ME1403 COMPUTER INTEGRATED MANUFACTURING

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ME1403 COMPUTER INTEGRATED MANUFACTURING
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UNIT 1

• INTRODUCTION

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Meaning and origin of CIM

• Computer integrated manufacturing includes all
  if the engineering functions of CAD/CAM ,and also
  includes firms business functions that are
  related manufacturing

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Computer Integrated Manufacturing (CIM)

• Incorporates all manufacturing processes

ASRS
AGV
Automated Assembly
NC Machining
Order Entry
CAD/CAM
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Computer-Integrated Manufacturing
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Introduction to Manufacturing system

• Manufacturing system divides into five groups
• Project
• Job type
• Repetitive
• Line
• Contionus

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Changes in manufacturing

• The changes of manufacturing in to
  modernization activities is required to overcome
  global competition, consumer demand for better
  product and quality and judicious application of
  newer technologies

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Computer control of manufacturing
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CIM software

• The CIM software is an integrated package
  containing as many individual programs
  functionally amalgamated into one as possible.
  The CIM requires the application programs that
  can be integrated

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Programming languages used in CIM

• Apt
• C
• FORTRAN
• MODULA-2
• PROLONG
• BASIC
• COBAL
• LISP
• PASCAL
• VAL

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Plant operation

• Various operations
• processing
• Assembly
• Material handling and storage
• Inspection
• Control

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Task modeling of CIM
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CIM managers Task
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Production planning

• The production planning is the function of
  setting the overall level of manufacturing output
  and other activities to satisfy the current
  planned levels of sales

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Production planning functions
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Manufacturing organization model
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CIM is synonymous with world-class measures such
as ?? lower manufacturing costs ?? higher
product quality ?? better production control ??
better customers responsiveness ?? reduced
inventories ?? greater flexibility ?? smaller
lot-size production
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Components Of CIM
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Why Use CIM?

• Responsiveness to Rapid Changes in Market Demand
  and Product Modification.
• Better Use of Materials, Machinery, Personnel,
  Reduction in Inventory.
• Better Control of Production and Management of
  the Total Manufacturing Operation.
• The Manufacture of High-Quality Products at Low
  Cost.

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Integrated systems Architecture
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UNIT II

• GROUP TECHNOLOGY AND COMPUTER AIDED PROCESS
  PLANNING

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Introduction

• Group technology was introduced by Frederick
  Taylor in 1919 as a way to improve productivity.
• One of long term benefits of group technology is
  it helps implement a manufacturing strategy aimed
  at greater automation.

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What is group technology?

• Group technology (GT) is a manufacturing
  philosophy that seeks to improve productivity by
  grouping parts and products with similar
  characteristics into families and forming
  production cells with a group of dissimilar
  machines and processes.

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Background

• The introduction of GT techniques in
• General Electric
• Lockheed Missiles and Space Co.
• Boeing
• GT viewed as
• An essential step in the move toward factory
  automation.
• A necessary step in maintaining a high quality
  level and profitable production.

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Group Technology

• Group technology implementation can be broken
  down into 3 different phases
• Actions on the manufacturing process
• Changes to the production process
• Results for the organization
• Examples of the impacts group technology has had
  on the production process.

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Part families

• A part family is a collection of parts which are
  similar either because of geometry and size or
  because of similar processing steps are required
  in their manufacture

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Parts classification and coding

• Part classification and coding system can be
  grouped into three types
• 1.Design attribute group
• 2.Manufacturing attribute group
• 3.Combined attribute group

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Various coding systems

• The widely used coding systems are
• DCLASS
• MICLASS
• OPITZ
• RNC
• CODE

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OPTIZ CLASSIFICATION SYSTEM
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Implementation Phases

• Group technology has the following actions on
  the manufacturing process
• Part Simplification
• Process Standardization
• Production Control

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Implementation Phases

• The changes group technologies can have on the
  production process.
• Tighter Parts Control
• Close physical layout of machine groups
• Orderings tied to production

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Implementation Phases

• The results that group technologies have at the
  organizational level.
• Systematic design and redesign
• High-quality level
• Less process planning time and setup time

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Impacts of Group Technology

• Different impacts group technology has on the
  production process
• Reduced purchasing cost
• Less redundant purchases.
• Accurate cost estimation
• A more efficient process
• Quicker design changes
• Standardized Parts
• Improved customer service
• Classification builds customer relationships

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PROCESS PLANNING

• Introduction
• Process planning consists of preparing a set
  of instructions that describe how to fabricate a
  part or build an assembly which will satisfy
  engineering design specifications. The resulting
  set of instructions may include any or all of the
  following

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PROCESS PLANNING STEPS

• Study the overall shape of the part. Use this
  information to classify the part and determine
  the type of workstation needed.
• Thoroughly study the drawing. Try to identify
  every manufacturing features and notes.
• If raw stock is not given, determine the best raw
  material shape to use.
• Identify datum surfaces. Use information on
  datum surfaces to determine the setups.
• Select machines for each setup.
• For each setup determine the rough sequence of
  operations necessary to create all the features.

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PROCESS PLANNING STEPS(continue)

• Sequence the operations determined in the
  previous step.
• Select tools for each operation. Try to use the
  same tool for several operations if it is
  possible. Keep in mind the trade off on tool
  change time and estimated machining time.
• Select or design fixtures for each setup.
• Evaluate the plan generate thus far and make
  necessary modifications.
• Select cutting parameters for each operation.
• Prepare the final process plan document.

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Process Planning Automation There are three
approaches to computeraided process planning
(CAPP) Manual Approach Not Computer-Aided.
Variant Approach Computers store/match existing
process plans. Generative Approach Computers
generate a process plan from scratch.
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Manual Approach The process plan is developed by
a skilled planner who is familiar with the
companys manufacturing capabilities. The steps
involved are 1. Study the overall shape of the
part. 2. Determine what stock material to use. 3.
Identify datum surfaces for setups 4. Identify
part features.
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Manual Approach Steps, contd 5. Group features
into setups. 6. Sequence the operations in the
setup 7. Select tools for each operation 8.
Determine fixtures for each setup 9. Final
Check 10. Elaborate Plan (e.g. feeds and
speeds) 11. Prepare process plan document
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COMPUTER-AIDED PROCESS PLANNING

• ADVANTAGES
• 1. It can reduce the skill required of a planner.
• 2. It can reduce the process planning time.
• 3. It can reduce both process planning and
  manufacturing cost.
• 4. It can create more consistent plans.
• 5. It can produce more accurate plans.
• 6. It can increase productivity.

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WHY AUTOMATED PROCESS PLANNING

• Shortening the lead-time
• Manufacturability feedback
• Lowering the production cost
• Consistent process plans

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PROCESS PLANNING
Machining features
Design
Workpiece Selection Process Selection Tool
Selection Feed, Speed Selection Operation
Sequencing Setup Planning Fixturing Planning Part
Programming
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VARIANT PROCESS PLANNING
GROUP TECHNOLOGY BASED RETRIEVAL SYSTEM
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PROBLEMS ASSOCIATED WITH THE VARIANT APPROACH

• 1. The components to be planned are limited to
  similar components previously planned.
• 2. Experienced process planners are still
  required to modify the standard plan for the
  specific component.
• 3. Details of the plan cannot be generated.
• 4. Variant planning cannot be used in an
  entirely automated manufacturing system, without
  additional process planning.

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ADVANTAGES OF THE VARIANT APPROACH

• 1. Once a standard plan has been written, a
  variety of components can be planned.
• 2. Comparatively simple programming and
  installation (compared with generative systems)
  is required to implement a planning system.
• 3. The system is understandable, and the planner
  has control of the final plan.
• 4. It is easy to learn, and easy to use.

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GENERATIVE APPROACH
A system which automatically synthesizes a
process plan for a new component.
MAJOR COMPONENTS

• (i) part description
• (ii) manufacturing databases
• (iii) decision making logic and algorithms

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ADVANTAGES OF THE GENERATIVE APPROACH

• 1. Generate consistent process plans rapidly
• 2. New components can be planned as easily as
  existing components
• 3. It has potential for integrating with an
  automated manufacturing facility to provide
  detailed control information.

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Some typical benefits include

• 1. 50 increase in process planner productivity
• 2. 40 increase in capacity of existing equipment
• 3. 25 reduction in setup costs
• 4. 12 reduction in tooling
• 5. 10 reduction in scrap and rework
• 6. 10 reduction in shop labor
• 7. 6 reduction in work in process

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UNIT III

• SHOP FLOOR CONTROL AND INTRODUCTION OF FMS

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What is Shop Floor Control?

• Definition Shop Floor Control (SFC) is the
  process by which decisions directly affecting the
  flow of material through the factory are made.

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Functions
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Planning for SFC

• Gross Capacity Control Match line to demand via
• Varying staffing (no. shifts or no.
  workers/shift)
• Varying length of work week (or work day)
• Using outside vendors to augment capacity
• Bottleneck Planning
• Bottlenecks can be designed
• Cost of capacity is key
• Stable bottlenecks are easier to manage
• Span of Control
• Physically or logically decompose system
• Span of labor management (10 subordinates)
• Span of process management (related technology?)

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Basic CONWIP

• Rationale
• Simple starting point
• Can be effective
• Requirements
• Constant routings
• Similar processing times (stable bottleneck)
• No significant setups
• No assemblies
• Design Issues
• Work backlog how to maintain and display
• Line discipline FIFO, limited passing
• Card counts WIP CT ? rP initially, then
  conservative adjustments
• Card deficits violate WIP-cap in special
  circumstances
• Work ahead how far ahead relative to due date?

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CONWIP Line Using Cards
CONWIP Cards
Production Line
Inbound Stock
Outbound Stock
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Card Deficits
Jobs with Cards
Jobs without Cards
Bottleneck Process
Failed Machine
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Tandem CONWIP Lines

• Links to Kanban when loops become single
  process centers
• Bottleneck Treatment
• Nonbottleneck loops coupled to buffer inventories
  (cards are released on departure from buffer)
• Bottleneck loops uncoupled from buffer
  inventories (cards are released on entry into
  buffer)
• Shared Resources
• Sequencing policy is needed
• Upstream buffer facilitates sequencing (and
  batching if necessary)

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Tandem CONWIP Loops
Basic CONWIP
Multi-Loop CONWIP
Kanban
Workstation
Buffer
Card Flow
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Coupled and Uncoupled CONWIP Loops
Bottleneck
Buffer
Job
CONWIP Loop
Card Flow
Material Flow
CONWIP Card
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Splitting Loops at Shared Resource
Routing A
Routing A
Routing B
Routing B
Card Flow
CONWIP Loop
Material Flow
Buffer
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Modifications of Basic CONWIP

• Multiple Product Families
• Capacity-adjusted WIP
• CONWIP Controller
• Assembly Systems
• CONWIP achieves synchronization naturally (unless
  passing is allowed)
• WIP levels must be sensitive to length of
  fabrication lines

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CONWIP Controller
Work Backlog
PN Quant



LAN
Indicator Lights
R
G
PC
PC
. . .
Workstations
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CONWIP Assembly
Processing Times for Line A
1
2
4
1
Processing Times for Line B
3
2
3
3
Assembly
Material Flow
Card Flow
Buffer
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Data Collection Devices

• special purpose data collection terminals
• card or badge reader
• CRT or LED display
• a fairly robust keypad
• MICR, OCR and punched cards
• bar-code readers

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Bar Codes

• The bar-codes used internally in factories are
  usually either item numbers, which identify
  materials, or order numbers, which allow the shop
  floor control system to track the progress of an
  order through production. Employee badges,
  machines, and production processes can also be
  bar-coded.

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Bar Code Readers

• essentially two types
• hand-held scanners and
• mounted scanners

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Flexible Manufacturing Systems
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Flexible Manufacturing Systems (FMS)

• An FMS is a reprogrammable manufacturing system
  capable of producing a variety of products
  automatically. Conventional manufacturing
  systems have been marked by one of two distinct
  features
• The capability of producing a variety of
  different product types, but at a high cost
  (e.g., job shops).
• The capability of producing large volumes of a
  product at a lower cost, but very inflexible in
  terms of the product types which can be produced
  (e.g., transfer lines).
• An FMS is designed to provide both of these
  features.

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FMS Components

• Numerical Control (NC) machine tools
• Automated material handling system (AMHS)
• Automated guided vehicles (AGV)
• Conveyors
• Automated storage and retrieval systems (AS/RS)
• Industrial Robots
• Control Software

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Flexible Manufacturing System
Computer control room
Tools
Conveyor
Machine
Machine
Pallet
Load
Unload
Parts
Finished goods
Terminal
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Classification of FMS-related Problems

• Strategic analysis and economic justification,
  which provides long-range, strategic business
  plans.
• Facility design, in which strategic business
  plans are integrated into a specific facility
  design to accomplish long-term managerial
  objectives.
• Intermediate-range planning, which encompasses
  decisions related to master production scheduling
  and deals with a planning horizon from several
  days to several months in duration.
• Dynamic operations planning, which is concerned
  with the dynamic, minute-to-minute operations of
  FMS.

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FMS Problems

• Part type selection (Askin) - selecting parts
  that will be produced in the FMS over some
  relatively long planning horizon.
• Part selection (Stecke) - from the set of parts
  that have current production requirements and
  have been selected for processing in the FMS,
  select a subset for immediate and simultaneous
  processing.
• Machine grouping (Stecke) - partition machines
  into groups where each machine in a group can
  perform the same set of operations.
• Loading (Stecke) - allocate the operations and
  required tools of the selected part types among
  the machine groups.
• Control - provide instructions for, and monitor
  the equipment in the FMS so that the production
  goals identified by the above problems are met.

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• FMS Layouts
• Progressive Layout
• Best for producing a variety of parts
• Closed Loop Layout
• Parts can skip stations for flexibility
• Used for large part sizes
• Best for long process times

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FMS Layouts Continued

• Ladder Layout
• Parts can be sent to any machine in any sequence
• Parts not limited to particular part families
• Open Field Layout
• Most complex FMS layout
• Includes several support stations

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Automated Material Handling

• Automated Guided Vehicle (AGV)
• Automated Storage and Retrieval System (ASRS)
• Conveyors

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Components of Flexible Manufacturing Systems

• NC
• CNC
• DNC
• Robotics
• AGV
• ASRS

• Automated Inspection
• Cells and Centers

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Flexible Automation

• Ability to adapt to engineering changes in parts
• Increase in number of similar parts produced on
  the system

• Ability to accommodate routing changes
• Ability to rapidly change production set up

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Applications and benefits of FMS

• To reduce set up and queue times
• Improve efficiency
• Reduce time for product completion
• Utilize human workers better
• Improve product routing
• Produce a variety of Items under one roof
• Improve product quality
• Serve a variety of vendors simultaneously
• Produce more product more quickly

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UNIT IV

• CIM IMPLEMENTATION AND DATA COMMUNICATION

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MANUFACTURING INFRASTRUCTURE
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The Local Area Network (LAN)

• The LAN has many variations
• Wired (or fiber) or Wireless
• Operate at speeds from 1 Mbps to 1 Gbps ()
• Support Desktops, Laptops, Personal Devices
• Allow access to many resources
• Print
• File Server
• Internet
• Mainframe
• Collaborative Planning
• Etc.

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LAN Characteristics

• Typically serves a limited area
• Typically serves a single organization
• Varies from serving a few users to thousands
• Provides access to shared services
• Through a Network Operating System (NOS)
• Examples Windows NT, Novell, HP Unix
• Uses some form of access control
• High speed network connection

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LAN Topologies

• LAN Topology describes how the network is
  constructed and gives insight into its strengths
  and limitations
• Bus
• Star
• Branching Tree
• Ring

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Bus Topology
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Bus/Tree Topology

• The original topology
• Workstation has a network interface card
• (NIC) that attaches to the bus (a coaxial
• cable) via a tap
• Data can be transferred using either
• baseband digital signals or broadband
• analog signals

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Star Topology
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Branching Tree
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Ring
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Access Control

• Like a noisy classroom--difficult to communicate
  if every terminal is going at the same time
• Two forms well discuss
• Non-Contention Access
• Token
• Contention Access
• Carrier Sense Multiple Access with Collision
  Detection (CSMA/CD)

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Token

• Used in Bus and Ring topologies
• Token Ring for instance
• A token is placed on the network and passed to
  each member of the network
• When someone has something to say, they grab
  the token and then transmit their information
• The message is sent to all other members of the
  network
• The member the message is addressed to hears
  the message and all others ignore the message
• Once the message is delivered, the token is freed
  for someone else to use

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Token Issues

• The system has very good control, but is complex
  in implementation
• If token is lost or mutilated, a member of the
  network must replace the token
• Usually automatic after some specified wait time
• System is deterministic
• That means that if a station has higher priority
  traffic to send, the system can deal with that,
  either by preemption or allocation

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UNIT V

• OPEN SYSTEM AND DATABASE FOR CIM

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Open system

• Generally Computer network architectures are
  based on the layering principle following a
  standard namely the reference model of OSI (open
  system inter connection). It is defied by ISO
  (International standard organization)

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OSI models seven layer
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Information flow through the layer
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CIM system database structure
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What is MAP

• The MAP is a hardware cum software
  implementable set of rules that facilitate
  information transfer among network computers and
  computer equipment

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What is TOP

• A related protocol standard is being adopted
  for office network is the technical and office
  protocol

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What is DBMS?

• Need for information management
• A very large, integrated collection of data.
• Models real-world enterprise.
• Entities (e.g., students, courses)
• Relationships (e.g., John is taking CS662)
• A Database Management System (DBMS) is a software
  package designed to store and manage databases.

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Why Use a DBMS?

• Data independence and efficient access.
• Data integrity and security.
• Uniform data administration.
• Concurrent access, recovery from crashes.
• Replication control
• Reduced application development time.

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Why Study Databases??
?

• Shift from computation to information
• at the low end access to physical world
• at the high end scientific applications
• Datasets increasing in diversity and volume.
• Digital libraries, interactive video, Human
  Genome project, e-commerce, sensor networks
• ... need for DBMS/data services exploding
• DBMS encompasses several areas of CS
• OS, languages, theory, AI, multimedia, logic

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Data Models

• A data model is a collection of concepts for
  describing data.
• A schema is a description of a particular
  collection of data, using the a given data model.
• The relational model of data is the most widely
  used model today.
• Main concept relation, basically a table with
  rows and columns.
• Every relation has a schema, which describes the
  columns, or fields.

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Levels of Abstraction

• Many views, single conceptual (logical) schema
  and physical schema.
• Views describe how users see the data.
  
• Conceptual schema defines logical structure
• Physical schema describes the files and indexes
  used.

View 1
View 2
View 3
Conceptual Schema
Physical Schema

• Schemas are defined using DDL data is
  modified/queried using DML.

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Structure of a DBMS
These layers must consider concurrency control
and recovery

• A typical DBMS has a layered architecture.
• The figure does not show the concurrency control
  and recovery components.
• This is one of several possible architectures
  each system has its own variations.

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Commercial query languages

• SQL-STRUCTURED QUERY LANGUAGE
• QUEL-QUERY LANGUAGE
• QBE-QUERY BY EXAMPLE

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SQL (STRUCTURED QUERY LANGUAGE)

• A query language is one with which a user
  requests information from the data base
• SQL is widely used in all organisations.
• Convient for the user
• The sql is embedded in a procedural languages
  such as C,COBAl,or PL/I

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SQL languages

• Oracle
• Informix
• SQL BASE XDB
• Sybase
• Progress

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