T E C H N I C A L A N D V O C AT I O N A L T R A I N I N G I N S T I T U T E

FA C U LT Y O F M E C H A N I C A L T E C H N O L O G Y
D E PA RT M E N T O F M A N U FA C T U R I N G T E C H N O L O G Y
M S C I N M A N U FA C T U R I N G T E C H N O L O G Y ( W E E K E N D )
ASSIGNMENT 1, FLEXIBLE MANUFACTURING SYSTEM

PREPAIRED BY GRUP 3
 Group Members

NAME ID, NO
1, Gemechu Derara. TTME/027/15
2, Fisseha Bedada TTME/025/15
3, Kaleab Teklu TTME/037/15
4, Frew Shewa TTME/024/15

Submitted date, 13/09/202 3

 CONTENTS OF THE PRESENTATION

INTRODUCTION

TYPES OF FLEXIBILITIES
DEFINITION OF FMS
BENEFITS OF FMS
BASIC COMPONENTS OF FMS

APPLICATION CHARACTERISTICS OF FMS

FLEXIBLE MANUFACTURING SYSTEM
LEVELS OF MANUFACTURING FLEXIBILITY
DIFFERENT TYPES OF FMS
TYPES OF FMS LAYOUTS
FACTORS INFLUENCING THE FMS LAYOUTS

• OBJECTIVES OF AN FMS
• AIMS OF FMS
• ADVANTAGES OF FMS
DISADVANTAGES OF FMS
AREA OF APPLICATION OF A FMS IN INDUSTRY
 1. Introduction
 In the middle of 1960s, market competition became more intense.
 During 1960 to 1970 cost was the primary concern. Later
quality became the priority. As the market became more
and more complex, speed of delivery became something
customer also needed.
 A new strategy was formulated (Customizability). The
companies have to adapt to the environment in which they
operate, to be more flexible in their operations and to satisfy
different market segments. Thus the innovation of FMS became
related to the effort of gaining competitive advantage.
 Cont..
First of all, FMS is a manufacturing technology
Secondly, FMS is a philosophy.
FMS incorporates a system view of manufacturing
 2. Types of Flexibilities

 1.Volume Flexibilities,
2,Mix Flexibilities,
3,Manufacturing Flexibilities,
4,Delivery Flexibilities,
 3. Definition of FMS
 A flexible manufacturing system (FMS) is an arrangement of
machines ... interconnected by a transport system.
“FMS consists of a group of processing work stations
interconnected by means of an automated material handling
and storage system and controlled by integrated computer
control system.”
FMS is called flexible due to the reason that it is capable of
processing a variety of different part styles simultaneously at the
workstation and quantities of production can be adjusted in
response to changing demand patterns.
 3.1 What is FMS ?
A flexible manufacturing system (FMS) is a production
method that is designed to easily adapt to changes in the
type and quantity of the product being manufactured.
Machines and computerized systems can be configured to
manufacture a variety of parts and handle changing levels
of production.
 A flexible manufacturing system (FMS) can improve
efficiency and reduce production costs, which are crucial
concerns in the process of business development
 4.Benefits of FMS
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

 5. BASIC COMPONENTS OF FMS

The basic components of FMS are:

1. Workstations
2. Automated Material Handling and
Storage system.
3. Computer Control System

 5.1 Work Station
 these workstations are typically computer numerical
control (CNC) machine tools that perform machining
operation on families of parts.
FMS are being designed with other type of processing
equipment's including
inspection stations,
assembly works and
sheet metal presses.
 The various workstations are
 CONT…

 (i) Machining centers

 (ii) Load and unload stations
 (iii) Assembly work stations
 (iv) Inspection stations
 (v) Forging stations
 (vi) Sheet metal processing, etc
 5.2. Automated Material Handling and Storage system:

The various automated material handling systems are used to

transport work parts and subassembly parts between the
processing stations, sometimes incorporating storage into function
The various functions of automated material handling and
storage system are
(i) Random and independent movement of work parts between
workstations
(ii) Handling of a variety of work part configurations
(iii) Temporary storage
(iv) Convenient access for loading and unloading of work parts
(v) Compatible with computer control
 5.3 Computer Control System

It is used to coordinate the activities of the processing

stations and the material handling system in the FMS.
The various functions of computer control system are:
(i) Control of each work station
(ii) Distribution of control instruction to work station
(iii) Production control
(vi) Traffic control
(v) Shuttle control
(vi) Work handling system and monitoring
(vii) System performance monitoring and reporting
6.Application characteristics of FMS
7.Flexible manufacturing system
 8.levels of manufacturing flexibility

there are three levels of manufacturing flexibility

(a) Basic flexibilities
1, Machine flexibility: The ease with which a machine can
process various operations
2, Material handling flexibility: A measure of the ease with
which different part types can be transported and properly
positioned at the various machine tools in a system
3, Operation flexibility: A measure of the ease with which
alternative operation sequences can be used for processing a
part type
 (b) System flexibilities

 1, Volume flexibility: A measure of a system’s capability to be

operated profitably at different volumes of the existing part types
 2, Expansion flexibility: The ability to build a system and expand
it incrementally
 3, Routing flexibility: A measure of the alternative paths that a
part can effectively follow through a system for a given process
plan
 4, Process flexibility: A measure of the volume of the set of part
types that a system can produce without incurring any setup
 5, Product flexibility: The volume of the set of part types that can
be manufactured in a system with minor setup

 (c) Aggregate flexibilities

1, Program flexibility: The ability of a system to run for

reasonably long periods without external intervention
2, Production flexibility: The volume of the set of part
types that a system can produce without major investment
in capital equipment
3, Market flexibility: The ability of a system to efficiently
adapt to changing market conditions

 9.DIFFERENT TYPES OF FMS

The different types of FMS are

1, Sequential FMS
2, Random FMS
3,Dedicated FMS
4, Engineered FMS
5, Modular FMS
1, Sequential FMS : It manufactures one-piece part batch type
and then planning and preparation is carried out for the next
piece part batch type to be manufactured. It operates like a
small batch flexible transfer line.
 CONT…

2, Random FMS: It manufactures any random mix of

piece part types at any one time.
3, Dedicated FMS: It continually manufactures, for
extended periods, the same but limited mix of piece part
batch types.
4, Engineered FMS: It manufactures the same mix of part
types throughout its lifetime.
5, Modular FMS: A modular FMS, with a sophisticated
FMS host, enables and FMS user to expand their FMS
capabilities in a stepwise fashion into any of the previous
four types of FMS.
 10. TYPES OF FMS LAYOUTS

The different types of FMS layouts are:

1. Progressive or Line Type
2. Loop Type
3. Ladder Type
4. Open field type
5. Robot centered type
 1.1. Progressive or Line type:

. It is most appropriate for a system in which the part

progress from one workstation to the next in a well-
defined sequence with no back flow. The operation of
this type of system is very similar to transfer type. Work
always flows in unidirectional path .
The machines and handling system are arranged in a
line as shown in the Fig.1.4 (a).
10.1.1Progressive or Line type FMS
 10.2. Loop Type:

The basic loop configuration is as shown in Fig. 1.4 (b).

The parts usually move in one direction around the loop,
with the capability to stop and be transferred to any
station. The loading and unloading station is typically
located at one end of the loop Fig.1.4 (b)

 10.3. Ladder Type:

 The loading and unloading station is typically located

at the same end. The sequence to the operation/transfer
of parts from one machine tool to another is in the form of
ladder steps as shown in Fig.1.4 (c)
 .

10.4.Open Field Type:

 The configuration of the open field is as shown in

Fig.1.4 (d). The loading and unloading station is typically
located at the same end. The parts will go through all
the substations, such as CNC machines, coordinate
measuring machines and wash station by the help of
AGV’s from one substation to another.

CONT…
 10.5. Robot Centered Type:
 Robot centered cell is a relatively new form of flexible
system in which one or more robots are used as the
material handling systems as shown in Fig.1.4 (e).
Industrial robots can be equipped with grippers that
make them well suited for handling of rotational parts.

10.5.1 Robot Centered Type:
 11. Factors Influencing the FMS Layouts

The various factors influencing the layouts of FMS are:

1, Availability of raw material
2, Proximity to market
3, Transport facilities
4 Availability of efficient and cheap labor
5 Availability of power, water and fuel
6, Atmospheric and climatic condition
7, Social and recreation facilities
8, Business and economic conditions
 12. OBJECTIVES OF AN FMS

the major aims of installing an FMS to be:

1, Decreased Lead Times
2, Increased Through put
3, Increased machine utilization
4, Improved Due Date Reliability
5, Decreased Store Inventors Levels
6, Decreased Work in Progress
7, Increased Quality
 13. AIMS OF FMS
1. To reduce costs
2. Better utilization of the production equipment reduction of
stocks (ex: Work in progress— capital shorter through put times)
3. Reduction of piece part unit costs.
4. To increase Technical Performance:
5. Increased production levels
6 Greater product mixture
7. Simultaneous product mixture manufacturing
8. Integration of the production system into the factory’s
logistical system
9. smaller batch sizes
 CONT…
10. Shorter or zero change over or reset of times
11. To improve Order Development:
12. Shorter lead times/delivery times
13. Determination of production capacities
14. To assist future Corporate Security:
15. Increased Competitiveness
16. Increased Quality
17. Improved Company Image
 14. Advantages of FMS

A, Faster, lower-cost changes from one part to another which will

improve capital utilization
B, Lower direct labor cost, due to the reduction in number of workers
C, Reduced inventory, due to the planning and programming
precision
D, Consistent and better quality, due to the automated control
E, Lower cost/unit of output, due to the greater productivity using the
same number of workers
F, Savings from the indirect labor, from reduced errors, rework,
repairs and rejects
 15. Disadvantages

A, Limited ability to adapt to changes in product or product

mix (ex. machines are of limited capacity and the tooling
necessary for products, even of the same family, is not
always feasible in a given FMS)
B, Substantial pre-planning activity
C, Expensive, costing millions of dollars
D, Technological problems of exact component positioning
and precise timing necessary to process a component
E, Sophisticated manufacturing systems
16 AREA OF APPLICATION OF A FMS IN INDUSTRY
Thanks for your attention!