Flexible Manufacturing System

(FMS)
Manufacturing System
Some Types of Manufacturing Systems
 Flexible Manufacturing Systems
(FMS)
• A flexible manufacturing system (FMS) is type
of cellular manufacturing in which a set of
numerically controlled machine tools and
supporting workstations connected by an
automated material handling system and
controlled by a central computer
 ELEMENTS OF FMS
• Automatically reprogrammable machines.
• Automated tool delivery and changing
• Automated material handling
• Coordinated control
 FMS FEATURES
• Many part types can be loaded
• Parts can arrive at machines in any sequence
• Parts identified by codes
• Many machines can be included
 FMS FEATURES
• Expensive to implement but savings can be
significant
• Floor space reducible by 1/3
• Equipment utilization up to 85% or more
• Detailed production sequence not needed
well in advance
• Reduced variable costs and throughput time
lead to enhanced manufacturing
competitiveness
 FMS FEATURES
• Reduced direct labor costs
• Three shifts readily feasible
• Ideal for JIT
• Can easily be turned over to new set of
products if the need arises
 FMS Benefits
• Increased machine utilization.
FMSs achieve a higher average utilization than
stand-alone machines in a conventional machine
shop. Reasons include:
(1) 24 hour per day operation,
(2) automatic tool changing at machine tools,
(3) queues of parts at stations, and
(4) dynamic scheduling of production that takes
into account irregularities from normal
operations. It should be possible to approach
80% to 90% asset utilization.
• Fewer machines required. Because of higher
machine utilization.
• Reduction in factory floor space can be achieved.
Compared to a job shop of equivalent capacity, a
FMS generally requires less floor area. Reductions
in floor space requirements = 40% to 50%.
• Greater responsiveness to change. A FMS improves
response capability to part design changes,
introduction of new parts, changes in production
schedule and product mix, machine breakdowns,
and tool failures. Adjustments can be made in the
production schedule from one day to the next to
respond to rush orders and special customer
requests.
• Reduced inventory requirements. Because
different parts are processed together rather than
separately in batches, WIP is less than in batch
production. Inventories of starting and finished
parts reduced also. Reductions = 60% to 80%.
• Reduced direct labor requirements and higher
labor productivity. Savings = 30% to 50%
• Opportunity for unattended production.
 MANUFACTURING FLEXIBILITY
• Basic
– Machine (variety of operations)
– Material handling (part mobility and placement)
– Operation (variety of operations producing same
part features)
 MANUFACTURING FLEXIBILITY
• SYSTEM
– Process (variety of parts producible with same
setup)
– Routing (ability to use different machines under
same setup)
– Product (changeover)
– Volume (production level)
– Expansion (added capacity)
 MANUFACTURING FLEXIBILITY
• Aggregated
– Program (unattended running)
– Production (ranges of parts, products, processes,
volume, expansion)
– Market (combination of product, process, volume
and expansion)
 FMS COMPONENTS
• Machines
• Part movement systems
• Supporting workstations
• System controller
 MACHINES
• Prismatic vs rotational parts
• Horizontal machining centers (hmc) and
head indexers (hi)
• Tool magazines and automatic tool
changers
 PART MOVEMENT
• Conveyors
• Tow carts
• Rail carts
• Agv’s (Automated Guided
Vehicle)
• Robots
 SUPPORTING WORKSTATIONS
• Load/unload stations
• Automatic part washers
• Coordinate measuring machines
 CONTROLLER
• Computer
• Worker (attendant)
• Tracking system for
–Parts
–Machines
FMS Planning and Design Issues
• Part family considerations.
The part family that will be processed on the FMS must be
defined. Part families can be based on product commonality
as well as part similarity. The term product commonality
refers to different components used on the same product.
• Processing requirements.
In machining applications, non rotational parts are produced
by machining centers, milling machines, and like machine
tools; rotational parts are machined by turning centers and
similar equipment.
FMS Planning and Design Issues
(continued)
• Physical characteristics of the workparts.
Part sizes and weights determine the size of
the machines and the size of the material
handling system.

• Production volume.
The production quantities determine how many
machines will be required. Production volume
is also a factor in selecting the most
appropriate type of material handling
equipment for the system.
FMS Planning and Design Issues
(continued)
• Variations in process routings. If variations
in process sequence are minimal, then an in-line
flow is most appropriate. As product variety
increases, a loop is more suitable. If there is
significant variation in the processing, a ladder
layout or open field layout are most appropriate.
• Work-in-process and storage capacity. If
WIP is too low, then stations may become
starved. If WIP is too high, then congestion
may result. The WIP level should be planned.
FMS Planning and Design Issues
(continued)

• Pallet fixtures. The number of pallet fixtures

required in the system must be decided. Factors
include: levels of WIP allowed in the system, and
differences in part style and size. Parts that
differ too much require different fixturing.
Consider modular fixturing.
• Tooling. Tooling decisions include types and
numbers of tooling at each station.
Consideration should also be given to the degree
of duplication of tooling at the different stations.
Tool duplication tends to increase routing
flexibility.
 FMS Operational Issues
• Scheduling and dispatching.
Scheduling of production dictated by the master
production schedule. Dispatching = launching of
parts into the system at the appropriate times.
• Machine loading.
Allocating operations and tooling resources among
the machines in the system to accomplish the
required schedule.
• Part routing.
Selecting routes to be followed by each part in the
production mix so as to maximize use of
workstation resources.
FMS Operational Issues
• Part grouping.
Selecting groups of part types for simultaneous
production, given limitations on available
tooling and other station resources.
• Tool management.
Managing available tools includes decisions on
when to change tools, allocation of tools to
stations, and similar issues.
• Pallet and fixture allocation.
Allocation of pallets and fixtures to parts in the
system.
 Computer Simulation of
Manufacturing Process & System
 Systems
• System – facility or process, actual or planned
Or
A body under consideration
– Examples abound …
 Manufacturing facility  Freeway system
 Bank or other personal-  Business process (insurance
service operation office)
 Transportation/logistics/distrib  Criminal justice system
ution operation  Chemical plant
 Hospital facilities (emergency  Fast-food restaurant
room, operating room,  Supermarket
admissions)
 Theme park
 Computer network
 Emergency-response system

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 Work With the System?
• Study the system – measure, improve, design,
control
• Study of system is required to analyze and to
obtain important information.
• Computer Simulation is used as a technique
for studying the system as an economical and
time efficient approach.

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 Models
• Model – set of assumptions/approximations about how the system works
– Study the model instead of the real system … usually much easier,
faster, cheaper, safer
– Can try wide-ranging ideas with the model
• Make your mistakes on the computer where they don’t count, rather than
for real where they do count
– Often, just building the model is instructive – regardless of results
– Model validity (any kind of model … not just simulation)
• Care in building to mimic reality faithfully
• Level of detail
• Get same conclusions from the model as you would from system

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 Computer Simulation
• Broadly interpreted, computer simulation refers to methods
for studying a wide variety of models of systems
– Numerically evaluate on a computer
– Use software to imitate the system’s operations and
characteristics, often over time
• Can be used to study simple models but should not use it if an
analytical solution is available
• Real power of simulation is in studying complex models
• Simulation can tolerate complex models since we don’t even
aspire to an analytical solution
• Computer Simulation is the important modern technique used
for studying the system using less resources, money and time.

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 System vs. Its Model

Real System
• Simplification Model
• Abstraction
• Assumptions

Understanding

Chapter 1 Introduction to Simulation

35
Modeling
 Model Classification

• Physical (prototypes) • Descriptive (performance

• Analytical (mathematical) analysis)

• Computer
• Prescriptive
(Monte Carlo
(optimization)
Simulation)

36
Physical (Prototypes)

Chapter 1 Introduction to Simulation

37
Modeling
 Analytical (Mathematical)

 

Single Stage Queuing Model


 1 1 
 W Wq  W  
       
 2
 n  P( N  n) L  W  Lq  Wq 
      
  1   
Chapter 1 Introduction to Simulation
38
Modeling
Computer (Monte Carlo Simulation)

Chapter 1 Introduction to Simulation

39
Modeling
Descriptive (Performance analysis)

Simulation
vs.
Real World

40
Prescriptive (Optimization)

41
 Typical Uses of Simulation
• Estimating a set of productivity measures in production systems,
inventory systems, manufacturing processes, materials handling and
logistics operations.
• Conducting war games to train military personnel or to evaluate the
efficacy of proposed military operations e.g. flying simulator etc.
• Evaluating and improving maritime port operations, such as container
ports or bulk-material marine terminals (coal, oil or minerals), so as to
find ways of reducing vessel port times.

• Finished products delivery from distribution centers or plants, vehicle

routing, traffic management

• Process improvement, start-up problems, equipment problems,

design of new facility, performance measurement

• Instability in supply chain, inventory/distribution systems etc.

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Simulation in Manufacturing