FLEXIBLE MANUFACTURING SYSTEM

AUTOMATED PROCESSES FMS {Flexible manufacturing system}

A flexible manufacturing system (FMS) is a group of numerically-controlled machine tools, interconnected by a central control system. The various machining cells are interconnected, via loading and unloading stations, by an automated transport system. Operational flexibility is enhanced by the ability to execute all manufacturing tasks on numerous product designs in small quantities and with faster delivery. It has been described as an automated job shop and as a miniature automated factory. Simply stated, it is an automated production system that produces one or more families of parts in a flexible manner. Today, this prospect of automation and flexibility presents the possibility of producing nonstandard parts to create a competitive advantage. DefinitionA Flexible Manufacturing System (FMS) is a production system consisting of a set of identical and/or complementary numerically controlled machine which are connected through an automated transportation system. Each process in FMS is controlled by a dedicated computer (FMS cell computer). The concept of flexible manufacturing systems evolved during the 1960s when robots, programmable controllers, and computerized numerical controls brought a controlled environment to the factory floor in the form of numerically-controlled and directnumerically-controlled machines. For the most part, FMS is limited to firms involved in batch production or job shop environments. Normally, batch producers have two kinds of equipment from which to choose: dedicated machinery or unautomated, general-purpose tools. Dedicated machinery results in cost savings but lacks flexibility. General purpose machines such as lathes, milling machines, or drill presses are all costly, and may not reach full capacity. Flexible manufacturing systems provide the batch manufacturer with another optionone that can make batch manufacturing just as efficient and productive as mass production. The first FMS was patent in 1965 by Theo Williamson who made numerically controlled equipment.
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AUTOMATED PROCESSES FMS {Flexible manufacturing system}

Equipmentof FMSPrimary equipment Work centers

Universal machining centers (prismatic FMSs) Turning centers (rotational FMSs) Grinding machines Nibbling machines

Process centers
Wash machines Coordinate measuring machines Robotic work stations Manual workstations

Secondary equipment
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AUTOMATED PROCESSES FMS {Flexible manufacturing system}

Support stations
Pallet/fixture load/unload stations Tool commissioning/setting area

Support equipment
Robots Pallet/fixture/stillage stores Pallet buffer stations Tools stores Raw material stores Transport system(AGVs,RGVs,robots) Transport units(pallets/stillages)

OBJECTIVES OF FMS Stated formally, the general objectives of an FMS are to approach the efficiencies and economies of scale normally associated with mass production, and to maintain the flexibility required for small- and medium-lot-size production of a variety of parts. Two kinds of manufacturing systems fall within the FMS spectrum. These are assembly systems, which assemble components into final products and forming systems, which actually form components or final products. A generic FMS is said to consist of the following components: 1. A set of work stations containing machine tools that do not require significant set-up time or change-over between successive jobs. Typically, these machines perform milling, boring, drilling, tapping, reaming, turning, and grooving operations. 2. A material-handling system that is automated and flexible in that it permits jobs to move between any pair of machines so that any job routing can be followed. 3. A network of supervisory computers and microprocessors that perform some or all of the following tasks: (a) directs the routing of jobs through the system; (b) tracks the status of all jobs in progress so it is known where each job is to go next; (c) passes the instructions for the processing of each operation to each station and ensures that the
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AUTOMATED PROCESSES FMS {Flexible manufacturing system}

right tools are available for the job; and (d) provides essential monitoring of the correct performance of operations and signals problems requiring attention. 4. Storage, locally at the work stations, and/or centrally at the system level. The jobs to be processed by the system. In operating an FMS, the worker enters the job to be run at the supervisory computer, which then downloads the part programs to the cell control or NC controller.

TYPES OF FMS Sequential FMS Random FMS Dedicated FMS Engineered FMS Modular FMS

APPLICATION OF FMS Metal-cutting machining Metal forming Assembly Joining-welding (arc , spot), gluing Surface treatment Inspection Testing

AUTOMATED PROCESSES FMS {Flexible manufacturing system}

Different FMSs levels are:
Flexible Manufacturing Module (FMM). Example: a NC machine, a pallet changer and a part buffer; Flexible Manufacturing (Assembly) Cell (F(M/A)C). Example: Four FMMs and an AGV (automated guided vehicle); Flexible Manufacturing Group (FMG). Example : Two FMCs, a FMM and two AGVs which will transport parts from a Part Loading area, through machines, to a Part Unloading Area; Flexible Production Systems (FPS). Example: A FMG and a FAC, two AGVs, an Automated Tool Storage, and an Automated Part/assembly Storage; Flexible Manufacturing Line (FML). Example: multiple stations in a line layout and AGVs

AUTOMATED PROCESSES FMS {Flexible manufacturing system}

BENEFITS OF FMS The potential benefits from the implementation and utilization of a flexible manufacturing system have been detailed by numerous researchers on the subject. A review of the literature reveals many tangible and intangible benefits that FMS users extol. These benefits include:

less waste fewer workstations quicker changes of tools, dies, and stamping machinery reduced downtime better control over quality reduced labor more efficient use of machinery work-in-process inventory reduced increased capacity increased production flexibility

The savings from these benefits can be sizable. Enough so that Ford has poured $4,400,000 into overhauling its Torrance Avenue plant in Chicago, giving it flexible manufacturing capability. This will allow the factory to add new models in as little as two weeks instead of two months or longer. Richard Truett reports, in Automotive News, that the flexible manufacturing systems used in five of Ford Motor Company's plants will yield a $2.5 billion savings. Truett also reports that, by the year 2010, Ford will have converted 80 percent of its plants to flexible manufacturing.

LIMITATIONS OF FMS-

AUTOMATED PROCESSES FMS {Flexible manufacturing system}

Despite these benefits, FMS does have certain limitations. In particular, this type of system can only handle a relatively-narrow range of part varieties, so it must be used for similar parts (family of parts) that require similar processing. Due to increased complexity and cost, an FMS also requires a longer planning and development period than traditional manufacturing equipment. Equipment utilization for the FMS sometimes is not as high as one would expect. Japanese firms tend to have a much higher equipment utilization rate than U.S. manufacturers utilizing FMS. This is probably a result of U.S. users' attempt to utilize FMS for high-volume production of a few parts rather than for a high-variety production of many parts at a low cost per unit. U.S. firms average ten types of parts per machine, compared to ninety-three types of parts per machine in Japan. Other problems can result from a lack of technical literacy, management incompetence, and poor implementation of the FMS process. If the firm misidentifies its objectives and manufacturing mission, and does not maintain a manufacturing strategy that is consistent with the firm's overall strategy, problems are inevitable. It is crucial that a firm's technology acquisition decisions be consistent with its manufacturing strategy. If a firm chooses to compete on the basis of flexibility rather than cost or quality, it may be a candidate for flexible manufacturing, especially if it is suited for low- to mid-volume production. This is particularly true if the firm is in an industry where products change rapidly, and the ability to introduce new products may be more important than minimizing cost. In this scenario, scale is no longer the main concern and size is no longer a barrier to entry. However, an FMS may not be appropriate for some firms. Since new technology is costly and requires several years to install and become productive, it requires a supportive infrastructure and the allocation of scarce resources for implementation. Frankly, many firms do not possess the necessary resources. Economically justifying an FMS can be a difficult task especially since cost accounting tends to be designed for mass production of a mature product, with known characteristics, and a stable technology. Therefore, it is difficult to give an accurate indication of whether flexible manufacturing is justified. The question remains of how to quantify the benefits of flexibility. In addition, rapidly7

AUTOMATED PROCESSES FMS {Flexible manufacturing system}

changing technology and shortened product life cycles can cause capital equipment to quickly become obsolete. For other firms, their products may not require processes at the technological level of an FMS. IBM found that a redesigned printer was simple enough for high-quality manual assembly and that the manual assembly could be achieved at a lower cost than automated assembly. Potential FMS users should also consider that some of the costs traditionally incurred in manufacturing may actually be higher in a flexible automated system than in conventional manufacturing.

1. LIVE EXAMPLE OF FMSOne of the most common examples of a flexible manufacturing system can be seen in the manufacturing of automobiles. Certain equipment is used to attach doors to a sedan. With just a few simple adjustments, that same line and equipment may be used to attach doors to a sport utility vehicle or some other type of vehicle. Often, the switchover can take place with very little disruption to the line, and may even happen during shifts. In fact, the automobile industry can potentially save a substantial amount of money using a flexible manufacturing system. A report in 2008 indicated that Ford Motor Company saved approximately $2.5 billion US Dollars by putting flexible systems in at five manufacturing plants. The company estimated it can save at least half of the cost of manufacturing updated models using the systems. In some cases, the machines may not only be used to produce or assemble different parts for different models, but to make customizations. These customizations, without a flexible system in place, would take much longer, and be much more expensive for the customer. Using machines with the ability to be flexible can not only speed the process up, but can improve customer satisfaction by bringing down the price.

Practical Implication of ford FMS -

AUTOMATED PROCESSES FMS {Flexible manufacturing system}

Through the use of reprogrammable tooling in the body shop, standardized equipment in the paint shop and common build sequence in final assembly, Ford can build multiple models on one or more platforms in one plant. Paint Shop

Body Shop

Final Assembly

In the body shop, where the sheet metal comes together to form the vehicles body, flexibility means more than 80 percent of the tooling is not specific to one model. It can be reprogrammed to weld a car or a truck or a crossover of similar size.

In the paint shop, flexibility means robotic applicators are programmed to cover various body styles as they move through the paint booth with equal precision. This results in minimizing waste and environmental impact while maximizing quality.

In the final assembly area, flexibility means the build sequence is the same among multiple models on one or more platforms allowing for efficient utilization of people and equipment.

2. FMS- an example of technology and an alternative layout The idea of an FMS was proposed in England (1960s) under the name "System 24", a flexible machining system that could operate without human operators 24 hours a day under computer control. From the beginning the emphasis was on automation rather than the "reorganization of workflow". Early FMSs were large and very complex, consisting of dozens of Computer Numerical Controlled machines (CNC) and sophisticate material handling systems. They were very automated, very expensive and controlled by incredibly complex software. There were only a

AUTOMATED PROCESSES FMS {Flexible manufacturing system}

limited number of industries that could afford investing in a traditional FMS as described above. Currently, the trend in FMS is toward small versions of the traditional FMS, called flexible manufacturing cells (FMC). Today two or more CNC machines are considered a flexible cell and two or more cells are considered a flexible manufacturing system. Thus, a Flexible Manufacturing System (FMS) consists of several machine tools along with part and tool handling devices such as robots, arranged so that it can handle any family of parts for which it has been designed and developed.

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