Computer Aided Design & Manufacturing 2023

Manufacturing
Module 1
PRODUCTION SYSTEM

A production system is the collection of people, equipment and procedures organized to

accomplish manufacturing operations of a company.

Production system consists of several components such as:

1. Production Machines.
2. Material Handling Systems.
3. Computer control system
4. Human Resources

Types of Production System

1. Manually operated System

 A Manually operated system consists of one or more number of workers
performing tasks without the aid of powered tools (Machines).
 The human resource (workers) will perform the operation using hand held
tools.
 Example: Filing and Fitting operations

2. Worker-Machine system
 Powered equipment’s such as lathe, drilling, milling machines etc. will be
used for processing. Human workers referred as operators work with these
power tools.
 Material transfer takes place manually.
 Example: lathe, drilling machines, milling machines in machine shop.

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 1

 Computer Aided Design & Manufacturing 2023
Manufacturing

3. Semi-automated Machines
 Such systems use machines controlled by computer and are referred as
Computer Numerical Control (CNC) machines. A set of instructions called as
NC programs are fed these Machines for performing operations.
 Human resource referred as programmers s used to feed the program.
Material transfer usually takes place manually and sometimes by conveyors.
 Example: CNC machine, where loading and unloading is performed by
human workers.

4. Fully automated Machines

 In such systems most of the operations like material processing, material
transfer loading and unloading operations are carried out by automated
machines (Robots or AGV’s).
 Periodic human is required in operations like switching on and switching off
the machines.
 Example: CNC Machine where a Robot is employed for Material handling

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 2

 Computer Aided Design & Manufacturing 2023
Manufacturing
Material Handling Systems

Functions of a Material handling system are

 Loading and unloading the Work units.

 Positioning the work units at each station.
 Transporting the work units between stations.
 Providing Temporary storage

Computer Control Systems

Some of the typical functions of computer control systems are:

 Controlling Material handling systems

 Production Scheduling
 Quality control
 Failure Analysis
 Operations Management
 Feedback control

Human resources

 Human resources are used either in the form of direct labour and indirect labour.
 Direct labour adds value to the work by performing operations.
 Indirect labour supports the production system in the activities like managing the
operations, programming the machines, scheduling the operations and so on.

Classification of Production Systems

Based on the product quantities produced in a given industry, production system can be
classified into three ranges:

1. Low volume production / Job shop production

2. Medium volume production / Batch production
3. High volume production / Mass production

Low volume production / Job shop production

 Job shop production is typically a system of manufacturing where specific products are
made in very small batches.
 Typically each job is different from previous.
 A job shop usually consists of different machines which are capable to perform various
operations.
 Ideally in a job shop production system, machines are grouped together based on their
function. Ex: Drilling machines are grouped together, and machines performing turning
operations are grouped together.
 Job shop production is employed in small and medium scale industries.

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 3

 Computer Aided Design & Manufacturing 2023
Manufacturing
Medium volume production / Batch production

 In batch production, the components are created stage by stage over a series of
workstations and different batches of products are made.
 In this type of system, a batch of one product is made after which the facility is changed
to produce a batch of the next product.
 In batch production system, a standard production line is set up for a product. The
production line can be changed, so that different products can be made.

High volume production / Mass production

 Mass production uses a standardized process of creating interchangeable parts in large

quantities at a low production cost.
 Mass production refers to the process of creating large numbers of similar products
efficiently.
 Mass production reduces the amount of time spent in individual product. This can allow
manufacturers to lower the cost per unit.
 Benefits mass production includes:
 Lower cost per unit
 Reduced manufacturing lead time
 Increased output

PLANT LAYOUT

Keeping in view the type of industry and volume of production, the types of layout are:

1. Fixed-position layout
2. Process layout
3. Product-flow layout

Fixed-position layout

In this type of layout, the term "fixed-position" refers to the product. The product remain in a
fixed position because it is too heavy or too big and as such it is economical and convenient
to bring the necessary tools and equipment's to work place along With the man power. This
type of layout is used in the manufacture of boilers, hydraulic and steam turbines, ships etc.

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 4

 Computer Aided Design & Manufacturing 2023
Manufacturing

Advantages Offered by Fixed Position Layout:

a. Material movement is reduced

b. Capital investment is minimized.
c. The task is usually done by a group of operators, hence continuity of operations is
ensured
d. Production centers are independent of each other. Hence, effective planning and
loading can be made. Thus total production cost will be reduced.
e. It offers greater flexibility and allow change in product design, product variety and
production volume.
Limitations of Fixed Position Layout:

a. Highly skilled man power is required.

b. Movement of machines and equipment's to production center may be time consuming.
c. Complicated fixtures are required for positioning of jobs. This may increase the cost
of production.

Process Layout
 The process layout is particularly useful where low volume production is required.
 In this type of layout, the machines are not arranged according to the sequence of
operations but are arranged according to the type of operations.
 This layout is common for non-repetitive jobs. Same type of operation facilities are
grouped together like all lathe machines will be placed at one place, all drilling machines
are at another place and so on.

Advantages of Process Layout

a. There will be less duplication of machines. Thus total investment in equipment Purchase
will be reduced.
b. It offers better and more efficient supervision through specialization at various levels.
c. There is a greater flexibility in equipment and man power thus load distribution is
easily controlled.
d. Better utilization of equipment.
e. Better control of process.

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 5

 Computer Aided Design & Manufacturing 2023
Manufacturing
Limitations of Process Layout
a. There will be long material flow lines and hence the process is time consuming.
b. More floor area is required.

Product layout

If all the processing equipment and machines are arranged according to the sequence of
operations of the product, the layout is called product layout. In this type of layout only one
type of products is produced in large quantities.

Advantages offered by Product Layout:

a. Less material handling cost

b. Better utilization of men and machines.
c. Less floor space.
d. Easy to control production.
e. Total production time is minimized.

Limitations of Product Layout:

a. Very limited flexibility in the process

b. The manufacturing cost increases with a fall in-volume of production.
c. If one or two lines are running light, there is a considerable machine idleness
d. A single machine break down may shut down the whole production line.
e. Specialized and strict supervision is essential.

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 6

 Computer Aided Design & Manufacturing 2023
Manufacturing
Automation

Automation is defined as "a technology concerned with the application of mechanical,

electronics, and computer-based systems to operate and control production."

Reasons for Automation

The use of automated manufacturing systems has been steadily increases over the past several
years. Automation's ability to process, assemble, inspect, and handle physical products in the
manufacturing process can benefit production facility in a number of ways. The various
reasons of automation are,

1. Increased productivity
Automation of manufacturing operations increases productivity by reducing the time to
perform repetitive task. Higher production rates (output per hour) are achieved with
automation compared to manual operations.
2. High cost of labour
High cost of labour is forcing business leaders to substitute machines for human labour.
As a result, higher investment in automated equipment has become economically
justifiable to replace manual operations.
Automation will replace manual operations and subsequently high cost of labour can be
reduced by using automated machines as they can have very high production rates.
3. Labour shortages
In many advanced nations there has been a general shortage of labour. Automation helps
to overcome the effects of labour shortage by replacing machines instead of labour.
4. Safety
Automation increase workplace safety. Workers are moved to supervisory roles where
they no longer have to perform in hazardous environment.
In addition, improved worker safety leads to financial savings with fewer healthcare and
insurance concerns for employers.
5. High cost of raw materials
The high cost of raw materials in manufacturing results in the need for greater efficiency in
using these materials. Automation helps in reduction of scrap and thus uses the materials
effectively.

6. Improved product quality

Automation has the capacity to improve-product quality. Applications are performed with
precision and high repeatability every time. Automation ensures the product is
manufactured with the same specifications and process every time. This level of
consistency can be hard to achieve any other way.

7. Reduced manufacturing lead time

The time elapsed between the customer order and product delivery is known as manufacturing
lead time (MLT). MLT is the Total time required to manufacture a product.

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 7

 Computer Aided Design & Manufacturing 2023
Manufacturing
Automation helps to reduce unproductive time like setup time, time required for loading and
unloading of parts, transfer of parts from one station to other. Thus automation-allows the
manufacturer to reduce the time between customer order and product delivery.
8. Reduction of in-process inventory
Work-in-process inventories represent a significant cost to the manufacturer. Automation
tends to accomplish this goal by reducing the time a work part spends in the factory.

Disadvantages of Automation

 Technology limits: Current technology is unable to automate all the tasks.Some tasks
cannot be easily automated, such as the production or assembly of products with
inconsistent component sizes or tasks where manual dexterity is required. There are
some things that are best left to human assembly and manipulation.
 Economic limits: Certain tasks would cost more to automate than to perform
manually. Automation is typically best suited processes that are repeatable, consistent
.
and high volume.
 Initial costs are relatively high: The automation of a new product or the construction
of a new plant requires a huge - initial investment compared to the unit cost of the
product.
 Maintenance: A skilled maintenance department is often required to service and
maintain automation system in proper working order. Failure to maintain the
automatic: system will ultimately result in lost production and/or bad parts being
produced.
 Increase in Unemployment: By increasing the amount of automation there are less
employees required causing high unemployment rates.

Types of Automation

Automation/has been classified into three types

1. Fixed (or) Rigid Automation

2. Programmable Automation
3. Flexible Automation

Fixed Automation (OR) Rigid Automation

 As the name suggests, in this automation these sequence of operations are fixed and
easier to perform.
 Fixed automation is used when the volume of production is high and product
variety is low. This kind of automation is mostly suitable for Mass Production. Here
the equipment is specially designed to produce a particular product. If the product
changes the same equipment cannot be used.
 Fixed automation has very high production rates.

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 8

 Computer Aided Design & Manufacturing 2023
Manufacturing
 Overall investment is less in case of fixed automation when compared to other types
of automation. Example, Oil refineries, chemical processing, Assembly lines special
purpose machines.

Programmable Automation

 In this type of Automation Sequences of operations can be interchanged.

 The sequence of operations are Controlled by program of instructions. If the product is
changed only program of instructions are changed but not the equipment.
 Programmable automation is used when production volume is low.
 This kind of automation is more suitable for Batch production. The Product variety
will be high in this automation compared to fixed automation if the product changes,
the same equipment can be used with minimal changes.
 Example, NC Machines, Industrial Robots

Flexible Automation

 It is an extension of programmable automation.

 A flexible automation system is able of producing a large variety of parts with
virtually no time lost for change over fromone Part style to the next.
 It covers the advantages of both fixed and programmable automation.
 The production rates are medium in flexible automation.
 The entire system is flexible to deal with variety of products.

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 9

 Computer Aided Design & Manufacturing 2023
Manufacturing
Automation Principles and strategies

USA principle is used to suggest the necessity of automation in an industry.

U SA principle stands for

 U: Understand the existing process

 S: Simplify the process
 A: Automate the process
Under the existing process
To understand the existing process one needs to know
 The inputs of the process
 The output of the process
 Type of process
 How each process adds value to product?
 Relation between the process
 Mathematical models between input and output variables
Simplify the process
 Before implementing automation, the, existing process can be simplified by
understanding the purpose of the process and if possible eliminate or combine the
process without affecting the overall process.
 It is important to ensure that the process uses appropriate technology.
Automate the process
After reducing the process to its simplest form, automation can be implemented by following
the ten strategies of automation.

The strategies of Automation and production system is given by

1. Specialization of operations
It involves the use of specialized equipment which performs each operation with greatest
possible efficiency. It reduces operation cycle time and increases productivity.
2. Combined operations
Complex parts require more than one processing operation. The strategy involves in
reducing the number of different processing machines (or) workstations through which the
part must be routed.
 It reduces number of workstations.
 Reduces work handling time.
 Reduces non-operational cycle time.
3. Simultaneous Operations
 It is the extension of combined operations.
 This strategy involves in performing the operations simultaneously in a single work
station.

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 10

 Computer Aided Design & Manufacturing 2023
Manufacturing
 In such strategy two or more operations are performed on the work part at the same
time.
 It reduces number of operations
 It reduces setup time, operational and non-operational cycle time.
4. Integration of operations
 This strategy involves linking several workstations into single integrated mechanism
by using automated work handling devices.
 It reduces number of workstations, work handling time and nonoperational time.
5. Increased Flexibility
 It involves in using the same equipment and machinery for variety of products
 It increases machine utilization
 It reduces setup -time, manufacturing lead time.
6. Improved material handling and storage
 It involves in the use of automated material handling systems which transfer work
parts between different stations.
 It also involves in the usage of Automated storage and Retrieval systems (ASRS)
 Reduces non-operational cycle time, setup time.
7. Online Inspection
 Traditionally inspection is carried out only after the entire process is completed. It
means that poor quality has already been produced by the time it is inspected.
 Online Inspection helps in reducing scrap
8. Process control and optimization
 In involves in the usage of different types of control mechanisms intended operate
individual process and associated equipment.
 It reduces operational and non-operational cycle time.
9. Plant operations control
 This is concerned with the control of all the operations at the plant level.
 All the departments in the plant are integrated by using high level of computer
networking in the factory.
 It reduces manufacturing lead time.
 It increases utilization.
9. Computer Integrated Manufacturing
 It involves in the integration of factory operations with engineering design several
business functions.
 It requires extensive use of computer applications, computer database networking
throughout the enterprise.
 It reduces Manufacturing lead time, Total cycle time.
 It increases quality and machine utilization.

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 11

 Computer Aided Design & Manufacturing 2023
Manufacturing
Computer Integrated Manufacturing
The term Computer integrated manufacturing (CIM) denotes the use of computer systems to
design the products, plan the production, and control the operations to perform various business
related functions needed in a manufacturing firm.

Salient Features of CIM

Following are various salient features of CIM;
1. Marketing: The need for a product is identified by the marketing division. The
specifications of the product, the projection of manufacturing quantities and the
strategy for marketing the product are also decided by the marketing department.
Marketing is used to estimate the manufacturing costs to assess the economic viability
of the product.
2. Product Design: The design department of the company establishes the initial database
for production of a proposed product. In a CIM system this is accomplished through
activities such as geometric modeling and computer aided design while considering the
product requirements and concepts generated by the creativity of the design engineer.
Configuration management is an important activity in many designs. Complex designs
are usually carried out by several teams working simultaneously, located often in
different parts of the world. The design process is constrained by the costs that will be
incurred in actual production and by the capabilities of the available: production

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 12

 Computer Aided Design & Manufacturing 2023
Manufacturing
equipment and processes. The design process creates the database required to
manufacture the part.
3. Planning: The planning department takes the database established by the design
department and enriches it with production data and information to produce a plan for
the production of the product. Planning involves several subsystems dealing with
materials, facility, process, tools, manpower, capacity, scheduling, outsourcing,
assembly, inspection, logistics etc. In a CIM system, this planning process should be
constrained by the Production costs and by the production equipment and process
capability, in order to generate an optimized plan.
4. Purchase: The purchase departments is responsible for placing the purchase orders and
follow up, ensure quality in the production process of the vendor, receive the items,
arrange for inspection and supply the items to the stores or arrange timely delivery
depending on the production schedule for eventual supply to manufacture and
assembly.
5. Manufacturing Engineering: Manufacturing Engineering is the activity of carrying
out the production of the product involving further enrichment of the database with
Performance data and information about the production equipment and processes. In
CIM, this requires activities like CNC programming, simulation and computer aided
scheduling of the production activity. This should include online dynamic scheduling
and control based on the real time performance of the equipment and processes to
assure continuous production activity. Often, the need to meet fluctuating market
demand requires the manufacturing system flexible and agile.
6. Factory Automation Hardware: Factory automation equipment further enriches the
database with equipment and process data, resident either in the operator or the
equipment to carry out the production process. In CIM system this consists of computer
controlled process machinery such as CNC machine tools, flexible manufacturing
systems (FMS). Computer controlled robots, material handling systems, computer
controlled assembly systems, flexibly automated inspection systems and so on.
7. Warehousing: Warehousing is the function involving storage-and retrieval of raw
materials, components, finished goods as well as shipment of items. In today's complex
outsourcing scenario and the need for just-in-time supply of components and
subsystems, logistics and supply chain management assume great importance.
8. Finance: Finance deals with the resources pertaining to money. Planning of
investment, working capital; and cash flow control, realization of receipts, accounting
and allocation of funds are the major tasks of the finance departments.

Benefits of CIM
 CIM provides a means for standardization of design and manufacturing process
 CIM improves the flexibility of manufacturing process.
 CIM results in lower manufacturing lead time.
 By incorporating CIM, the time taken during design, planning, scheduling can be
reduced there by increasing the productivity.
 Cost and time taken for prototype testing can be minimized.

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 13

 Computer Aided Design & Manufacturing 2023
Manufacturing
 Accuracy in design process and all the process that support manufacturing is increased.

 Existing tools and equipment can be used with very -few modifications if t product
changes.
 CIM improves the quality of the product
 Overall cost of manufacturing can be reduced.
 Cost of inventory can be reduced.
 CIM increases machine utilization by eliminate (or) reducing machine setup
 CIM reduces (or) eliminates defects.

Scope of CIM

 Computer Integrated manufacturing includes all of the design functions of CAD/CAM but
it also improves the firm's business functions that are related to manufacturing.
 CIM technology can be applied to all of the operational functions and information process
functions in manufacturing from order receipt, through design and production to provide
Shipment.

Mohan G, Dept. of Mechanical, SVIT, Bangalore-64 Page 14