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Chapter 19:
Where to Apply FMS Technology The plant presently either:
Produces parts in batches or
Uses manned GT cells and management wants toautomate the cells
It must be possible to group a portion of the parts made in
the plant into part families
The part similarities allow them to be processed onthe FMS workstations
Parts and products are in the mid-volume, mid-variety
production range
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Flexible Manufacturing System -
Defined A highly automated GT machine cell, consisting of a group
of processing stations (usually CNC machine tools),
interconnected by an automated material handling and
storage system, and controlled by an integrated computer
system
The FMS relies on the principles of GT
No manufacturing system can produce an unlimited
range of products
An FMS is capable of producing a single part family or
a limited range of part families
Flexibility to work on mixed-model
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Types of FMS Kinds of operations
Processing vs. assembly
Type of processing If machining, rotational vs. non-rotational
Number of machines (workstations):
1. Single machine cell (n= 1)2. Flexible manufacturing cell (n= 2 or 3)
3. Flexible manufacturing system (n= 4 or more)
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Single-Machine Manufacturing Cell (n=1)
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A single-machine CNC machining cell (n=1)
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Flexible Manufacturing Cell
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A two-machine flexible manufacturing cell
for machining (n = 2 or 3)
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A five-machine flexible manufacturing system
for machining (n = 5)
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Features of the Three Categories
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FMS Components / Elements:1. Workstations (kinds of machines) & cells
2. Automated material and parts handling,
storage and transport system
3. Computer control system
4. Human labor
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1. Workstations Load and unload station(s)
Factory interface with FMS
Manual or automated
Includes communication interface with
worker to specify parts to load, fixtures
needed, etc.
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1. Workstations CNC machine tools in a machining type
system
CNC machining centers (3 to 5 axis)
Milling machines
Turning machines
Assembly machines
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2. Material-Handling and Storage
Systems Functions:
Random, independent movement of parts between
stations Capability to handle a variety of part styles: prismatic
& rotational
Standard pallet fixture base
Workholding fixture can be adapted Temporary storage
Convenient access for loading and unloading
Compatibility with computer control
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2. Material Handling Equipment Primary handling system establishes basic FMS layout
Secondary handling system - functions:
Transfers work from primary handling system toworkstations
Position and locate part with sufficient accuracy
and repeatability for the operation
Reorient part to present correct surface for
processing
Buffer storage to maximize machine utilization
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3. Computer Control System A computer system is interfaced to all
elements / components.
Categories of functions:
Workstation control
Production control
Traffic control
Tool control
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4. Human Resource Humans are needed to manage the operations of the
system.
Functions include:
Loading raw workparts into the system
Unloading finished parts from the system
Changing and setting of tools Performing equipment maintenance and repair
Performing NC part programming, etc.
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FMS Benefits Increased machine utilization
Reasons:
24 hour operation likely to justify investment Automatic tool changing
Automatic pallet changing at stations
Queues of parts at stations to maximize utilization
Dynamic scheduling of production to account for
changes in demand
Fewer machines required
Reduction in factory floor space required
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FMS Benefits Greater responsiveness to change
Reduced inventory requirements
Different parts produced continuously rather than inbatches
Lower manufacturing lead times
Reduced labor requirements
Higher labor productivity
Opportunity for unattended production
Machines run overnight ("lights out operation")
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Storage SystemsFunctionto store materials (e.g., parts, work-in-
process, finished goods) for a period of time and
permit retrieval when required
Used in factories, warehouses, distribution centers,
wholesale dealerships, and retail stores
Important supply chain component Automation available to improve efficiency
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Conventional Storage Methods
Bulk storage - storage in an open floor area
Problem: achieving proper balance between storage
density and accessibility
Rack systems - structure with racks for pallet loads Permits vertical stacking of materials
Shelving and bins - horizontal platforms in structural
frame
Steel shelving comes in standard sizes Finding items can be a problem
Drawer storage - entire contents of each drawer can be
viewed
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Bulk Storage
Bulk storage arrangements: (a) high-density bulk storageprovides low accessibility, (b) bulk storage with loads forming
rows and blocks for improved accessibility
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Drawer Storage
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Automated Storage SystemsMechanized and automated storage equipment to reduce
the human resources required to operate a storage
facility Significant investment
Level of automation varies
In mechanized systems, an operator participates in
each storage/retrieval transaction In highly automated systems, loads are entered or
retrieved under computer control
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Objectives and Reasons for
Automating Storage Operations To increase storage capacity
To increase storage density
To recover factory floor space currently used for WIP To improve security and reduce pilferage
To reduce labor cost and/or increase productivity
To improve safety
To improve inventory control To improve stock rotation
To improve customer service
To increase throughput
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Types of Automated Storage System1. Automated Storage/Retrieval System
(AS/RS)
Rack system with mechanized or automated
crane to store/retrieve loads
2. Carousel Storage System
Oval conveyor system with bins to containindividual items
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AS/RSUnit load AS/RS
with one aisle
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CNC Machining Center with Automatic Pallet
Changer - Stores One Part (single station
manufacturing cells)
Automatic
pallet changer
integrated witha CNC
machining
center for
manual loadand unloading
of workparts.
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Storage Capacities Greater Than
One Machining centers:
Various designs of parts storage unit
interfaced to automatic pallet changer (orother automated transfer mechanism)
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Storage Capacities Greater Than
One
Machining center and automatic pallet changer with pallet
holders arranged radially; parts storage capacity = 5
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Storage Capacities Greater Than
One
Machining center and in-line shuttle cart system with pallet
holders along its length; parts storage capacity = 16
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Automated Guided Vehicles (AGVs)An Automated Guided Vehicle System (AGVS) is a
material handling system that uses independently
operated, self-propelled vehicles guided along definedpathways in the facility floor
Types of AGV:
Driverless trains
Pallet trucks Unit load AGVs
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Automated Guided Vehicles:
Driverless Automated Guided Train
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Common
application is
moving heavy
payloads over
long distances
in warehouses
and factories
withoutintermediate
stops along the
route
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Automated Guided Vehicles:
AGV Pallet Truck Used to move
palletized loads
along predetermined
routes
Vehicle is backed
into loaded pallet by
worker; pallet is then
elevated from floor
Worker drives pallet
truck to AGV guide
path and programs
destination
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Automated Guided Vehicles:
Unit Load Carrier Used to move unit
loads from station to
station
Often equipped forautomatic
loading/unloading of
pallets and tote pans
using roller conveyors,
moving belts, ormechanized lift
platforms
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FMS: machine centres, measuring & inspection
station & AGV
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Terminologies: Flexible manufacturing cellmade flexible by using
machine centres, CNC machines, industrial robots,
handling systems, etc.
Flexible manufacturing system
Machine cellmanually operated production machines
laid out in a line, L, U-shaped configuration (cellular
manufacturing). For family of parts that are similar.
Transfer lineproduction line for mass production