Unit 2

DATA INTEGRATION
By- Prof. Priyanka S. Barde
Data Integration
• CAD-CAM Integration,
• Product development through CIM
• Design Activities in a networked environment
• Networking in a manufacturing company,
• Hardware elements of networking,
• CIM Database
• Database requirements of CIM,
• Database management
• Database Models,
• EDM
• Product Data Management (PDM)
• Product life cycle Management(PLM)
CAD CAM Integration
From Design toManufacturing
 Now we are in the Manufacturing
domain

Design domain: Manufacturing

How to create domain: How to
geometry make part Need to
consider
• Manufacturing
process
• Material
• Machine
 Computer-Aided Manufacturing
(CAM)
 Definition
 The technology concerned with the use of computer
systems to plan, manage, and control manufacturing
operations through either direct or indirect computer
interface with the plant’s production resources.

>
 CAD/CAM
Integration
 Goal of integration
 To facilitate coordination of work and information flow
across organizational boundaries
– “Enterprise Integration Modeling”, Charles J. Petrie, The
MIT Press

< Example concept of CAD/CAM

integration >
 Integration in Product Cycle Level
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Product development through CIM
Integration in Database Level
Product Development Through CIM
• Engineering the product consists of process planning, tool
design, facility design, capacity planning, quality
assurance activities, procurement, assembly planning,
etc.
• Marketing department will have the responsibility of
carrying out appropriate product launch activities as well
as planning the sales and service network, advertising
and training of sales and service personnel.
Product Development cycle
DESIGN ACTIVITY IN A NETWORKED
ENVIRONMENT
• Several large-scale design activities require several
engineers (sometimes even hundreds) to work on
different aspects of design
- Examples are design of aircrafts and VLSI and UVLSI chip
designs.
• In a network linking several CAD systems, a situation may
arise where designers at several different locations need
to access the same design data.
• Design control, in its simplest form, ensures that two
different designers never modify the same design
independently.
Networking in a manufacturing company
• A manufacturing company carries out a number of
operations using computers.
• These include:
1. Master production scheduling and planning
2. Pay roll and human resources management
3. Purchasing and receiving
4. Order entry and invoicing
5. Shop management
6. Warehouse management
operations to be carried by computers

7. Tool crib management

8. Time keeping
9. Quality control
10. Shipping
11. Materials handling
12. Inventory control
13. Processing operations
14. Marketing
 Example
Network communication
 Web-based CAD/CAM
Integration
 Micro Machining System (MIMS)
 Micro machining service using the
internet
 Communication with 3-tier client-server
model
 Upload STL file

< Curve-based
approaches >
Web-based CAD/CAM Integration (cont.)

 SmartFab
 Micro machining using
SolidWorks 3rd Tier Fab.
1st Tier 2nd Tier
CAD API CAD
Software *DFM Web Micro
Module Server Fab.
Data
base
PolyCAM Micro
*CNC
NC Code
STL Model
Web • Tool/Material
Machining Plan
Generatio
Browse n information
r Cost • Design check
Estimatio • NC codes
n • Cost estimation
: Internet
: Local Network *CNC: Computer Numerical
Control
*DFM: Design for
< Architecture of Manufacturing
SmartFab >
 IPD Integrated Product Development
• When new product development (NPD) processes are
characterized in two dimensions – management philosophy and
team structure – IPD is considered an integrated waterfall
system. IPD processes, such as systems engineering, rely
heavily on documentation and formal reviews. These gateways
must be passed before a project can move to the next phase.
Thus, IPD systems are typical examples of waterfall processes.
• On the other hand, because IPD processes take advantage of
cross-functional teams, they are characterized by integrated
team structures. Team members from purchasing, maintenance,
and other services participate in early design phases alongside
the R&D, development, engineering, and marketing
departments.
 IPD Integrated Product Development

1 – Understand Customer Needs

• As in any product or process development system that
is successful, customer needs must be determined
upfront. Most IPD processes, like systems engineering
and project management, place emphasis on
gathering complete customer requirements early in
the development effort. Customer requirements
include desired functionality and quality.
• 2 – Plan and Manage the Product Development
Effort
• Planning any product development project should
address overall, long-term strategic goals. IPD adds a
focus to the specific business and innovation plans as
well as longer range technology acquisition and
development.
 IPD Integrated Product Development
3 – Use Integrated Teams
• It should be apparent that in a rapid development environment that
cross-functional teams better serve project efficiency. Manufacturing and
maintenance participation during development of Product specifications
can smooth the transition to production and facilitate quality
implementation. Empowered project teams will take ownership of the
product goals, resulting in a more successful commercialization.
• 4 – Integrated Process Design
As indicated, manufacturing, purchasing, and customer service
personnel should be involved with product design. Excluding support
disciplines when setting requirements and design specifications can reduce
the product’s performance and result in costly delays. Worse yet, problems
encountered post-launch are more difficult to resolve if the support staff is
unfamiliar with the product. By integrating all disciplines in the design effort,
product performance is optimized over its life cycle.
 IPD Integrated Product Development
5 – Manage Cost from the Beginning
• An additional advantage of using integrated teams (principle
#3) and integrated process design (principle #4) is that a
product’s life cycle cost is more accurate. Target new product
costs should be set early in the requirements phase and the
project should be managed within this constraint. Early phase
design changes are less expensive and effective planning
can help to manage non-recurring development expenses.
6 – Involve Stakeholders Early
• Products are not commercialized without external project
participants. IPD stresses that by involving vendors, suppliers,
distributors, and other stakeholders early in the design process
can reduce cost and development schedules. Understanding
vendor limitations and capabilities enhances the team’s ability to
predict cost and time-to-market.
 IPD Integrated Product Development
7 – Develop Robust Designs
• One of the reasons an IPD system is successful in product
development is that the process drives toward optimized and
robust designs. Many tools are available for the teams, such as
design of experiments, failure mode and effects analysis, and
lessons learned reviews. Risk in product development is
minimized by applying knowledge from past experiences and by
tapping into the broad backgrounds of the cross-functional team
members.
8 – Integrated CAD/CAM Tools
Today much of product development and design can be done
digitally. These tools, like computer-aided design (CAD) and
computer-aided manufacture (CAM), should be utilized fully in cross-
functional product development efforts. IPD systems emphasize
modeling not only for the product but also for construction,
manufacturing, engineering, and maintenance. Computer-aided
design tools can streamline development processes.
 IPD Integrated Product Development
9 – Simulate the Product Performance and Manufacturing
• Building on the use of computer-aided engineering tools (principle
#8), IPD processes utilize simulation for quality control and
performance validation. Checking for variations in digital mock-ups
can save cost in construction and maintenance. Today, 3D printing
models are relatively inexpensive to produce and can help to
validate product and operational variables early in the design
process as well as to garner customer feedback.
10 – Create an Efficient Development Approach
• One rule of project management teaches us that as the number of
team members grows, the number of communication channels
can nearly double. Efficient development teams should be limited
to the required number of participants to make decisions. Policies,
procedures, and paperwork ought to be minimized for the team to
focus on the product development goals. Empowered teams
(principle #3) can reach higher performance levels when
unencumbered by bureaucracy.
 IPD Integrated Product Development
11 – Continuously Improve the Design
Process
• IPD systems encourage improvement by
re-engineering the design process to
eliminate activities that do not add value.
Benchmarking other NPD processes
and industry participants sets objective
goals for life cycle development and
time-to-market standards. Team
members should be trained in innovation
and these IPD
SNJB's principles
LS K. B. Jain to recognize
College of Engineering,
Chandwad, Nashik
 Broad Integration
 PDM (Product Data Management)
 Control CAD file revisions
 Manage all data related to project

 PLM (Product Life-cycle Management)

 Product Development Management (PDM)
 Include all actors (company departments, business
partners, suppliers, OEM, and customers)
 Share product data
 Apply common processes
 Leverage corporate knowledge
 Data
Exchange
 Standard formats for data exchange
 IGES (Initial Graphics Exchange Specification)

3D CAD data

 STEP (Standard for the Exchange of Product

model data)

 DFX (Drawing eXchange Format)


2D drawing data

 STL (Stereo Lithography)


De facto standard in rapid prototyping

 VRML (Virtual Reality Modeling Language)


3D model on web
Data Exchange (cont.)
Networking in a manufacturing company

They're used to connect systems in various buildings

present in various locations. Modbus is a type of serial
communication protocol used in business networks.
Supervisory networks are used to connect various
computers to supervise other computers and systems,
and are mainly used in manufacturing industries.
Networking in a manufacturing company

Networks, as we know, are a medium to transfer

data. Networks, however, vary based on the volume
of data being transferred. Industrial networks refer
to networks that deal with transfer of data on a large
scale. This means that they allow us to connect
various devices across large spaces and enable
communication between them by allowing us to
transfer huge chunks of data between them.

Traditional networks may sound highly efficient, but

in reality, are limited to a very small number of
systems. Industrial networks are designed to cater to
real-time needs and the demands of a large number
of systems.
 Network Techniques

1. Network technology can be broadly classified into two categories.

They are Local area network (LAN) or Wide area networks (WAN).
LANs are intended to serve a number of users who are physically
located close together. WANs are more akin to telephone network,
tying different people in different buildings, cities or even countries.
2. A message is routed through several interim points before reaching
its final destination; a WAN may also incorporate the ability to
automatically change to an alternate message routing path if the
computer at one location fails. A LAN (local area network) has 2 to
10 times more traffic on it than a wide area network (WAN). Each
individual point within a network that can communicate through the
network is called a node. Each node is assigned a unique address.
This way, a destination address can be put into each message and
it can be sent to correct recipient.
Local Area Network (LAN)

A network is a linking of a group of computers to communicate

with each other and share software and hardware resources
via the cables and interfaces that connect the computers and
peripherals. Application softwares used in a network allow
several users access the same program and data at the same
time. As the name implies, a Local Area Network or LAN is a
system that covers short distances. Usually LAN is limited to a
single department or a single building or a single campus.
Typical data transmission speeds are one to 100 megabits per
second.
LAN
Factory LAN
Enterprise Wide Network
Components of a Small Local Area Network

A LAN in a CIM setup is a system comprising the

following basic components:
(i) Computers: (PC’s, Design Workstations, CNC
Systems, robots, PLC’s etc.)
(ii) Network Cable: A transmission cable is attached
to each device (computer/ peripheral) to enable the
transmission of messages from one device to
another.
The details of cables commonly used are given in
Table
(ii) Network Cable
Cables used in Networking
Network Wiring Methods

There are two basic ways by which three or more nodes can be
incorporated in a network. These are point-to-point and multi-drop
Network Topologies
(i) Star Network: This means running a separate cable or line between server and
each node. This is useful when a master slave relationship exists between the
server and the nodes. For sending data and files from one node to another a
request should be made to the server, which establishes a dedicated path between
the nodes. The data can be transmitted through this path.
 Network Topologies
(ii) Ring Network: This involves connecting all nodes in series. The cable will
normally loop back to form a full circle. This is some times used when nodes
are widely separated, as each node can act as a repeater (amplifier) for
message destined for downstream nodes. The data will have to pass through
other nodes before reaching the server. The data is sent in the form of a
packet which contains both source and destination addresses of the data. As
the packet circulates through the ring the destination station copies the data
into its buffer and the packet continues to circulate until it goes back to
source workstation as an acknowledgement.

(iii) Bus Networks: This type on interconnection allows all nodes to share the
same cable. Any message that travels on the cable is “seen” by every node
on the cable. This topology uses both base band and broadband
transmission.

(iv) Hybrid Networks: This includes features of more than one topology to
achieve the optimal trade-off of reliability, performance, flexibility and cost.
Networking

Wide-area network (WAN) A network that connects two or

more local-area networks over a potentially large
geographic distance Often one particular node on a LAN is
set up to serve as a gatewayto handle all communication
going between that LAN and other networks
Communication between networks is called internetworking
The Internet, as we know it today, is essentially the ultimate
wide-area network, spanning the entire globe
• Metropolitan-area network (MAN) The communication
infrastructures that have been developed in and around
large cities
Networking in a manufacturing company

7 Types of Computer Networks

•PERSONAL AREA NETWORK (PAN)
•LOCAL AREA NETWORK (LAN)
•WIRELESS LOCAL AREA NETWORK
(WLAN)
•METROPOLITAN AREA NETWORK (MAN)
•WIDE AREA NETWORK (WAN)
•STORAGE AREA NETWORK (SAN)
•VIRTUAL PRIVATE NETWORK (VPN)
Hardware elements of networking

Types of network devices

Here is the common network device list:
•Hub
•Switch
•Router
•Bridge
•Gateway
•Modem
•Repeater
•Access Point
Hardware elements of networking

Hub
Hubs connect multiple computer networking devices together. A
hub also acts as a repeater in that it amplifies signals that
deteriorate after traveling long distances over connecting cables.
A hub is the simplest in the family of network connecting devices
because it connects LAN components with identical protocols.
A hub can be used with both digital and analog data, provided its
settings have been configured to prepare for the formatting of the
incoming data. For example, if the incoming data is in digital
format, the hub must pass it on as packets; however, if the
incoming data is analog, then the hub passes it on in signal form.
Hubs do not perform packet filtering or addressing functions; they
just send data packets to all connected devices. Hubs operate at
the Physical layer of the
Open Systems Interconnection (OSI) model. There are two types
of hubs: simple and multiple port.
Hardware elements of networking
• Introduction of CIM necessitates every manufacturing
engineer to be aware of the basic hardware elements of a
network.
• The components required for a small network
(sayrestricted to a computerized design action or
production planning department) have been described
earlier.
1. LAN ADAPTERS
These adapters are used for client workstations
running DOS and Windows or OS/2 or
2. ETHERNET SWITCH
• Using high-speed, parallel paths among connected
Ethernet LAN segments and devices uses Ethernet
Switch to increase bandwidth 400 percent.
• By using this switch, LAN congestion is reduced, so
frequent LAN users get extra capacity without crowding
out others on the same network.
3 . ETHERNET WORKGROUP HUBS
• Workgroup hubs allow the addition of up to 8 or 16
stations to an existing Ethernet network to prevent
network congestion.
3 . ETHERNET WORKGROUP HUBS
• They automatically partition any port connected to a
device, which generates repeated collisions, and re-
enable the port when the condition clears.
4. WIRELESS LAN ADAPTERS
• These adapters provide seamless LAN access to any
unwired PC. One can even create a LAN among
notebook PCs in conference rooms, airplanes -
anywhere.
• Uses diffused infrared light. So transmissions are secure
and do not have to be aimed.
5. FDDI ADAPTERS
• The Fiber Distributed Data Interface (FDDI) delivers the
bandwidth you need for even the most demanding
network applications.
• Micro Channel, ISA and EISA systems benefit from
100Mbps speed to the desktop—just the capacity you
require for today’s graphics intensive applications.
6 . FDDI WORKGROUP CONCENTRATOR
• The workgroup concentrator is a low cost hub solution. It
works with existing hubs to serve as a high-speed link or
backbone.
7.TOKEN-RING ADAPTERS
• Token-Ring adapters are available for ISA, EISA,
PCMICA, Micro Channel and PCI buses.
• They offer low price, easy installation, reduced network
maintenance costs, and enhanced functionality.
8. ROUTER
• Many branch networks need a cost-effective, high
performance multi-protocol routing and bridging solution
that connects to the main network.
 CIM Database
Database Models

Network Database
The network database is a combination of several hierarchies in which child files
can have more than one parent file, thereby establishing a many-to- many
relationship among data. A hierarchical model is actually a subset of a network
model.
Examples of network database languages are TOTAL and IDMS.

In both hierarchical and network databases data relationships are predefined and
embedded in the structure of the database. Access to data is processed by
associated application programs. A limitation of both hierarchical and network
systems is the restriction they place on data access. They both require that the
rules of data access be defined when the data structure is defined. The access
rules are difficult to modify after the database has been implemented. They are
suited for batch operations that are highly structured and repetitive involving
high transaction rates.
 CIM Database
Database Management

The following list summarizes the problems of file systems that

can be overcome by DBMS.
i. Data dependence
ii. Rigidity
iii. Static nature
iv. Lack of integration
v. Data duplication
vi. Inconsistency
vii. Difficulty in sharing information
viii. Inefficiency
ix. Inability to handle adhoc requests.
CIM
Database
• Computer Integrated Manufacturing integrates all the
functions related to the manufacture,the successful
implementation of CIM lies in the efficient way relevant
data is shared among the different segments of CIM.
• The CIM database comprises basically four classes of
data:
1. Product Data
2. Manufacturing Data
3. Operational Data
4. Resource Data
 CIM Database
Database Models

Relational Database Management Systems (RDBMS)

Data is organized in the form of a table for a large variety of
manufacturing applications.
An example of such a set of data is given in Table
Dimensions for Deep Groove Ball Bearings
CIM Data Base
DATABASE REQUIREMENTS OF CIM
• A major challenge facing the implementation of CIM is to
establish the type of data needed to bridge the
mechanical design and manufacturing functions.
- Following is the list of varied tasks one might expect to
accomplish in a CIM environment.
1. Designing assemblies and performing tolerance analysis
on those assemblies.
2. Preparing production drawings of assemblies, individual
parts, tooling, fixtures and other manufacturing facilities.
3. Creating analytical models of parts for structural,
kinematical and thermal analysis
DATABASE REQUIREMENTS OF CIM

4. Calculating weights, volumes, centres of gravity and

other mass properties and costs of manufacturing.
5. Classifying existing parts according to shape, function,
and the process.
6 . Preparing part lists and bill of materials
 CIM Database
Database Models

Parts of Lath Assembly

PDM(Product Data Management)
CAD systems originally provided electronic drawings,
but then evolved to creating designs in 3D. In the 70’s
and 80’s, CAD users can build a 3D virtual prototype and
with digital mock-up interactively simulate product
performance and check for system interferences. Since
the late 80’s, other product development functionalities
such as manufacturing have been introduced to CAD
systems to provide manufacturing industry with tools
doing design, process planning and manufacturing all
under the same roof, hence the birth of CAD/CAM
systems.
PDM(Product Data Management)

It is however worth noting that the focus has been mainly

on managing part geometry and other geometry-related
information. For example, when assembly modelling is
done, there is little to manage elements like versions and
configurations, maturity and affectivities’, or the
relationships and links to other information that is being
generated
during the innovation phase of the design process.
PDM(Product Data Management)
PDM(Product Data Management)

S
 PDM

Databases are one component needed to deliver instant, accurate

data. Engineering information systems are the other.
An engineering data management system should automatically
notify members of the design team with updates and circulate
latest change orders. In order to derive maximum benefit from
CAD it must be possible to deliver CAD data efficiently and
seamlessly to all downstream applications related to engineering
planning. Product data management is a technology developed to
meet this need.

PDM systems work on network layouts called client-server

architectures. The server is also called a vault, even though the
information may be distributed over several workstations. The
vault acts as the heart of an engineering network. The vault or the
server has the capabilities to handle efficiently large amounts of
complex information. Product development engineers access the
vault through their desktop computers called clients.
 PDM
The features of a PDM system include:
• Electronically track, access, sort and retrieve design data
enabling the engineers to work on the most recently updated
designs.
• Integrating the design environment by providing facilities for
viewing drawings created in different CAD systems like
AutoCAD, PRO/E, Unigraphics, CADDS 5, I-DEAS, Solid
Edge, Solid Works etc.
• Providing a CAD view-and-mark up package to view
complete designs on the screens of the clients so that planning
engineers can satisfy themselves that designs are complete
before they are released to manufacturing planning.
• Retrieving drawings and designs based on limited information
so that design engineers can retrieve already available
designs, thereby saving valuable time in product development.
 PDM

The features of a PDM system include:

• Capturing design revision information from a variety of

documents like drawings, part lists, bill-of-materials (BOM).
• Providing data security through multi-tier access control.
• Creating comprehensive back-up and recovery procedures.
• Automatic disk clean-up of old drawing versions and batch
back-up.
• Generating audit trails such as who designed the part, who
modified the part, who approved the design etc.
• Providing graphical user interface tool kits so as to enable the
design team to create new applications.
In short PDM is an excellent tool for concurrent engineering.
PDM systems efficiently manages design reviews by getting the
right documents and the drawings to the right people in the
quickly.
PDM

Advantages of PDM
PDM offers several benefits for the speedy execution of product
development projects:
• PDM helps engineers to access design drawings in minutes.
• Managers know how many drawings were released for fabrication.
• Manufacturing engineers know exactly when to start fabrication.
• Two designers cannot simultaneously edit the same drawing.
• Two drawings cannot have the same drawing numbers.
• All information from drawing-release statistics to revision details
pass to the primary project management system that tracks overall
project status for all the company activities.
• The PDM system keeps a complete history of the modifications,
when the modifications took place and keeps all previous versions of
data for a period defined by the company.
• Subcontractors can be given direct access to PDM database.
Controls ensure that no subcontractor can access data associated
with the sub-sets of projects he is not involved with.
Benefit of PDM
• Reduced Product Development Cycle Time
• Reduced Complexity of Accessing the Information of
a Company
• Improved Project Management
• Improved Lifecycle Design
Engineering Data Management(EDM)
 Engineering Data Management(EDM)
EDM's Role
One of the prime motivation for EDM is the sheer
volume and diversity of engineering data. An
exhaustive description of a part or an assembly
requires a huge amount of documentation. The
more complex the item, the more diverse is the
documentation. The following information topics
could easily be listed under the heading of the
complete set of the engineering documentation
of a part or an assembly:
 Engineering Data Management(EDM)
• Drawings,
• CAD models,
• part lists,
• structural analysis models,
• spread sheets,
• technical notes,
• measurements results,
• manufacturing instructions,
• assembly instructions,
• organizational relations,
• material properties,
• schematics,
• applicable standards,
• photos and shaded images.
Engineering Data Management(EDM)

SNJB's LS K. B. Jain College of Engineering,

EDM Basic Concept
Chandwad, Nashik
Product life cycle
Management(PLM)
Fundamental Concepts of PLM
• Universal, secure, managed access and use of
product definition information
• Maintaining the integrity of that product
definition and related information throughout the
life of the product or plant
• Managing and maintaining business processes
used to create, manage, disseminate, share and
use the information.
Product life cycle
Management(PLM)
 Product life cycle
Management(PLM)
The core of PLM (product lifecycle management) is in the
creation and central management of all product dataand the
technology used to access this information and knowledge.
PLM as a discipline emerged from tools such as CAD,CAM and
PDM, but can be viewed as the integration of these tools with
methods, people and the processes through all stages of a
product’s life.

It is not just about software technology but is also a

businessstrategy.

For simplicity the stages described are shown in a traditional

sequential engineering workflow. The exact order of event
and tasks will vary according to the product and industry in
question but the main processes are:
Product life cycle
Management(PLM)
THANK YOU