OVERVIEW OF CAD, CAM &

CIM
 PRODUCT DESIGN
• Product design is a critical function in the
production system.
ADVANTAGES
• Productivity of designer can be improved
• Quality of the design can be enhanced
• Documentation of design can be improved
• Manufacturing database can be created
 GENERAL DESIGN PROCESS
The general process of design is
characterized as an iterative process
consisting of six phases.
• Recognition of Need
• Problem Definition
• Synthesis
• Analysis and Optimization
• Evaluation
• Presentation
 Recognition of need
• Recognition of need involves the
realization that a problem exists for which
some corrective action can be taken in the
form of a design solution.
• This recognition might mean identifying
some deficiency in a current machine
design by an engineer or perceiving of
some new product opportunity by a
salesperson.
 Problem definition
• Problem definition involves a thorough
specification of the item to be designed.
This specification includes the physical
characteristics
Function
Cost
Quality
Operating performance.
 Synthesis and analysis
• Synthesis and analysis are closely related and
highly interactive in the design process
• Each of the subsystems of the product must be
conceptualized by the designer, analyzed, improved
through this analysis procedure, redesigned,
analyzed again, and so on.
• The process is repeated until the design has been
optimized within the constraints imposed on the
designer.
• The individual components are then synthesized
and analyzed into the final product in a similar
manner.
 Evaluation
• Evaluation is concerned with measuring
the design against the specifications
established in the problem definition
phase.
• This evaluation often requires the
fabrication and testing of a prototype
model to assess operating performance,
quality, reliability, and other criteria.
 Presentation
• Presentation is concerned with
documenting the design by means of
drawings, material specifications,
assembly lists, and so on.
• Documentation means that the design
data base is created.
CAD
 CAD
• Computer-Aided Design (CAD) is defined
as any design activity that involves the
effective use of the computer to create,
modify, analyze, or document an
engineering design.
 GEOMETRIC MODELING
• It Involves the use of a CAD system to
develop a mathematical description of the
geometry of an object. These capabilities
permit the designer to construct a model of
a new product (or its components) or to
modify an existing model.
• There are various types of geometric
models used in CAD. One classification
distinguishes between two-dimensional (2D)
and three-dimensional (3D) models.
TYPES OF GEOMETRIC MODELS
• Two-dimensional models are best utilized
for design problems in two dimensions,
such as flat objects and layouts of buildings.
• Three-dimensional CAD systems are
capable of modelling an object in three
dimensions. The operations and
transformations on the model are done by
the system in three dimensions according
to user instructions. This is helpful in
conceptualizing the object.
• Geometric models in CAD can also be classified
as either wire-frame models or solid models.
• A wire-frame model uses interconnecting lines
(straight line segments) to depict the object .
• Wire-frame models of complicated geometries
can become somewhat confusing because all of
the lines depicting the shape of the object even
the lines representing the other side of the object
• Wire-frame representation is still often
inadequate.
 Solid modelling
• Solid modelling is the most recent development
in geometric modelling.
• In solid modelling, an object is modelled in solid
three dimensions, providing the user with a vision
of the object very much like it would be seen in
real life. It provides a more accurate
representation of the object.
• Also, the geometric model can be stored in the
CAD system as a 3-D solid model. This is useful
for calculating mass properties, to perform
interference checking between mating
components during assembly , and in other
engineering calculations.
 ENGINEERING ANALYSIS
The analysis involves
• Stress-strain calculations
• Heat transfer analysis
• Dynamic simulation
The availability of software for engineering
analysis on a CAD system greatly increases
the designer's ability and willingness to
perform a more thorough analysis of the
proposed design.
Examples of engineering analysis
• Mass property analysis
• Interference checking
• Tolerance analysis
• Finite element analysis
• Kinematic and dynamic analysis
• Discrete event simulation
DESIGN REVIEW AND EVALUATION
Some of the CAD features that are helpful in
evaluating and reviewing a proposed design
include:
Automatic dimensioning
To determine precise distance between surfaces
on the geometric model identified by the user.
Error checking
This term refers CAD algorithms that are used to
review the accuracy and consistency of
dimensions and tolerances and to assess whether
the proper design documentation format has been
followed.
Animation of discrete-event simulation
Displaying the solution of the discrete-event
simulation in animated graphic, is a helpful
means of presenting and evaluating the
solution.
Plant layout design –
Designing the floor layout and physical
arrangement of equipment in a facility.
 AUTOMATED DRAFTING
• Automated Drafting is a form of useful
presentation and documentation.
• Systems can be used as automated drafting
machines to prepare highly accurate
engineering drawings quickly.
• It is estimated that a CAD system increases
productivity in the drafting function by
about fivefold over manual preparation of
drawings.
 CAD SYSTEM HARDWARE
• The hardware for a typical CAD system consists of
the following components.
• One or more design workstations
• Digital computer
• Plotters, printers and other output devices
• Storage devices
• ln addition, the CAD system would have a
communication interface to permit transmission of
data to and from other computer systems, thus
enabling some of the benefits of computer
integration
CAD SYSTEM HARDWARE
CAM
 COMPUTER AIDED
MANUFACTURING
• Computer-Aided Manufacturing (CAM) is
defined as the effective use of computer
technology in manufacturing planning and
control. i.e, CAM is most closely
associated with functions in manufacturing
engineering. The applications of CAM can
be divided into two broad categories.
• Manufacturing Planning
• Manufacturing Control
 MANUFACTURING PLANNING
• CAM applications for manufacturing
planning are those in which the computer
is used indirectly to support the
production function, but there is no direct
connection between the computer and the
process.
• The computer is used "off-line“ to provide
information for the effective planning and
management of production activities.
 APPLICATIONS
• The important applications of CAM in
Manufacturing planning are as follows.
• Computer-aided process planning (CAPP)
• Computer assisted NC part programming
• Computerized machinability data systems
• Development of work standards
• Cost estimating
• Production and inventory planning
• Computer aided line balancing
• Computer-aided process planning (CAPP)
Process planning is concerned with the
preparation of route sheets that list the
sequence of operations and work centers
required to produce the product and its
components.
• Computer-assisted NC part programming
For complex part geometries, computer-
assisted part programming represents a
much more efficient method of generating
the control instructions for the machine tool
than manual part programming.
• Computerized machinability data systems
One of the problems in operating a metal
cutting machine tool is determining the
speeds and feeds that should be used to
machine a given work part.
Computer programs have been written to
recommend the appropriate cutting
conditions to use for different materials.
• Development of work standards
The time study department has the
responsibility for setting time standards on
direct labor jobs performed in the factory.
Establishing standards by direct time study
can be a tedious and time-consuming task.
There are several commercially available
computer packages for setting work
standards.
These computer programs use standard time
data that have been developed for basic work
elements that comprise any manual task.
 Cost estimating
• The task of estimating the cost of a new
product has been simplified in most
industries by computerizing several of the key
steps required to prepare the estimate.
• The computer is programmed to apply the
appropriate labor and overhead rates to the
sequence of planned operations for the
components of new products.
• The program then sums the individual
component costs from the engineering bill of
materials to determine the overall product
cost.
 Production and inventory planning
These functions include
Maintenance of inventory records.
Automatic reordering of stock items when
inventory is depicted.
Production scheduling, maintaining current
priorities for the different production orders.
Material Requirements Planning.
Capacity Planning.
• Computer-aided line balancing
Finding the best allocation of work
elements amongst the stations on an
assembly line is a large and difficult
problem.
Computer programs have been developed
to assist in the solution of this problem.
 MANUFACTURING CONTROL
• The second category of CAM application
is concerned with developing computer
systems to implement the manufacturing
control function.
• Manufacturing control is concerned with
managing and controlling the physical
operations in the factory.
 APPLICATIONS
• The important applications of CAM in
Manufacturing Control are as follows.
• Process monitoring and control
• Quality control
• Shop control
• Inventory control
• JIT production systems
• Process monitoring and control
It is concerned with observing and
regulating the production equipment and
manufacturing processes in the plant.
The applications of computer process
include transfer lines, assembly systems,
NC, robotics, material handling and flexible
manufacturing system
• Quality control includes a variety of
approaches to ensure the highest possible
quality levels of the manufactured product.
• Shop control
It refers to Production management techniques
for collecting data from factory operations and
using the data to help to control production and
inventory in the factory.
• Inventory control
Inventory control is concerned with maintaining
the most appropriate levels of inventory in the
face of two opposing objectives.
Minimizing the investment and storage costs of
holding inventory .
Maximizing service to customers.
• Just-in-time production systems
It refers to a production system that is
organized to deliver exactly the right
number of each component to
downstream workstations in the
manufacturing sequence just at the time
when that component is needed.
 CAD/CAM
• CAD/CAM denotes the integration of
design and manufacturing activities by
means of computer systems.
• Earlier, the activities involved in designing
the product were separated from the
activities associated with manufacturing.
• Using CAD/CAM technology, it is possible
to establish a direct link between product
design and manufacturing engineering.
CIM
 COMPUTER INTEGRATED
MANUFACTURING
• Computer Integrated Manufacturing (CIM)
includes all of the engineering functions of
CAD/CAM, but it also includes the firm's
business functions that are related to
manufacturing.
• The ideal CIM system applies computer and
communications technology to all of the
operational functions and information
processing functions in manufacturing from
order receipt, through design and production,
to product shipment.
SCOPE OF CIM
COMPUTERISED ELEMENTS OF
CIM
 FUNCTIONS OF CIM
•The CIM concept is that all of the
firm's operations related to
production are incorporated in an
integrated computer system to
assist, augment and automate the
operations.
•In CIM, the output of one activity
serves as the input to the next
activity.
 FUNCTIONS OF CIM
• Customer orders are initially entered by
the company's sales force or directly by
the customer into a computerized order
entry system.
• The orders contain the specifications
describing the product.
• The specifications serve as the input to
the product design department.
• New products are designed on a CAD system.
• The components that comprise the product
are designed, the bill of materials is compiled,
and assembly drawings are prepared.
• The output of the design department serves
as the input to manufacturing engineering,
where process planning, tool design, and
similar activities are accomplished to prepare
for production. Process planning is
performed using CAPP.
• The output from manufacturing engineering
provides the input to production planning
and control, where material requirements
planning and scheduling are performed
using the computer system.
• Full implementation of CIM results in the
automation of the information flow through
every aspect of the company's organization.
 Characteristics of CIM
• Computer-integrated manufacturing (CIM) is the
manufacturing approach of using computers to control
the entire production process.
• This integration allows individual processes to exchange
information with each other and initiate actions.
• Through the computers integration, productivity can be
increased and less error-prone, although the main
advantage is the ability to create automated
manufacturing processes.
• Typically CIM relies on closed-loop control processes,
based on real-time input from sensors.
• It is also known as flexible design and manufacturing.
• The term "CIM" is both a method of
manufacturing and the name of a computer-
automated system in which individual
engineering, production, marketing, and
support functions of a manufacturing
enterprise are organized.
• In a CIM system, functional areas such as
design, analysis, planning, purchasing, cost
accounting, inventory control, and distribution
are linked through the computer with factory
floor functions such as materials handling
and management, providing direct control and
monitoring of all the operations.
VARIOUS ACTIVITIES IN CIM
• CIM also encompasses the whole lot of
enabling technologies including total quality
management, business process reengineering,
concurrent engineering, workflow automation,
enterprise resource planning and flexible
manufacturing
• A distinct feature of manufacturing today is
mass customization.This implies that though
the products are manufactured in large
quantities, products must incorporate
customer-specific changes to satisfy the
diverse requirements of the customers. This
requires extremely high flexibility in the
manufacturing system.
 CIM Software
CIM software comprises computer programs to
carry out the following functions:
– Management Information System
– Sales & Marketing & Finance
– Database Management
– Modeling and Design
– Analysis
– Simulation
– Communications
– Monitoring
– Production Control
– Manufacturing Area Control
• CIM encompasses the entire range of product
development and manufacturing activities with all the
functions being carried out with the help of dedicated
SW packages.
• The data required for various functions are passed
from one application SW to another in a seamless
manner.
– For example, the product data is created during
design
– This data has to be transferred from the modeling
SW to manufacturing SW without any loss of data.
• CIM use a common DB wherever feasible to integrate
design, manufacturing and associated business.
• CIM reduces the human component of manufacturing
and thereby relieves the slow and expensive
processes leading to error-prone components.
 CIM HARDWARE:

– CNC, Computer numerical controlled machine

tools
– DNC, Direct numerical control machine tools
– PLCs, Programmable logic controllers
– Robots
– Computers
– Controllers
– Network devices
– Interfacing equipments
– Monitoring equipments
 Benefits of CIM
Integration of technologies brings the following
benefits:
1. Creation of a truly interactive system that enables
manufacturing functions to communicate easily with
other relevant functional units.
2. Accurate data transferability among manufacturing
plant or subcontracting facilities at implant or
diverse locations.
3. Fast responses to data-changes for manufacturing
flexibility.
4. Increased flexibility towards introduction of new
products.
5 Improved accuracy and quality in the manufacturing
process .
6. Improved quality of the products.
7. Control of data-flow among various units
and maintenance of user-library for
system-wide data.
8. Reduction of lead times which generates a
competitive advantage.
9. Streamlined manufacturing flow from
order to delivery.
10. Easier training and re-training facilities.
 3 STEP PROCESS FOR
IMPLEMENTATION OF CIM
 World class standards
CIM helps to achieve the following world
class standards such as
• Decrease in manufacturing cost
• Increase in product quality
• Increase in productivity
• Increase in customer responsiveness
• Decrease in inventory cost
• Increased flexibility
• Increased production control
 3 STEP PROCESS FOR
IMPLEMENTATION OF CIM
1. Assessment of the enterprises in the
areas of
Technology
Human resource and
System
2. Simplification
3. Implementation with performance
measures
 I. Assessment of the enterprise
• TECHNOLOGY
The current level of technology and the process
sophistication available in manufacturing should
be assessed.
• HUMAN RESOURCES
Tendency of humans to resist the
implementation of new technology.
The current state of employee readiness for the
adoption of CIM across the enterprise is to be
assessed.
• SYSTEM
The reason why production system function as
they do.
1.1 Issues faced during CIM implementation

Lack of in-house technical expertise

Top management does not grasp benefits

Inadequate planning or lack of vision

Unavailability of funds

Fear of poor impl.

Many

other
s

10 20 3 4 5
0 0 0
• One of the major problems faced during the
implementation of CIM is Lack of in-house of
expertise.
• It can be solved by educating each and every
one in the industry about the following.
1. The importance of industry in the national
and international level (to acquire market
place).
2. The Importance of global principles.
3. The Software and hardware items that are
needed to implement CIM.
 1.2 Global Principles
• Team work
• Total quality
• Improved productivity
• Zero inventory
• Brain storming
• Zero defect manufacturing
• Continuous improvement
• Common database
• Readiness to accept ideas from anybody
2. SIMPLIFICATION – ELIMINATION
OF WASTE
• Simplification is nothing but elimination of
waste from each and every activity to
improve the productivity and effectiveness
of the department and organisation.
• What is waste ?
Every possible move or operation or
activity that does not add value to the
product like moving, waiting in the queue,
waiting for process setup, inspection etc.
can be regarded as the waste.
 Strategies to eliminate waste
• Attack waste fundamentally so that it can
be reduced to 10%.
• M1 trucks M2

• M1 Conveyors M2
 3 step rule for elimination
REDUCTION TOTAL %

Reduce by 50% 50

Reduce by 50% again 75

Make it 10% of what it originally was 90

A world class company works the 3

step rule to arrive at a 90% reduction of
waste.
 3. IMPLEMENTATION WITH
PERFORMANCE MEASURES
• Measuring the success of implementation of
CIM at regular intervals.
• Recording the changes in key manufacturing
and business parameters like
Decreased product cycle time
Increased inventory turns by product
Decreased production setup time
Increased manufacturing efficiency
Increased quality and decreased rework
Increase in employee output or productivity
Increased employee continuous improvement
suggestions
DIFFERENT PERFORMANCE LEVELS
AFTER IMPLEMENTATION OF CIM
LEVEL PLANNING AND CONTROL CONTINUOUS IMPROVEMENT
PROCESSES PROCESS
Class A Effectively used by company It has become a way of life for
wide. employees, suppliers and
Generating significant customers improved quality,
improvements in customer decreased cost and contributing to
service, productivity, inventory a competitive advantage
and cost

Class B Supported by top managements, More departments participating

used by middle management to and achieve involvement with
achieve measurable company some suppliers and customers
improvements making substantial contribution in
many areas
Class C Operated primarily as better Process utilised in limited areas
methods for ordering materials some departmental
contributing to better inventory improvements
management
Class D Information inaccurate and Process not established