Computer-Integrated Manufacturing (CIM) integrates design, manufacturing, and business functions

using computer and communication technologies. It includes CAD/CAM (Computer-Aided Design

and Manufacturing) and extends beyond them to cover business operations related to
manufacturing.

Scope of Computer-Integrated Manufacturing (CIM)

CIM covers a broad range of functions, integrating design, manufacturing, and business processes
through computer technology.

1. Product Design (CAD)

 Geometric modeling: 3D modeling of components and assemblies.

 Engineering analysis: Structural, thermal, and motion analysis of products.

 Design evaluation & automated drafting: Testing and optimization of designs.

2. Manufacturing Planning

 Process planning (CAPP): Defines machining, assembly, and processing steps.

 Material Requirement Planning (MRP): Ensures availability of raw materials.

 Production scheduling: Plans manufacturing activities for optimal efficiency.

3. Factory Operations (CAM)

 NC part programming: Automated programming of CNC machines.

 Process control: Real-time monitoring of production.

 Shop floor control: Supervising and optimizing production activities.

4. Manufacturing Control

 Quality control: Ensures defect-free manufacturing through automated inspections.

 Inventory control: Manages material flow and storage.

 Production monitoring: Tracks performance, defects, and workflow optimization.

5. Business Functions

 Order processing & customer billing: Automated order entry and invoicing.

 Enterprise Resource Planning (ERP): Centralized system for managing production and
finance.

 Supply chain management: Integrates suppliers, logistics, and inventory tracking.

1. Computer-Aided Design (CAD) System

✅ Used for designing products, parts, and assemblies using software like AutoCAD, SolidWorks, and
CATIA.
✅ Provides 3D modeling, simulation, and engineering analysis to optimize design.
✅ Directly integrates with CAM to ensure seamless transition from design to manufacturing.

📌 Example: In the automotive industry, CAD is used to design engine components and chassis
structures.

2. Computer-Aided Manufacturing (CAM) System

✅ Converts CAD models into machining instructions for CNC (Computer Numerical Control)
machines.
✅ Automates processes like milling, drilling, turning, and robotic welding.
✅ Uses G-codes and M-codes to program CNC machines.

📌 Example: Aerospace industries use CAM for precision machining of aircraft turbine blades.

3. Computer-Aided Process Planning (CAPP)

✅ Determines the optimal sequence of operations for manufacturing a product.

✅ Eliminates manual process planning by using standardized databases.
✅ Ensures efficient resource utilization and reduces production time.

📌 Example: CAPP systems help factories decide whether casting, forging, or machining is the best
method for production.

4. Production Planning and Control (PPC)

✅ Plans and schedules manufacturing operations to optimize efficiency.

✅ Uses Material Requirements Planning (MRP) to manage raw material supply.
✅ Balances machine workloads to avoid production bottlenecks.

📌 Example: Factories use PPC to ensure timely production of automobile parts and avoid
overstocking.

5. Flexible Manufacturing System (FMS)

✅ Automates machine tool selection, material handling, and scheduling.

✅ Uses Automated Guided Vehicles (AGVs) and robotics to move materials.
✅ Allows quick reconfiguration of machines to produce different products.

📌 Example: BMW factories use FMS to switch between different car models without stopping
production.

6. Automated Material Handling System

✅ Uses conveyor belts, robots, and AGVs to transport materials between workstations.
✅ Reduces manual labor and improves efficiency.
✅ Minimizes production delays and improves workflow.

📌 Example: Amazon warehouses use automated robots to sort and move packages efficiently.

7. Quality Control Systems

✅ Ensures products meet desired specifications using automated inspection tools like CMM
(Coordinate Measuring Machines).
✅ Uses Machine Vision Systems and Laser Scanners for real-time defect detection.
✅ Reduces waste and improves product reliability.

📌 Example: Electronics manufacturers use automated X-ray inspection systems to check circuit
boards.

8. Enterprise Resource Planning (ERP) System

✅ Integrates inventory management, order processing, finance, and human resources.

✅ Provides real-time data to optimize decision-making.
✅ Reduces operational costs and improves efficiency.

📌 Example: SAP ERP is widely used in industries to manage supply chains and financial planning.

Benefits of CIM

CIM offers several advantages that enhance productivity, efficiency, and cost-effectiveness in
manufacturing.

1. Increased Productivity

 Automates repetitive tasks, reducing cycle time and increasing output.

 Reduces dependency on manual labor.

2. Improved Product Quality

 CAD and CAM integration allows precise design and manufacturing.

 Automated quality control systems reduce defects.

3. Reduced Manufacturing Lead Time

 Faster transition from product design to production.

 Real-time scheduling and monitoring reduce delays.

4. Cost Reduction

 Less material waste due to optimized process planning.

  Lower labor costs due to automation.

5. Efficient Resource Utilization

 Minimizes inventory costs with just-in-time (JIT) production.

 Reduces energy and material wastage through optimized planning.

6. Flexibility in Manufacturing

 Quick adaptation to new product designs and changes.

 Flexible manufacturing systems (FMS) allow batch and customized production.

7. Better Communication & Decision Making

 Centralized data systems (ERP, MRP) integrate all departments.

 Real-time monitoring improves management efficiency.

Limitations of CIM

1. High Initial Investment Cost

 Requires significant capital for setting up automated machines, software, and networking
systems.

2. Complexity in Implementation

 Requires integration of various software and hardware, making implementation

challenging.

3. Skilled Workforce Requirement

 Demands highly trained personnel to operate and maintain CIM systems.

 Continuous training is needed to keep up with technological advancements.

4. Risk of System Failures

 Cybersecurity threats and system crashes can disrupt the entire production process.

 Downtime due to software or hardware failures can lead to huge losses.

5. Resistance to Change

 Employees may resist automation due to job security concerns.

 Shifting from traditional manufacturing requires organizational restructuring.

Tape Format in CNC

Before modern storage technologies, punched tape was used to store CNC programs. The tape
format followed a standardized structure to encode machining instructions.

1. Structure of Punch Tape

 Width: Typically 1-inch wide tape with multiple columns.

 Encoding: Binary-coded decimal (BCD) or EIA (Electronic Industries Alliance) codes were
used.

 Data Representation: Each row of punched holes represented an NC command (G-codes &
M-codes).

 Storage & Execution: Tape readers would sequentially read commands and send them to
the machine control unit (MCU).

📌 Example: The punched tape contained G-code sequences like:

nginx

CopyEdit

N001 G01 X50 Y25 F100

N002 G02 X75 Y50 R25

Each command directed the tool movement, speed, and cutting operations.

2. Evolution Beyond Tape Format

 Magnetic tapes, floppy disks, and electronic storage replaced punched tapes due to higher
data density and reliability.

 DNC (Direct Numerical Control) was developed to eliminate physical tape handling.

Direct Numerical Control (DNC)

DNC was introduced in the 1960s to control multiple CNC machines using a central computer.

1. Working of DNC

 The mainframe computer sends NC program instructions directly to CNC machines.

 Eliminates the need for punch tape readers.

 Commands are transmitted one block at a time in real-time (Behind-the-Tape Reader (BTR)
mode).

2. Components of DNC System

 Central Computer – Stores and sends part programs.

 Bulk Memory Storage – Holds multiple NC programs.

 Telecommunication Lines – Connects computers with CNC machines.

 CNC Machines (MCUs) – Execute instructions received from the DNC system.
3. Advantages of DNC

✅ No physical tape handling – Eliminates issues like tape wear and reading errors.
✅ Real-time feedback – CNC machines send data back to the central computer.
✅ Multi-machine control – A single DNC system can manage multiple machines simultaneously.

📌 Example: Aerospace manufacturers use DNC to send NC programs to multiple CNC machines in
real time for high-precision machining.

Tooling for CNC Machines

The tooling for CNC machines is discussed in your uploaded PDF (cim complete notes.pdf) on pages
373-376.

1. Cutting Tools

CNC machines use a variety of cutting tools depending on the machining operation:
✅ End Mills – Used for milling, slotting, and contouring.
✅ Drill Bits – Used for drilling holes of different diameters.
✅ Turning Tools – Used in lathe operations for cutting cylindrical parts.
✅ Reamers & Taps – Used for finishing holes and threading.
✅ Grinding Wheels – Used for precision surface finishing.

Tool Material Types:

 High-Speed Steel (HSS) – Used for general machining.

 Carbide Tools – Offer high cutting speeds and long tool life.

 Diamond & CBN (Cubic Boron Nitride) – Used for high-precision finishing.

2. Tool Holding & Automatic Tool Changing

Tool Holding Systems:

 Collets & Chucks – Secure the tool in the CNC spindle.

 Tool Holders (HSK, BT, CAT) – Used to attach cutting tools to CNC machines.

Automatic Tool Changer (ATC):

 Stores and switches tools automatically during machining.

 Common ATC designs: Carousel type, Chain type, and Random Access ATC.

📌 Example: A CNC machining center may have 20-80 tool slots to switch between different tools
automatically.
3. Workpiece Holding & Fixturing

To ensure accurate machining, CNC machines use work-holding devices such as:
✅ Vices & Clamps – Used for milling operations.
✅ Chucks & Faceplates – Used in turning operations.
✅ Magnetic & Vacuum Fixtures – Used for non-rigid materials like thin sheets.

📌 Example: Lathe chucks hold cylindrical workpieces securely while rotating at high speeds.

4. CNC Machine Accessories

✅ Coolant Systems – Prevents overheating and improves tool life.

✅ Chip Conveyors – Removes metal chips to maintain a clean workspace.
✅ Probing Systems – Used for automatic tool measurement & alignment.