Week 1-4
 
 

Topics:

1. The needs for CIM
2. The meaning & scope of CIM
3. The intricacies of manufacturing
4. The need for integration
5. The role of information technology in CIM

The needs for CIM

1.What is the importance of manufacturing?

2.What are the traditional practices of U.S. manufacturing?

3.What are the environmental changes that affect U.S. manufacturing?

4.How well did the U.S. adapt to the above changes?
 

 

The meaning & scope of CIM

1.What is CIM?

2.What is the CIM wheel?

3.What is the difference between CIM I and CIM II?

4.What are the factors that led to the development of CIM?

5.What are the promises of CIM?
 
 

The intricacies of manufacturing

1.What is the meaning of manufacturing?

2.What criteria are suggested to categorize the various manufacturing operations, facilities and processes?

3.How are the manufacturing operations, facilities, and processes classified according to the above criteria?

4.What is a system approach to manufacturing?

5.What are the insights gained in adopting a system view of manufacturing?
 

 

The need for integration

1.What are the islands of automation?

2.What needs to be done to revoke the islands of automation?

3.What is integration from a MIS perspective?

4.What is the implication of the above view for CIM?
 
 

The role of information technology in CIM

1.What is information technology?

2.How have computers been used in manufacturing?

3.What are the significant developments of information technologies?

4.What are the impacts of these developments on manufacturing?
 
 

The needs for CIM

1.The importance of manufacturing

• Wealth
• Service industries
• International competitiveness

2.Traditional practices of U.S. manufacturing:

• expansion
• conservatism
• emphasis on production volume
• manufacturing as a support function
• command-and-control view of manufacturing

3.Environmental changes

• increased domestic and global competition
• proliferation of new products
• shorter product life & development cycle
• smaller production volumes
• more product customization & variety
• new technologies
• fewer direct labor & middle management
• higher demand on skilled & technical knowledge
• reduce in direct labor costs
• increase in equipment, materials, distribution, energy & other overhead costs
• more emphasis on quality, service & reliability
• changing cost structure that is based on raw materials, fabricated parts, and machine usage in addition to labor costs

4.The performance of U.S. manufacturing

• growth trend in manufacturing output
• growth in manufacturing productivity
• Trade deficits
• Declining trend in durable goods manufacturing employment
• Manufacturing investment is below that in other countries
• High cost of investment capital
• Shrinking market share:

Electronics35% - 10% from 1972 to 1987

Semiconductor90% - 60%

Automobile44% - 25%

Aircraft95% - 65%
 
 

5.Response to the decline

• A shift from the traditional management goal of maximizing stability, productivity, return on investment in the short term to the new goal of maximizing adaptability to a rapidly changing market, with long-term competitiveness as the first priority
• Recognize the importance of a strong manufacturing sector
• Reassessment of total business strategy
• Selecting & implementing the proper technologies effectively
• Striving for more efficient use of resources

 
 

The meaning & scope of CIM

1.What is CIM (James Harrington 1973)?
- a computer system?

- a management philosophy?

- a competitive strategy?

- a data management and networking problem?

- a concept?

- a technology?

- a method for eliminating direct labor?

- a deterministic technical system?

- a socio-technical system?

- a buzz word?
 
 

**CIM is the integration of the total manufacturing enterprise through the use of integrated systems and data communications coupled with new managerial philosophies that improve organizational and personnel efficiency (CASA/SME 1990)
 

 

2.The CIM Wheel (Figure 1.1) (SME 1985)

- a central core : integrated system architecture (communication, information resources, data)

- manufacturing activities: planning & control, product & process, factory automation

- management functions: strategic planning, marketing, manufacturing, human resource management, finance
 

 

3.CIM I vs. CIM II

Data integration vs. Transaction & Operation integration
 

 

4.Factors in CIM Development

-NC technology

-Computer technology

-Manufacturing challenges
 

 

5.Benefits of CIM (Table 1.2)
 
 

Promises of CIM

• Responsiveness
• Flexibility
• Cost & quality

 
 

Tangible Benefits of CIM
 
 

Companies that have at least 10 years experience with CIM on a fairly large scale:

• 30-60% reduction of WIP
• 200-500% increased yield in acceptable parts & products
• 30-60% reduction in total lead time
• 15-30% reduction in product design-engineering costs

National Research Council, Washington, D.C., 1986
 
 

Arthur Andersen's clients who have implemented CIM:

• 90% reduction in manufacturing lead time
• 25% reduction in costs of direct & indirect labor
• 75% reduction in machine setup time

The intricacies of manufacturing

1.The meaning of manufacturing

• The management of resources for the entire manufacturing enterprise
• A series of interrelated activities (operation, inspection, transportation, storage) to accomplish the prime objective of converting raw materials into quality goods
• A conceptual system whose major functions are business, engineering, human resources, and production

2&3.Classification of types of manufacturing
 

4.System view of manufacturing

• System characteristics: (1) component

(3) goal orientation

(4) flexibility

• Input-Output model

5.Implementation of the system concept through CIM

• Problems are handled through computerization and timely information control of a manufacturing system or its subsystems

 
 

The need for integration

1.Islands of automation

• Individual processes are automated without concern for compatibility with one another

• Batch processing of accumulated information vs.

   

• Bottom-up approach in automation lacks management support

2.What needs to be done?

• A realization of full CIM as a major long-term goal

• Strategic plan for R&D and CIM implementation:

(1) Plan from the top down;

(2) Implement from the bottom up.
 
 

3.Integration from a MIS perspective

• Data Integration: a single view of corporate information

• Transaction Integration: a single transaction per event

• Operational Integration: a common interface among applications

4.CIM = CAD + CAM + MIS

• Design goes beyond the release of design documentation to manufacturing
• Sales, service, and manufacturing data need to be available to design engineers
• Standardization of product definition, e.g., MAP (Manufacturing Automation Protocol), TOP (Technical & Office Protocol), PDDI (Product Definition Data Interface), PDES (Product Data Exchange Specification)
• Aggregation of data into a single data base for all corporate activities

 
 

The role of information technology in CIM

1.Information Technology

Forms of technology involved in capturing, manipulating, communicating, presenting, and using data
 

 

IT = Hardware + Software + Database + Telecommunication
 
 

2.Computers in Manufacturing
 

Era	Application	Hardware/Software
50s & 60s	finance accounting	Mainframe/FORTRAN
70s	MRP, scheduling, inventory control	Mainframe/COBOL
80s	NC, CAD/CAM	Mini
90s	Integration	Micro

 

®90% of manufacturers worldwide use computers in:

CAD

Production control

NC and CNC programming

Inspection & quality control

MRP/MRP II

3.Significant developments of computer technology

Hardware

• PCs (32-bit) and PLCs (Programmable Logic Controllers)
• Workstations
• Optobus
• Microprocessor technology: (Pipelining, Superscalar/Parallel Processing, Cache, RISC) ® smaller, faster & cheaper

Software

• Integrated packages
• Graphics
• Expert systems
• Voice recognition systems
• Image processing systems
• UNIX operating system
• Software agents

Data base

• Affordable mass storage devices
• RDBMS (Relational Data Base Management Systems)
• Object-Oriented DBMS
• Data warehouse

Telecommunication

• The new "M" of production (Man, Machine, Material, Money,  Message)
• Fiber-Optics
• Digitalization
• Wireless networks
• Internet

 Internet statistics (U.S. Internet Council, 1999)
 

Internet access in US	90,000 (1993)	81 million (1999)
% of US households with Internet access	33% (1999)	50% (2003)
Time it takes to penetrate 30% of US households	38 years (telephone) 17 years (TV)	13 years (PC) 7 years (Internet)
No. of web pages	829 million (1998)	1.45 billion (1999) 7.7 billion (2002)
No. of e-mail messages sent	4 trillion (1998)	7 trillion (2000)
No. of e-mails AOL handled daily	28 million (Feb. 98)	51 million (Feb.99)

 

4.Technological Impacts on Manufacturing

• New materials (self-assembly, intelligent), microelectromechanical systems, etc. ® New, Smaller, Faster, Safer, Cheaper products
• Hard components of manufacturing (machinery, equipment) ® Soft components of manufacturing (information flow, database) ® bits & pieces of manufacturing activities ® entire system of manufacturing ® trend towards a full CIM
• Define a "factory of the future"

   

Future View (Tomorrow's Manufacturing Technologies)

• MicroRobots
• Mechatronic systems - integrate sensors, actuators, and control functions in one system to improve precision, performance, efficiency, and ease of use.
• Smart materials - change shape, color, form, phase, electric fields, magnetic fields, optical properties, and other physical characteristics in a pre-selected response to stimuli in the environment (simplify products, add features, reduce material use, reduce the expense and complexity of providing product variations)
• Solar power
• Concurrent engineering
• Rapid prototyping & production
• Feature-based programming - both geometric and non-geometric part information (information on part tolerances, surface finishes, impact on manufacturing costs, etc.)
• Virtual reality systems (mindware)