override this at the item level. For
example you may want to increase the amount of bolts or fasteners shown on the BOM to compensate
for loss when the unit is shipped.
Each revision of an item has an unique BOM as changes to the attached file can impact the BOM
structure, the components contained within the assembly and the quantities. Vault provides a
comparison tool to compare one revision of the BOM against the other, highlighting any differences.
Figure 12: Differences are highlighted

Out-of-the-box you can export an item or a selection of items to various formats (typically Microsoft
Excel) which can then be shared with others or other applications. The BOM can be exported in one
of two ways: (a) a tree hierarchal view showing each sub-assembly and their components and (b) a
flat layout with re-used items rolled up into a single row showing the total quantity (i.e. cut list).
Figure 13: Export shown in Microsoft Excel
To expand on this functionality you can look to partner products:
● We use a product called CADLink (from QBuild) which pushes Vault Items into our ERP,
creating or updating the ERP parts, and populating the BOM in ERP. Our planners then utilize
the BOM to create the method of manufacturing, adding the required operations.
● Another example is using CoolOrange’s powerPLM to link the Vault Item Master to Fusion
Manage, providing an associative link with PLM.
Practical No 07
Aim: To Study FMS system and identify various elements of FMS
Objective:
To Study FMS system and identify various elements of FMS
FMS:
A flexible manufacturing system (FMS) is an arrangement of machines ... interconnected by a

transport system. The transporter carries work to the machines on pallets or other interface units so
that work-machine registration is accurate, rapid and automatic. A central computer controls both
machines and transport system.
FMS consists of a group of processing work stations interconnected by means of an automated

material handling and storage system and controlled by integrated computer control system.‖
FMS is called flexible due to the reason that it is capable of processing a variety of different part
styles simultaneously at the workstation and quantities of production can be adjusted in response to
changing demand patterns.
BASIC COMPONENTS OF FMS: The basic components of FMS are: 1. Workstations 2. Automated
Material Handling and Storage system. 3. Computer Control System 1. Workstations: In present day
application these workstations are typically computer numerical control (CNC) machine tools that
perform machining operation on families of parts. Flexible manufacturing systems are being designed
with other type of processing equipment‘s including inspection stations, assembly works and sheet
metal presses.The various workstations are
1. Machining centers
2. Load and unload stations
3. Assembly work stations
4. Inspection stations
5. Forging stations
6. Sheet metal processing, etc.
2. Automated Material Handling and Storage system: The various automated material handling
systems are used to transport work parts and subassembly parts between the processing stations,
sometimes incorporating storage into function.The various functions of automated material handling
and storage system are
1. Random and independent movement of work parts between workstations
2. Handling of a variety of work part configurations
3. Temporary storage
4. Convenient access for loading and unloading of work parts
5. Compatible with computer control.
3. Computer Control System: It is used to coordinate the activities of the processing stations and the
material handling system in the FMS. The various functions of computer control system are: (i)
Control of each work station (ii) Distribution of control instruction to work station (iii) Production
control (vi) Traffic control (v) Shuttle control (vi) Work handling system and monitoring (vii) System
performance monitoring and reporting
DIFFERENT TYPES OF FMS
The different types of FMS are
1. Sequential FMS
2. Random FMS
3. Dedicated FMS
4. Engineered FMS
5. Modular FMS
Sequential FMS: It manufactures one-piece part batch type and then planning and preparation is
carried out for the next piece part batch type to be manufactured. It operates like a small batch flexible
transfer line. Random FMS: It manufactures any random mix of piece part types at any one time.
Dedicated FMS: It continually manufactures, for extended periods, the same but limited mix of piece
part batch types. Engineered FMS: It manufactures the same mix its lifetime. Modular FMS :modular
FMS with a sophisticated FMS host, enables and FMS user to expand their FMS capabilities in a
stepwise fashion into any of the previous four types of FMS. modular FMS, with a sophisticated FMS
host, enables and FMS
MODES OF MANUFACTURING UNIT OR JOB TYPE OF PRODUCTION: This type of

production is most commonly observed when you produce one single unit of a product.
A typical example of the same will be tailored outfits which are made just for you or a cake which is
made just like you want it.Example of Unit type of production .It is one of the most common types of
products used because it is generally used by small businesses like restaurants, individual products
providers or individual services providers.…It is also a type of production used by very premium
companies like Harley Davidson, or Dell. Harley Davidson actually has a lot of accessories which can
be customized, and which suit the individual. Same ways, you can design your own DELL laptop on
their website with the given specifications.
Features of Unit production or Job Production :
1. Depends a lot on skill
2. Dependency is more on manual work than mechanical work
3. Customer service and customer management plays and important role
Batch type of Production:
It is one of the types of production most commonly used in consumer durables, FMCG or other such
industries where there are large variety of products with variable demands. Batch production takes
place in batches. The manufacturer already knows the number of units he needs to a manufacturer and
they are manufactured in one batch. So, if a manufacturer has the shortage of Product X and 100 units
of this product is consumed in one month, then the manufacturer can give orders for batch production
of 100 units of Product X. Example of Batch production
LG has many different types of home appliance products in its portfolio. It has to manufacture all
these different variants of the same type of product. There would be 10-20 types of mixer grinders
alone in the product portfolio of LG home appliances. Thus, a company like LG manufactures these
variants via Batch production. First, one type of mixer will be manufactured completely and then the
second type will be manufactured. They are manufactured on the basis of demand. Depending on
demand, the batch production can produce the number of units required in one batch.
Features of Batch production:
1. Production is done in batches.
2. The total number of units required is decided before the batch production starts
3. Once a batch production starts, stopping it midway may cost a huge amount to the company.
4. Demand plays a major role in a batch production. Example – seasonality of products.
Mass Production or Flow production
• One of the best examples of mass production is the manufacturing process adopted by Ford.
• Mass production is also known as flow production or assembly line production.
• It is one of the most common types of products used in the automobile industry and is also used in
industries where continuous production is required.
• An Assembly line or mass production plant typically focus on specialization.
• There are multiple workstations installed and the assembly line goes through all the workstations
turn by turn.
• The work is done in a specialized manner and each workstation is responsible for one single type of
work.
• As a result, these workstations are very efficient and production due to which the whole assembly
line becomes productive and efficient.
• Products which are manufactured using mass production are very standardized products.
• High sophistication is used in the manufacturing of these products.
• If 1000 products are manufactured using mass production, each one of them should be exactly the
same.
• There should be no deviation in the product manufactured.
Features of Mass Production
1. Mass production is generally used to dole out huge volumes of the product
2. It is used only if the product is standardized
3. Demand does not play a major role in a Mass production. However, production capacity determines
the success of a mass production.
4. Mass production requires huge initial investment and the working capital demand is huge too.
Continuous production or Process production :
• There is a lot of confusion between mass production and continuous production.
• It can be differentiated by a single element.
• The amount of mechanical work involved.
• In Mass production, both machines and humans work in tandem.
• However, in continuous production, most of the work is done by machines rather than humans.
• In continuous production, the production is continuous,24×7 hours, all days in a year.
• A good example of the Continuous production is brewing.
• In brewing, the production goes on 24 hours a day and 365 days a year. This is because brewing
takes a lot of time and production is important.
• As a result, there is a continuous input of raw materials such as malt or water, and there is
continuous output in the form of beer or other alcoholic drink.
• The key factor in this is that the brewing and fermentation process itself is time-consuming, and the
maximum time is spent in the fermentation which is a continuous process
• There are many chemicals which are manufactured in the form of a continuous process due to the
huge demand across the world. Similarly, the Plastic industry is known to adopt the continuous
production methodology where production can go continuously for weeks or months depending on the
demand.
• Once the production starts, you only need to feed in the raw material, and the machines turn out the
finalized products.
Features of Continuous production:
1. Majority of the work is done by machines rather than humans
2. Work is continuous in nature.
3. Once production starts, it cannot be stopped otherwise it will cause huge loss.
4. A very controlled environment is required for continuous production

Practical no 8
Aim: Modeling and Simulation of Computer Integrated Manufacturing System
Objective
❖ To demonstrate the modeling of a CIM cell comprising of different processing stations using
3D graphical user interface.
❖ To demonstrate the operation of the CIM cell through 3-D graphical animated simulation of
the operations at different workstations.
❖ To demonstrate the parts and production flow as well as interaction between the various
components involved in the CIM cell.
❖ To demonstrate the monitoring of production management functions in the CIM cell.
Theory
What is Computer Integrated Manufacturing (CIM)?
Computer Integrated Manufacturing (CIM) is the technology for integration of all the
operational and information processing functions in a manufacturing enterprise ranging from order
receipt from customers to design, process planning, material requirement planning, manufacturing
resources planning , purchasing, production planning and control, marketing and sales etc. The
integration of the total manufacturing enterprise is accomplished through the use of computer and data
communication technologies coupled with various managerial philosophies to improve the
organizational and personal efficiencies.
What is CIM cell?
CIM cell is an automated manufacturing system comprising of one or more automated processing
stations typically computer numerical control (CNC) machine tools, one or more equipment for
automated material handling and transport such as robots, conveyors. storage devices to store raw
materials, work-in-progress and finished products that may include storage racks, and Automated
Storage and Retrieval Systems (ASRS), one or more quality control equipment’s such as machine
vision system, Coordinate Measuring Machine(CMM), etc., and a CIM software for overall
integration, planning and control of the various operational and information processing function at
individual stations of the CIM cell.
A typical CIM cell
The Figures show the components of some typical CIM cells and their components.
Fig: A CIM cell with two stations.
Fig: A CIM cell with six stations.
CNC MACHINE:
The machines shown in the cells are typically CNC machines which can be either a CNC milling
machine that is equipped with an Automatic Tool Changer (ATC) or a CNC lathe that is equipped
with an index able tool turrent. Figures below show two CNC machines. CNC Milling machines can
be employed for two/three axes machining of plane and sculptured surfaces for various operations like
milling and drilling by using rotating tools. Loading and unloading of the parts at the CNC machine
are carried out automatically using an industrial robot as shown.
Fig: A CNC milling machine Fig: A CNC lathe machine
CIM SOFTWARE:
It provides a centralized control of on line production operations at each of the individual station
devices of the CIM cell. It sends commands to station devices for starting and stopping the production
and receives responses from the station devices which enable it to track the flow of parts during a
CIM production cycle. It further maintains a database containing information on the physical and
communication control configuration of the CIM cell, bill of materials used to produce each part, the
order specifying the part to be produced, inventory of raw materials and parts, definition of machines
in the CIM cell and manufacturing process that they can perform and the content of all the storage
locations. It further provides a web accessible interface to remotely access a specific CIM cell and
track the production cycle in real time for online tracking of the CIM production cycleby providing a
Graphic Display tab to enables display of the image of a CIM cell in 3D that can dynamically and
accurately simulate the operations of all individual station devices in the CIM cell, a View Scheduler
tab to view the production timing and schedule which is a Gantt chart utility to display the exact
timing and scheduling of the different phases of production,a View Program tab to view the current
production status for viewing the current production work order and track its status, a View Leaf tab
to view the description of the current production activities in the current CIM cell describing the
current operation being performed on each item as well as the operation that will follow immediately,
View Order tab to view a copy of the manufacturing order of the current cell, a View Storage tab to
view part location in the storage for viewing a list of every storage location defined in the CIM system
and storage status, a View Device tab to view device activities at various stations for viewing a list of
every robot and machine as well as a description of the current action being performed,etc..
Fig: A screenshot of the CIM software
Experimental Setup
The CIM system consists of two cells. Cell 1 is the storage, assembly and quality control station,
which consists of the following equipments:
A storage rack for storing the raw materials, work-in-process inventory as well as finished products,
An assembly jig for building the assembly,
A camera and image processing system for automated inspection, and
A Scorbot robot manipulator.

Cell 2 is a machining station, which consists of a CNC milling machine. Figure below shows a 3D
graphical view of the CIM cell. For further details on the above equipments.
Fig: 3D graphical view of the CIM cell
The Scorbot robot is used for CNC machine loading/unloading tasks, material handling for
storage/retrieval of parts to/from storage as well as for presenting the part at the quality control station
and for assembly. The manufacturing operations that can be carried out in the CIM system are milling
of plexiglass blocks, assembly operations, material handling between stations and the quality control
of parts by machine vision.
The overall CIM system is run with a supervisory host control system consisting of two cell work
station PC's for the two cells and a host computer. The host computer allows management of CIM
orders and operations via the CIM Manager - OpenCIM software system architecture. The OpenCIM
offers various capabilities like CIM management, parts definition, order definition, machine
definition, automatic CNC programs downloading for CNC machines, MRP package, 3D graphic
animated simulation for on-line tracking of the whole system, reports generator for production reports,
CIM scheduler module (GANNT chart). The CIM Manager software via OpenCIM provides
centralized control of on-line production activities. It sends commands to station devices and receives
responses, which enable it to track the flow of parts during production.
Practical No 9
Aim : Machine vision based quality control
Objective
❖ To demonstrate inspection of parts by machine vision for quality control.
❖ To demonstrate various steps of image processing.

Theory
Machine Vision Machine vision may be defined as the process of extracting, characterizing and
interpreting information from images of a three dimensional world.
Sensing and Digitizing
It is the process that yields a visual image of sufficient contrast that is typically digitized and stored in
the computer memory.
Image processing and analysis
The digitized image is subjected to image processing and analysis for data reduction and interpretation
of the image. It may be further subdivided into: Preprocessing - It deals with techniques like noise
reduction and enhancement details Segmentation - It partitions an image into objects of interest.
Description - It computes various features like size, shape, etc. suitable for differentiating one object
from another. Recognition - It identifies the object by pattern matching. Interpretation - It finally
assigns a meaning to an ensemble of recognized objects in the scene Application: The current
application of machine vision is inspection, part identification, location and orientation.
Performing Inspection by Pattern Matching
A pattern matching model or template of the object to be inspected is first created. This pattern will
form the basis of performing inspection of the object. An image of the object is grabbed with a
camera. In the next step, by using the image processing software, the pattern matching model created
earlier is searched in the captured image for inspection of the object. The object is inspected for
various aspects such as its position relative to the pattern matching model, the % score that reflects the
correspondence between the image of the object and the pattern matching model, the dimensions of
the object, perimeter of the .object, surface area of the object and so on.
Sensing and Digitizing
Visual information is converted to electrical signals by visual sensors. When sampled spatially and
quantized in amplitude, these signals yield a digital image. Image sensing requires some type of
imaging device (such as camera) and a digitizer which stores video frames in the computer memory.
Vision Cameras
The principal imaging devices used for machine vision are television cameras, consisting of either a
tube (vidicon camera) or the solid state camera (CCD, CID or silicon bipolar sensor cameras), and
associated electronics. Solid state imaging devices offer a number of advantages over tube cameras
such as, lighter weight, smaller size, longer life and lower power consumption. However, the
resolution of certain tubes is still beyond the capabilities of solid state cameras.
CCD Cameras
A Charged Coupled Device (CCD) camera is shown in which an image is projected onto the CCD,
which detects, stores and reads out the accumulated charge generated by the light pattern of the image.
Light detection occurs through the absorption of light on a photoconductive substrate (e.g. silicon).
CCD devices can be subdivided into two categories: line scan sensors and area sensors.
Preprocessing
Preprocessing deals with techniques like noise reduction and enhancement details. There are several
approaches of preprocessing used in machine vision systems. The preprocessing approaches typical of
the methods satisfying the requirements of computational speed and low implementation cost are
discussed.
Noise reduction or smoothing
Smoothing operations are used for reducing noise and other effects that are introduced in an image as
a result of sampling, quantization, transmission or disturbances in the environment during image
acquisition and digitizing. One straightforward technique for image smoothing is neighborhood
averaging in which a smoothed image is generated whose intensity at every point is obtained by
averaging the intensity values of the pixels of the given image contained in a predefined neighborhood
of that point. One of the principal difficulties in this technique is that it blurs edges and sharp details.
This blurring can be reduced by the use of so called median filters in which the intensity of each pixel
is replaced by the median of the intensities in a predefined neighborhood of that pixel, instead of by
the average.
Enhancement
Segmentation process subdivides a sensed image into constituent parts or objects. It is one of the most
important elements of automated vision system, since it is at this stage of processing that objects are
extracted from a scene for subsequent recognition and analysis. Segmentation algorithms are
generally based on one of the two basic principles: Similarity and Discontinuity. The principal
approaches in the first category are based on thresholding and region growing, and that in the second
category are based on edge detection.
Segmentation
Segmentation process subdivides a sensed image into constituent parts or objects. It is one of the most
important elements of automated vision system, since it is at this stage of processing that objects are
extracted from a scene for subsequent recognition and analysis. Segmentation algorithms are
generally based on one of the two basic principles: Similarity and Discontinuity. The principal
approaches in the first category are based on thresholding and region growing, and that in the second
category are based on edge detection.
Thresholding
In its simplest form, thresholding is a binary conversion technique in which each pixel is converted
into a binary value, either black or white. This is accomplished by using a frequency histogram of the
image and establishing what intensity (gray level) is to be the border between black and white.
Region growing
Once thresholding is established, the next step is to identify particular areas associated with objects
within the image. Such regions usually possess uniform pixel properties computed over the area. As
the name implies, region growing is a procedure that group's pixels or sub regions into larger regions
based on attribute similarities. The simplest approach is pixel aggregation, where one can start with a
set of seed points and grow regions from these by appending to each seed those neighboring pixels
that have similar properties, e.g. intensity, texture or colour.
Edge detection
Edge detection considers the intensity change that occurs in the pixels at the boundary or edges of a
part. Once a region of similar attributes has been found, the boundary can be determined by a simple
edge following procedure. For a binary image, the procedure is to scan the image from the top left
until a pixel within the region is encountered. For a pixel within the region, turn left and step;
otherwise, turn right and step until the path has returned to the starting image, when the boundary is
traversed. The contour - following procedure can extended to gray level images.
Experimental Setup
The set-up consists of the following:
A USB colour camera mounted on a stand
Matrox image processing system with various image analysis tools such as image preprocessing and
enhancement, colour image analysis, pattern matching, blob analysis, etc
Procedure
1. Place the part under the camera
2. Go to the start menu and run ViewFlex by selecting Programs->ViewFlex.The ViewFlex
toolbar will be displayed as shown in figure. (insert snapshot of viewflex toolbar)
3. Click on the Image Processing Tools icon from ViewFlex toolbar to load Matrox Inspector
8.0.
4. Click on the camera icon to open the camera window. Click on Snapshot icon to grab(capture)
the picture of the object and display it in a frame. The captured image will be put into the
current frame of the image.
5. Click the ROI (Region of Interest) icon and outline the perimeter of the object.
6. Click on the Pattern Matching icon as shown in figure (insert screen shot of pattern matching
dialog box) to display the Pattern Matching Model dialog box. From the Dimension tab,you
will see the object that was outlined using the ROI icon. From the Search tab, click All. From
the Angle tab, check Enable search with rotate. Then enter 180 for Delta Negative,and 180 for
Delta Positive (this enables a full 360 degree search). Click Search. This will build a
Measurement Table containing all the positions of the object.
7. Save the Pattern Matching Model in the Pattern folder, located in the ViewFlex root folder.
Ensure that the Pattern dialog box is selected when saving.
8. Open the result table and expand the pattern model in the folder tree. Check that the name you
gave is listed in the tree.
9. Use this name when you find object.
10. Use step 4 to capture the image of the object. Click Search. This will build a Result Table
containing all the positions of the object, Score(% matching with the template), and the
Angle.
Practical No 10
Aim: Remote Monitoring and Operation of a Computer Integrated Manufacturing System
Objective
❖ To demonstrate the operation of an actual CIM cell by providing remote access to the the
operations at different workstations.
❖ To To demonstrate the parts and production flow as well as interaction between the various
components involved in the CIM cell.
❖ To demonstrate monitoring of production management functions in real time in the CIM cell.
Experimental Setup
The CIM system consists of two cells. Cell 1 is the storage, assembly and quality control station,
which consists of the following equipments:
❖ A storage rack for storing the raw materials, work-in-process inventory as well as finished
products,
❖ An assembly jig for building the assembly,
❖ A camera and image processing system for automated inspection, and
❖ A Scorbot robot manipulator.

Cell 2 is a machining station, which consists of a CNC milling machine. Figure below shows a 3D
graphical view of the CIM cell. For further details on the above equipments.
Fig: 3D graphical view of the CIM cell

The Scorbot robot is used for CNC machine loading/unloading tasks, material handling for
storage/retrieval of parts to/from storage as well as for presenting the part at the quality control station
and for assembly. The manufacturing operations that can be carried out in the CIM system are milling
of plexiglass blocks, assembly operations, material handling between stations and the quality control
of parts by machine vision.
The overall CIM system is run with a supervisory host control system consisting of two cell work
station PC's for the two cells and a host computer. The host computer allows management of CIM
orders and operations via the CIM Manager - OpenCIM software system architecture. The OpenCIM
offers various capabilities like CIM management, parts definition, order definition, machine
definition, automatic CNC programs downloading for CNC machines, MRP package, 3D graphic
animated simulation for on-line tracking of the whole system, reports generator for production reports,
CIM scheduler module (GANNT chart). The CIM Manager software via OpenCIM provides
centralized control of on-line production activities. It sends commands to station devices and receives
responses, which enable it to track the flow of parts during production.
Procedure
Steps involved:
Describe the steps for the CIM system start up.
Describe the steps for remotely monitoring the operations of the CIM cell.
Describe the steps for the CIM system shut down.
Users, who wish to remotely access the CIM set-up, are required to first book a slot by using the
Remote Experiment tab. Next follow the instructions provided in Step II given below.
Steps I and III are instructions meant for the operators who would be present on site and responsible
for actually operating the CIM cell in the laboratory.
Step I: Steps for system start up
Turn on the Mains switch for the compressor on the ground floor.
Make sure that the power supply to the FMS lab is turned on.
Turn on the power supply to the UPS of Manager PC, Workstation 1, Workstation 2 and the Robot
Controller.
Turn on the three PCs.
Turn on the Robot Controller
Turn on the CNC Controller
Turn on the Remote Control Switch for the Compressor.
Open the valve of compressed air supply and make sure that the gauge pressure is 6 bar
Log in to the Manager PC.
Please follow the safety precautions given below.
Make sure that the Teach Pendent is on the hanger and in Auto Mode, and Emergency Button is not
pressed.
Make sure that the Emergency Button of the Robot Controller is not pressed and the Red power LED
is ON.
Make sure that four LEDs at the LAN switcher are ON.
Make sure that there are three MILL SUP parts in Rack1.
Make sure that the two XV parts are in Rack2.
Make sure that there is no part in the Jig.
Make sure that there is no part in the Trash bin.
Make sure that there are no parts below the camera and the Table is clean.
Make sure that there is no part in the Robot Gripper.
Make sure that the Robot is in safe place to Home.
Make sure that the air dial indicator on the side of the CNC Mill is not zero.
Make sure that there are three tools in the Tool Changer and one tool inside the Spindle.
Make sure that there is no part in the vise.
Make sure that the vise is Open and has two Aluminium spacer and one plexiglass spacer.
Make sure that the CNC mill is clean.
Make sure that the Emergency Button on CNC Mill is not pressed
Make sure that the spindle speed is CNC ON.

Log in to the Workstation 1 and Workstation 2.
Steps for loading the Software in Workstation PCs 1 and 2 and the Manager PC
Loading software in Manager PC
❖ Click on the CIM Manager icon.
❖ Open CIM Manager Window will be displayed as follows.
Loading software in CIM Station 2
❖ Click on the Loader of WS2 icon.
❖ The CIM DDLoader menu will be displayed.

❖ Click on the Green Button.
❖ Two softwares will load as follows.
❖ On the SCORBASE software, click on the Home icon.
❖ Homing menu will be displayed and the Robot will start its Homing Procedure.
❖ Wait until all the Boxes are ticked and the Robot has stopped homing.
❖ Make sure that program ST2 is loaded. If not, load it from Z:\IIT\WS2\ROBOT2 folder
❖ Station 2 is now ready to run in FMS.

Loading software in CIM Station 1
❖ Click on the Home icon.
❖ Machine Home Window will load.
❖ Click on the Home button.
❖ The machine will now home all three axes.
❖ Wait until the homing is completed.
❖ On the Top Menu, click on File, and START.NC program

If it is not shown, load it from Z:\IIT\WS1\VMC0600 FOLDER
❖ START program will load.
❖ Click on the Green RUN.
❖ The Run program menu will be displayed.
❖ Click on the Run Program button.
❖ Please verify the ATC configuration message will be displayed.

● Click on OK.
● Configure ATC window will be displayed.
● Look at the Mill and verify that the tool shown on the window is physically present in the
spindle.
● Click OK.
● The START program will run.
● A yellow bar will show on top of the software window.
● The Mill is now ready to run in FMS.

● Minimize the Mill software.
● On Desktop, click on the Loader of the WS1.

● The CIM DDLoader menu will be displayed
● FMS is now ready to run.
Steps for creating MRP and Manufacturing Order in Manager PC
Go to the CIM Manager PC. For creating an MRP and Manufacturing Order of the different parts to
be produced in the CIM cell and running the CIM system, perform the following steps:
● Select IIT from user projects and click on CIM manager icon.
● From the CIM Modes menu, select the Real mode.
● Click on Utility Programs menu from menu bar and select MRP
● Choose the order you want to run by selecting the Part name from the drop-down menu and
Enter Required Qty, Priority and Due Date.
● Click Save Order
● Click on the MRP icon From the message box with the prompt
● Click on the manufacturing order tab.
● In the Manufacturing Order window, click the Order you want to run and Part Name. It will
change the color to green.
● Next click MO (Manufacturing Order) icon on the toolbar. From the message box
with the prompt "Manufacturing Order Done" click OK.
● Save and Exit MRP menu.
Steps for running a CIM production cycle
● From the main screen of the CIM Manager, click Reset Storage icon from the tool bar.
● Click on the Green "START" icon on the CIM Manager menu.

● Make sure that all the devices change from yellow to green.
● At this moment, the program of production is initialized into the system. Click on the Green
Arrow "RUN" icon on the main screen to run the production.

● View the progress of the orders by clicking on the View Program tab.
● For Graphic Display of the various operations at the workstation in the CIM cell, click the
Graphic Display tab.
● When the order is completed, the CIM Message will appear "Order Has Been Completed"
● Click on the red stop button

● If you want to run a new order, make sure that you replace all the parts back in the correct
places in the initial state of storage.
Step II: Steps of using the WebcimViewer for remotely monitoring the operations of the CIM
cell
● First download and install the Web Viewer client by simply clicking here. Select run in order
to run this program from its current location.
The Web Viewer Client Setup window will be displayed. When the installation is complete, click
Finish.
● Select Save in order to save this program to a specified directory for future installations.
3.Open the Internet Explorer (version 6.0 and higher), and enter the following IP address in
the address field: http://203.110.245.95/WebCimViewer/start.ASP
(Note: The Web Viewer application enables you to remotely access a specific CIM cell and
track the production cycle from the various view tabs.) A webpage will be displayed as
follows.
Click Start. The Open CIM Web Viewer appears displaying the Graphic Display Window as
shown below with the following tabs to help in tracking the CIM production cycle.
Graphic Display Tab to show a 3D display of the operations being performed in the CIM cell.
View Scheduler Tab to display the scheduler information of the CIM cell.
View Program Tab to display the A-Plan (meaning, the production work order) of the CIM
cell.
View Leaf Tab to display the production activities in the CIM cell.
View Order Tab to display the current manufacturing order.
View Storage Tab to display the current location of parts in the CIM cell.
View Device Tab to display the actions performed by system devices.
View Pallet Tab to display the pallets in the CIM cell and the current status of each pallet.
Web Viewer Status Bar to display CIM cell information, such as current status, elapsed time,
etc.
View About Tab to display dialog with information about Web CIM Viewer software and
CIM software of the Cell that is currently in view.
For details on how to use the above tabs for tracking the CIM production cycle, please refer
to the video tutorials given in the User Guide page.
Step III: Steps for using IP camera for remotely viewing the operations of CNC:
● Open Internet Explorer browser and type http://203.110.245.36 in the address bar.
● Once the page gets loaded, the login window will come up as shown in the figure below.
Enter Username: admin

Password: 123456
● Then the IP camera page loads. If you are viewing this page for the first time, it will ask you
to install the plugin as shown below.
● Click on install and it will install the plugin.

● Then you will be able to view the CIM cell operations through IP camera as shown in the
figure below.
tep IV: Steps for system shut down
● Make sure that all the produced parts are removed from the rack and new supplied parts are
placed in the rack.
● Make sure that the two XV parts are in their rack positions.
Steps for shutting down the WorkStation 1

● Go to the Workstation 1 PC and Exit from the CNC Device driver.
● In CNCBase software, click on the red stop button and OK.
● Exit the CNCBase software.
● Shut down the PC.
● Turn off the Mill controller.
● Turn off the Workstation 1 UPS.
Steps for shutting down the WorkStation 2

● Go to the Workstation 2 PC and in Scorbase software go to the last subroutine
(SHUTDOWN) and run lines 247 and 248 in RUN SINGLE LINE.
● Exit from the ViewFlex.

● Exit from the Scorbase software. Do not save.
● Turn off the Robot controller.
● Turn off the Robot Controller UPS.
● Turn off the Workstation 2 UPS.
Steps for shutting down the CIM Manager PC

● Go to the CIM Manager PC and exit from the Manager software.
● Turn off the Manager PC UPS.
Steps for shutting down the Electricity and Air

● Turn off the Power supply to the Manager PC and Workstations.
● Close the valve for compressed air supply.
● Turn off the remote control switch for compressor.
● Turn off the Mains Power Supply to the FMS Lab.
● Downstairs, turn off the Mains power supply to the compressor

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MMCOE, Dept. of Mechanical Engg.

Marathwada Mitra Mandal's

Department of Mechanical Engineering

Computer Integrated Manufacturing

Academic Year 2023-24

Modelling of Mechanical Component using any 3D CAD software, Preparing CNC

Modelling of Mechanical Component using any 3D CAD software, Preparing CNC

6 Modeling and Simulation of Computer Integrated Manufacturing System.

7 Machine vision based quality control

8 Remote Monitoring and Operation of a Computer Integrated Manufacturing System.

Practical Number: 01 Date:

Double click on Mastercam X5

Following window will occur

Click on Line on Sketcher Toolbar

Create Profile in Second Quadrant as per dimensions

Click on Solid Tab

Select the Line for revolve

Click on OK in Chain Toolbar

Select the Axis as shown

Click on Revolve chain option

Enter 3600 angle-click OK.

Geometry will appear as in following figure.

Go to Machine Type in main Menu

Go to Properties on Operation Manager

Click on Stock Setup

Into stock tab click on properties

Click on make from 2 points

Tick on Use Margin Button

Input the Margin on OD, Right & Left side.

Click on Preview lathe boundaries-Enter.

Click on Chuck Jaws Properties.

Chuck will look as in following picture.

Select Face Operation-click ok.

Select Right hand Rough Tool

Click on Face Parameters

Click on Select Points

Select the Point from where we want to start machining.

Also select second point as origin.

Tool path will be generated.

Click on Verify Selected Operations

This will give you 3D View of operation.

Now Go to Tool Path-Select Rough

Chaining window will appear

Select the chain as shown in following Figure

Select Right Hand Tool as shown

Click on Rough Parameters Tab

Following path will be generated.

In this way we have completed with the Turning Operation.

For Grooving Operation:

Draw the geometry as per the dimensions.

Go to Solid- Revolve the Geometry.

Go to Machine Type in main Menu

Go to Properties on Operation Manager

Click on Stock Setup

Into stock tab click on properties

Click on make from 2 points

Tick on Use Margin Button

Input the Margin on OD, Right & Left side.

Click on Preview lathe boundaries-Enter.

Draw Chuck as shown.