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Computers in Manufacturing Enterprises: Flexible Manufacturing Systems (FMS)

Flexible manufacturing systems (FMS) integrate automated technologies like CNC machine tools, automated material handling equipment, and computer control to achieve a highly automated production system capable of producing mid-volume, mid-variety parts. An FMS represents one of the highest levels of manufacturing automation by flexibly processing different part families on processing stations like machining centers while computer control coordinates activities. Analysis methods for evaluating and optimizing FMS performance include static models, queuing models, and computer simulation.

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43 views

Computers in Manufacturing Enterprises: Flexible Manufacturing Systems (FMS)

Flexible manufacturing systems (FMS) integrate automated technologies like CNC machine tools, automated material handling equipment, and computer control to achieve a highly automated production system capable of producing mid-volume, mid-variety parts. An FMS represents one of the highest levels of manufacturing automation by flexibly processing different part families on processing stations like machining centers while computer control coordinates activities. Analysis methods for evaluating and optimizing FMS performance include static models, queuing models, and computer simulation.

Uploaded by

anon_440773342
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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8/29/2015

Computers in Manufacturing Enterprises


Flexible Manufacturing Systems: Automation, Production Systems and CIM by M.P.
Groover
August 27, 2015

Vandana Srivastava

Flexible Manufacturing Systems (FMS)

one of the types of machine cells

integrates many concepts and technologies into one highly automated production
system

the technologies included are:

flexible automation
group technology (GT)
CNC machine tools: Numerical control (NC) is the automation of machine tools that are operated by
precisely programmed commands encoded on a storage medium; in Computer numerical
control (CNC), computers play an integral part of the control.
automated machine handling between machines

Automated guided vehicles (AGV)


Conveyors
Automated storage and retrieval systems (AS/RS)

computer control of machines (DNC) and material handling

represents one of the highest level of achievement in automated production

8/29/2015

Flexible Manufacturing Systems - Introduction

Where to Apply FMS Technology ?

plant presently either:


Produces parts in batches or
Uses manned GT cells and management wants to automate the cells

It must be possible to group a poron of the parts


made in the plant into part families
part similarities allow them to be processed on the FMS workstations

Parts and products are in the mid-volume, mid-variety production range

advantage of FMS over transfer line is flexibility to run a variety of product


specifications; transfer lines produce one or limited number of product
types

http://homes.ieu.edu.tr/~aornek/ISE314-Ch19.pdf

8/29/2015

Where to Apply FMS Technology ?

Flexibility Tests in an Automated


Manufacturing System
To qualify as being flexible, a manufacturing system
should satisfy the following criteria (yes answer for
each question):
Can it process different part styles in a non-batch mode?

Can it accept changes in production schedule?

Can it respond gracefully to equipment malfunctions and breakdowns?

Can it accommodate introduction of new part designs?

http://homes.ieu.edu.tr/~aornek/ISE314-Ch19.pdf

8/29/2015

Components of FMS
Processing
stations

FMS
additional
component is
human labor

Material
Handling and
Storage

Computer
Control System

* typically CNC machine tools,


performing machining
operations on part families
* are being designed for other
types of processing
equipments

different automated material


handling equipment are used to
transport workpart between
work stations; sometimes
storage is also incorporated in
the function

used to coordinate activities


of the processing stations and
material handling systems

The Hattersley Newman Hender F.M.S - Example




manufactures high and low pressure bodies and


caps for water, gas and oil valves

components require a total of 2750 parts for their


manufacture

fixtures that are not used live in F.M.S. are stored


in fixture store; store is served by a
stacker crane and motor roller conveyors.

system contains two processing centres a


wash machine and two manual workstations

loading and unloading is performed at stations


with the instructions received on a computer
interfaced with the host

transport system consists of a controller and 8


Automated Guided Vehicles (A.G.V.).

http://www.aame.in/2008/10/flexible-manufacturing-systems_26.html

8/29/2015

F.M.S Working Example


example: Flexible Manufacturing System
(https://www.youtube.com/watch?v=2qc0-yTXBts)

Classification of FMS
FMS
fully automated system consisting of
automated workstations, automated
material handling and computer control

grouping of 4 or more machines

both cells and FMSs rely on GT


approach in their design

Manufacturing
cell
may or may not include automated material
handling or use computer control

can be used to refer to a machine group


consisting manually operated or automated
machines

may have 3 or fewer machines

8/29/2015

Classification of FMS

based on part geometry


prismatic: cubelike and require milling and related machining operations
round: cylindrical and disk-shaped and require turning and related machining operations

based on part variety


Dedicated FMS

designed to produce a limited variety of part styles


complete universe of parts to be made on the system is known in advance
part family likely based on product commonality rather than geometric similarity

Random-order FMS

appropriate for large part families


new part designs and engineering changes will be introduced
production schedule is subject to daily changes

 Random-order FMS:
 must be more flexible than the dedicated FMS and require more sophisticated computer control
system
http://homes.ieu.edu.tr/~aornek/ISE314-Ch19.pdf

Flexible Manufacturing cell

example of FM cell
(https://www.youtube.com/watch?v=hNGzFJqUnjE)

8/29/2015

Flexible Manufacturing System


https://www.youtube.com/watch?v=wkddDUkKxsg

FMS Workstations

depends on the type of work being accomplished


Machining
centers
Forging
Stations

Head
Changers

Sheet metal
processing
machines

Head
indexers
FMS Workstations

Inspection
stations

Milling
modules

Assembly
workstations

Turning
modules

8/29/2015

Material Handling and Storage System


Functions

Random and
independent
movement of
workparts
between
workstations

handle a variety of
workpart
configurations

temporary storage

convenient access
of loading and
unloading
workparts

compatible with
computer control

FMS Layout Configurations


(a) In-line
(b)

In-line both direction

(c)

Loop

www.nuigalway.ie/staff.../unit_15_flexible_manufacturing_systems.pdf

8/29/2015

FMS Layout Configurations


(d) Rectangular
loop
(e) Ladder
(f) open field
(g) Robot-centred

www.nuigalway.ie/staff.../unit_15_flexible_manufacturing_systems.pdf

FMS computer control system


1.

Workstation control

2.

Supervisory control among workstations


(workstation coordination)

3.

Production control (part rate and mix)

4.

Traffic control (manage part delivery


systems)

5.

Shuttle control (part handling between


machine and primary handling system)

6.

Workpiece monitoring (status of various


systems)

7.

Tool control (location and tool life)

8.

Performance monitoring and reporting


(report operational data)

9.

Diagnostics (identify sources of error,


preventive maintenance

www.et.byu.edu/~ered/ME482/PPT_Lectures/Ch8-FMS.ppt

8/29/2015

Analysis Methods for FMS


Models

Static or Deterministic models


-used to provide gross estimate of
system parameters as capacity,
throughput and utilization
- do not permit proper evaluation
of operating characteristics
- tend to overestimate FMS
performance

Queuing Models
- based on queuing theory
- permit inclusion of certain
dynamic charteristics, but in a
simple way
- calculated measures are usually
average values for steady state
operation of FMS

Computer Simulation
- event simulation on a computer
is most flexible approach to model
a FMS

Advantages of FMS
to reduce set up and queue times and improve utilization
Improve efficiency
improve product routing and reduce WIP
produce a variety of items with improved quality and more
quickly (reduce MLT)

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