Computer Integrated Manufacturing

Unit 3 Group Technology And FMS

Dr.S.Thirumalai Kumaran
Associate Professor / Mechanical
PSG iTech
 Group Technology

• Group technology is a manufacturing philosophy in which

similar parts are identified and grouped together to take
advantage of their similarities in design and production.
Challenging Task:
• Identifying the part families. If the plant makes 10,000 different
parts, reviewing all of the part drawings and grouping the parts
into families is a substantial and time consuming task.
• Rearranging production machines into machine cells. It is time-
consuming and costly to plan and accomplish this rearrangement,
and the machines are not producing during the changeover.
 Benefits of GT

• GT promotes standardization of tooling, fixturing, and setups.

• Material handling is reduced because the distances within a
machine cell are much shorter than within the entire factory.
• Process planning and production scheduling are simplified.
• Setup times are reduced, resulting in lower manufacturing lead
times.
• Work-in-process is reduced.
• Worker satisfaction usually improves when workers collaborate
in a GT cell.
• Higher quality work is accomplished.
 Machine Groups

What's the difference????

 Part Family

Two parts of identical shape and

size but different manufacturing
requirements:
(a)1,000,000 pc/yr, tolerance = • A family of parts with similar
manufacturing process requirements
±0.010 in., material = 1015 CR but different design attributes
steel, nickel plate
(b)100 pc/yr, tolerance = ± 0.001 • All parts are machined from
cylindrical stock by turning; some
in., material = 18-8 stainless parts require drilling and/or milling.
steel.
 Part Family

• Part family is a collection of parts that are similar either in

geometric shape and size or in the manufacturing steps.
• Visual inspection (Intuitive Grouping) involves the classification
of parts into families by experienced technical staff in the plant
who examine the physical parts/photographs and arrange them
into groups having similar features.
(1) Design attributes: concerned with part characteristics such as
geometry, size, and material
(2) Manufacturing attributes: consider the processing steps
required to make a part.
 Parts Classification and Coding

• Design retrieval: A designer wants to develop a new part can use

a design retrieval system to determine if a similar part already
exists. Simply changing an existing part would take much less
time than designing a whole new part from scratch.
• Automated process planning: The part code for a new part can
be used to search for process plans for existing parts with
identical or similar codes.
• Machine cell design. The part codes can be used to design
machine cells capable of producing all members of a particular
part family.
 Types of Coding

• Hierarchical structure, also known as a monocode, in

which the interpretation of each successive symbol
depends on the values of the preceding symbols
• Chain-type structure, also known as a polycode, in which
the interpretation of each symbol in the sequence is
always the same; it does not depend on the values of
preceding symbols
• Mixed-mode structure, a hybrid of the two previous
coding schemes.
Hierarchical structure
1 means the part is cylindrical (rotational), and 2 means the geometry
is block-like. In 15, 5 means length-to-diameter ratio and in 25, 5
means length-to-breadth ratio.

Chain-type structure
1 means the part is cylindrical (rotational), and 2 means the geometry
is block-like. Both in 15 and 25, 5 means length of the part.
Optiz Coding System
 Production Flow Analysis

PFA consists of the following steps:

• Data collection: The minimum data
needed in the analysis are the part
number and operation sequence.
• Sortation of process routings: The
parts are arranged into groups
according to the similarity of their
process routings. Thus, all
operations/machines are reduced to
code numbers.
• PFA chart: The processes used for each pack are then displayed in
a PFA chart. The chart is a tabulation of the process or machine
code numbers for all of the part packs.

• Cluster analysis: From the pattern of data in the PFA chart, related
groupings are identified and rearranged into a new pattern that
brings together packs with similar machine sequences.
 Problem

• Apply the rank-order clustering technique to the

part-machine incidence matrix to identify logical part
families and machine groups.
 Flexible Manufacturing System

• A flexible manufacturing system (FMS) is a highly automated GT

machine cell, consisting of one or more processing stations (usually
CNC machine tools), interconnected by an automated material handling
and storage system and controlled by a distributed computer system.

• Is this FMS?
 When to call a system as FMS?
All 4 should be satisfied

• Part-variety test: Can the system process different part or

product styles in a mixed model (non-batch) mode?
• Schedule-change test: Can the system accept changes in
production schedule, that is, changes in part mix and/or
production quantities?
• Error-recovery test: Can the system recover from equipment
malfunctions and breakdowns, so the production is not
disrupted?
• New-part test: Can new part designs be introduced into the
existing part for which the system was designed? Also, can
design changes be made in existing parts without any challenge
to the system?
Three types of system compared with four
types of flexibility
 Single Machine Cell

Single machine cell consists of one CNC machining center combined with a
parts storage system for unattended operation
 Flexible Manufacturing Cell

FMC consists of two or three processing workstations + a parts

handling system.
 Flexible Manufacturing System

FMS has four or more processing stations connected mechanically by a

common parts-handling system and electronically by a distributed
computer system.
 FMS Components

• The three basic components of a flexible manufacturing

system are (1) workstations, (2) material handling and storage
system (FMS Configuration), and (3) computer control
system.
• Workstation: (1) load/unload stations, (2) machining stations,
(3) assembly, (4) other stations and equipment.
• Material handling and storage system: (1) in-line layout,
(2) loop layout, (3) open field layout, and (4) robot-centered
cell
In-line Layout
Loop Layout
Open Field Layout
Robot-Centered Cell
 Computer Control System

• Workstation Control: In a fully automated system, each station is

usually controlled by a computer, like CNC.
• Distribution of Instructions: Programs for the machines are stored in
a central computer and sent out as needed. This system also lets you
update or change programs.
• Production Control: Manage the production mix and speed by
directing pallets to the load/unload area and instructing operators on
which parts to load, based on daily production targets and available
materials.
• Traffic Control: Handle the movement of parts between stations by
managing switches, stopping parts at transfer points, and moving
pallets to loading or unloading areas.
 Computer Control System
• Shuttle Control: Oversee the secondary handling system at each
workstation, making sure it works with the main traffic control and
machine operations.
• Tool Control: Manage the tools by tracking their locations and checking
their condition. Monitor tool life to know when replacements are
needed.
• Performance Monitoring: Collect and summarize data on system
performance, such as machine uptime and production quantities. Provide
reports to management and offer real-time system status when
requested.
• Diagnostics: Identify problems when malfunctions occur, plan
maintenance, and prevent system failures to reduce downtime and
increase system availability.
 FMS Planning and Design Issues

• Part Family: An FMS should be set up to handle a specific group of

similar parts. This setup lets all parts for a product be completed before
assembly.
• Processing Needs: The type of parts and their processing needs decide
which machines are used. Non-rotational parts use milling machines;
rotational parts use turning centers.
• Physical Size: The size and weight of parts determine the size of the
machines and handling systems needed.
• Production Volume: The number of parts to be made affects how many
machines are needed and helps in choosing the right handling
equipment.
 FMS Operations Management Issues
• Scheduling and Dispatching: Plan production based on the master schedule
and start parts at the right times.
• Machine Loading: Decide which parts go on which machines and set up
the necessary tools.
• Part Routing: Choose the best paths for parts to follow to use resources
efficiently.
• Part Grouping: Group similar parts for simultaneous production,
considering tool and resource limits.
• Tool Management: Decide when to replace tools and how to assign them
to machines.
• Pallet and Fixture Allocation: Assign pallets and fixtures to parts. Ensure
the right fixtures are ready before starting production and use modular
fixtures for flexibility.
 Benefits of FMS

• Increased machine utilization

• Fewer machines required
• Reduction in factory floor space
• Greater responsiveness to change
• Reduced inventory requirements
• Lower manufacturing lead times
• Reduced direct labor requirements and higher labor productivity
• Opportunity for unattended production
 Cellular Manufacturing

• Cellular manufacturing is an application of group

technology in which dissimilar machines or processes
have been aggregated into cells, each of which is
dedicated to the production of a part or product family,
or a limited group of families.
• Two aspects of cellular manufacturing are considered in
this section: (1) the composite part concept, (2) machine
cell design.
 Composite Part Concept

• There is always a correlation between part design features and the

production operations required to generate those features.
• Round holes are made by drilling, cylindrical shapes are made by
turning, flat surfaces by milling, and so on.
• A production cell designed for the part family would include those
machines required to make the composite part. Such a cell would
be capable of producing any member of the family, simply by
omitting those operations corresponding to features not possessed
by the particular part.
• The cell would be designed to allow for size variations within the
family as well as feature variations.
Machine Cell Design
 Key Machine Concept

• A certain machine in a cell that is more expensive to operate than

the other machines or that performs certain critical operations in
the plant. This machine is referred to as the key machine. It is
important that the utilization of this key machine be high, than
the other machines in the cell have relatively low utilizations.
• The other machines are referred to as supporting machines, and
they should be organized in the cell to keep the key machine busy.
• In a sense, the cell is designed so that the key machine becomes
the bottleneck in the system.
 Holier Method

• A GT cell has four machines: 1, 2, 3, and 4. An analysis of

50 parts processed on these machines has been
summarized in the from–to chart. Determine the most
logical machine sequence using the Hollier method.
3 2 1 4
Compute (a) the percentage of in-sequence moves, (b)
the percentage of bypassing moves, and (c) the
percentage of backtracking moves
• In-sequence moves = 40 + 30 + 25 = 95
• Bypassing moves = 10 + 15 = 25
• Backtracking moves = 5 + 10 = 15
• Total number of moves = 135
(a) Percentage of in-sequence moves = 95/135 = 0.704 = 70.4%
(b) Percentage of bypassing moves = 25/135 = 0.185 = 18.5%
(c) Percentage of backtracking moves = 15/135 = 0.111 = 11.1%
Problem

Bottleneck
A FMA consists of a load/unload station and two machining workstations.
Station 1 is the load/unload station with one server (human worker).
Station 2 performs milling and has three identical CNC milling machines.
Station 3 performs drilling and has two identical CNC drill presses. The
stations are connected by a part-handling system with two carriers. The
mean transport time is 2.5 min. The FMS produces three parts, A, B, and
C. The part-mix fractions and process routings for the three parts are
presented shown. The operation frequency fijk = 1 for all i, j, k. Determine
(a) maximum production rate, (b) production rates of each product, (c)
utilization of each station, (d) average utilization, and (e) number of busy
servers at each station.
WL1=[(4+2)(1)(0.4)+(4+2)(1)(0.35)+(4+2)(1)(0.25)]

nt = mean no. of transports, Tr = mean transport time

WL=[(3*0.4)+(3*0.35)+(2*0.25)]x2.5

Rp* is production rate at bottleneck condition=3/20.75

U1=(6*0.1446 pc/min)=0.867

BS1=(6*0.1446 pc/min)=0.867
Individual part production rates Rpj*
RpA*=8.675x0.4=3.470 pc/hr
RpB*=8.675x0.35=3.036 pc/hr
RpC*=8.675x0.25=2.169 pc/hr

Ūs=[(0867*1)+(1*3)+(0.668*2)] / (1+3+2) = 0.8675

 Extended Bottleneck (Problem)

Use the extended bottleneck model on the data provided for

the previous problem to compute hourly production rate,
manufacturing lead time, and waiting time for four values of
N: (a) N = 4, (b) N = 6, (c) N = 7, and (d) N = 10.

N*=Rp* x MLT1
where N* = critical value of N, the dividing line between the bottleneck and non-
bottleneck cases. If N < N*, then case 1 applies. If N ≥ N*, then case 2 applies.
Rp* = 3/20.75 = 0.1446 pc/min (refer previous problem)

MLT1 = 6 + 20.75 + 9.25 + 6.875 = 42.875 min = ~42.9 min

N* = 0.1446 x 42.9 = 6.2 pc

(a) N=4<N*=6.2 (Case 1 applies)

MLT1=42.9 min, Rp=0.0933 pc/min, Tw=0
(b) N=6<N*=6.2 (Case 1 applies)
MLT1=42.9 min, Rp=0.1399 pc/min, Tw=0
(c) N=7>N*=6.2 (Case 2 applies)
Rp*=0.1446 pc/min, MLT2=48.4 min, Tw=(48.4-42.9)=5.5 min
(d) N=10>N*=6.2 (Case 2 applies)
Rp*=0.1446 pc/min, MLT2=69.167 min, Tw=26.3 min
 Sizing the FMS

The bottleneck model is used to calculate the number of servers

required at each workstation to achieve a specified production rate.
It would be useful during the initial stages of FMS design in
determining the “size” of the system.
• Given the workloads, the number of servers at each station i is
determined as
si = Minimum Integer ≥ Rp(WLi)
• where si = number of servers at station i; Rp = specified
production rate of all parts to be produced by the system,
pc/min; and WLi = workload at station i, min.
 Problem

Consider the datas from the previous problem. The

FMS will operate 24 hr/day, 5 days/wk, 50 wk/yr.
Determine (a) the number of servers that will be required
at each station i to achieve an annual production
rate of 60,000 parts/yr and (b) the utilization of each
workstation.
• FMS operation/year will be 24 * 5 * 50 = 6,000 hr/yr.
• Rp = 60000/6000 = 10 pc/hr = 0.1667 pc/min
• From previous problem we know that WL1 = 6.0 min, WL2
= 20.75 min, WL3 = 9.25 min, WL4 = 6.875 min
• s1=minimum integer≥0.1667(6) = 1 server
• s2=minimum integer≥0.1667(20.75)=3.458=4 servers
• s3=minimum integer≥0.1667(9.25)=1.54=2 servers
• s4=minimum integer≥0.1667(6.875)=1.146=2 servers
• U1 = 1.0/1 = 1.0 = 100%
• U2 = 3.458/4 = 0.865 = 86.5%
• U3 = 1.54/2 = 0.77 = 77%
• U4 = 1.146/2 = 0.573 = 57.3%
Thank You