INTRODUCTION TO FLEXIBLE

MANUFACTURING SYSTEM

CHAPTER 1
 1. INTRODUCTION
• A flexible manufacturing system (FMS) is a highly automated GT (group
technology) 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.
• FMS is called flexible is that it is capable of processing a variety of
different part styles simultaneously at the various workstations, and the mix
of part styles and quantities of production can be adjusted in response to
changing demand patterns.
• FMS relies on the principles of group technology. No manufacturing
system can be completely flexible. There are limits to the range of parts or
products that can be made in an FMS. Accordingly, a FMS is designed to
produce parts (or products) within a defined range of styles, sizes, and
processes. FMS is capable of producing a single part family or a limited
range of part families.
 1.1 Various types of flexibility
• Machine flexibility: Capability of a machine to perform a variety of
operations on a variety of part types and sizes.
• Routing flexibility: Alternative machines, sequences or resources can
be used for manufacturing a part for changes resulting from equipment
breakdowns, tool breakages, controller failures, etc.
• Process flexibility: Ability to absorb changes in the product mix by
performing similar operations, producing similar products or parts.
• Product flexibility: Ability to change over to a new set of products
economically and quickly in response to markets.
• Production flexibility: Ability to produce a range of products without
adding capital equipment.
• Expansion flexibility: Ability to change a manufacturing system with
a view to accommodating a changed product envelope.
The different types of FMS are
• 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.
• Random FMS: It manufactures any random mix of piece part types at
any one time.
• Dedicated FMS: It continually manufactures, for extended periods,
the same but limited mix of piece part batch types.
• Engineered FMS: It manufactures the same mix of part types
throughout its lifetime.
• 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
1.2 Volume-variety relationship
 1.3 Classification of the manufacturing system based on
Volume-variety considerations
Transfer Line (High-Volume, Low-Variety Production system, H-L)
• Machines dedicated to manufacture of one or 2 product types.
• Nearly no flexibility
• Maximum utilization and high production volume
• Direct labor cost is minimal
• Low per unit cost
Stand Alone NC machines / Flexible Manufacturing module (Low-
Volume High-Variety Production system, L-H)
• Highest level of flexibility
• Low utilization and low production volume
• Very high per unit cost
Mid-Volume Mid-Variety Production systems, M-M: Manufacturing
Cell, Flexible manufacturing system, Special Manufacturing System
* Manufacturing Cell
• Low to mid-volume, most of the parts are manufactured in batch mode
• Similar to an FMS, but no central control
• Most flexible in CIM category
• Lowest production rate in CIM systems
* Flexible manufacturing system
• Actual M-M manufacturing system.
• Automated material-handling system, NC machines (flexible machines), automated
tools and pallet changer, auto-gauge systems, etc.
• Allows both sequential and random routing of a wide variety of parts.
• Higher production rate than manufacturing cell
• High degree of overlap between this and cell manufacturing system
• Higher flexibility than special manufacturing systems
* Special Manufacturing System
• Least flexible category of CIM system
• Multi-spindle heads and low-level controller
• High production rate and low per unit cost
• Main difference: Fixed-path material-handling system links the machines together.
Sequence based dedicated machines.
 2. OBJECTIVES AND AIMS OF AN FMS
Objectives of an FMS: Decreased Lead Times; Increased Through put;
Increased machine utilization; Improved Due Date Reliability; Decreased Store
Inventors Levels; Decreased Work in Progress; Increased Quality
Aims of an FMS:
• To reduce costs
• Better utilization of the production equipment reduction of stocks (ex: Work in
progress— capital shorter through put times)
• Reduction of piece part unit costs.
• To increase Technical Performance: Increased production levels, Greater
product mixture, Simultaneous product mixture manufacturing, Integration of
the production system into the factory’s logistical system, Smaller batch sizes,
Shorter or zero change over or reset of times
• To improve Order Development: Shorter lead times/delivery times,
Determination of production capacities
• To assist future Corporate Security: Increased Competitiveness, Increased
Quality, Improved Company Image
 ADVANTAGES AND DISADVANTAGES OF FMS
IMPLEMENTATION
Advantages
• Faster, lower-cost changes from one part to another which will improve capital
utilization
• Lower direct labor cost, due to the reduction in number of workers.
• Reduced inventory, due to the planning and programming precision
• Consistent and better quality, due to the automated control
• Lower cost/unit of output, due to the greater productivity using the same number of
workers
• Savings from the indirect labor, from reduced errors, rework, repairs and reject
Disadvantages
• Limited ability to adapt to changes in product or product mix (ex. machines are of
limited capacity and the tooling necessary for products)
• Substantial pre-planning activity n Expensive, costing millions of dollars
• Technological problems of exact component positioning and precise timing necessary to
process a component
• Sophisticated manufacturing systems
 3. THE COMPONENTS OF AN FMS
• Physical subsystem: (1) Workstations: CNC machine tools, inspection
equipment, load & unload area. (2) Storage-retrieval systems. (3) Material
handling systems
• Control subsystem: (1) Control hardware. (2) Control software
• The three basic components of an FMS are (1) workstations, (2) material
handling and storage system, and (3) computer control system. In addition,
even though an FMS is highly automated, people are required to manage and
operate the system. Functions typically performed by humans include (1)
loading raw work parts into the system, (2) unloading finished parts (or
assemblies) from the system, (3) changing and setting tools, (4) performing
equipment maintenance and repair, (5) performing NC part programming, (6)
programming and operating the computer system, and (7) managing the
system.
1. Workstations: computer numerical control (CNC) machine tools that
perform machining operation on families of parts. FMS are being
designed with other type of processing equipment including inspection
stations, assembly works and sheet metal presses. The various
workstations are: (i) Machining centers, (ii) Load and unload stations
(iii), Assembly workstations, (iv) Inspection stations, (v) Forging stations,
(vi) Sheet metal processing, etc.
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
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 workstation
(ii) Distribution of control instruction to workstation
(iii) Production control
(vi) Traffic control
(v) Shuttle control
(vi) Work handling system and monitoring
(vii) System performance monitoring and reporting
FMS computer control system
CNC machine tools
Material handling systems
Coordinate measuring machine
 4. FMS TYPES LEVEL OF FLEXIBILITY
1. Dedicated FMS
– Designed to produce a limited variety of part styles
– The 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
2. Random-order FMS
– Appropriate for large part families
– New part designs will be introduced
– Production schedule is subject to daily changes
• The trade-off between flexibility and productivity can be seen in these
two system types. The dedicated FMS is less flexible but capable of
higher production rates. The random-order FMS is more flexible but at
the cost of lower production rates.
 5. FMS LAYOUTS
• Progressive layout:
-Best for producing a variety of parts
• Closed loop layout:
-Parts can skip stations for flexibility
-Used for large part sizes
-Best for long process times
• Ladder layout:
-Parts can be sent to any machine in any sequence
-Parts not limited to particular part families
• Open field layout
-Most complex FMS layout
-Includes several support stations
FMS IN-LINE LAYOUT
• Straight line flow, well-
defined processing sequence
similar for all work units
• Workflow is from left to
right through the same
workstations
• No secondary handling
system
Linear transfer
system with
secondary parts
handling system at
each workstation
to facilitate flow in
two directions
 FMS LOOP LAYOUT

• One direction flow, but variations in processing

• Rectangular layout allows recirculation of pallets back

Multiple loops and ladders,

• Suited to the
handling of
rotational
parts and
turning
operations
A modern manufacturing
FMS for Sheet Metal Fabrication
Manufacturing systems
 FMS APPLICATION CONSIDERATIONS
• Flexible automation is applicable to a variety of manufacturing
operations. FMS technology is most widely applied in machining
operations. Other applications include sheet metal pressworking and
assembly.
• Flexible Machining systems. Historically, most of the applications of
flexible machining systems have been in milling and drilling operations
(nonrotational parts), using CNC machining centers. FMS applications
for turning (rotational parts) were much less common until recently, and
the systems that are installed tend to consist of fewer machines.