FLEXIBLE FLEXIBLE MANUFACTURING MANUFACTURING

SYSTEMSSYSTEMS

FLEXIBLE FLEXIBLE MANUFACTURING MANUFACTURING

SYSTEMSSYSTEMS

MODELING AND MODELING AND ANALYSIS OFANALYSIS OF

MANUFACTURING MANUFACTURING SYSTEMSSYSTEMS

DEFINITIONDEFINITION

A FLEXIBLE MANUFACTURING SYSTEM A FLEXIBLE MANUFACTURING SYSTEM ((FMSFMS) IS A SET OF ) IS A SET OF NUMERICALLY NUMERICALLY CONTROLLED MACHINE TOOLS CONTROLLED MACHINE TOOLS AND AND SUPPORTING WORKSTATIONS SUPPORTING WORKSTATIONS CONNECTED BY AN CONNECTED BY AN AUTOMATED AUTOMATED MATERIAL HANDLING SYSTEM MATERIAL HANDLING SYSTEM AND AND CONTROLLED BY A CONTROLLED BY A CENTRAL CENTRAL COMPUTERCOMPUTER

ELEMENTS OF FMSELEMENTS OF FMS

► AUTOMATICALLY REPROGRAMMABLE AUTOMATICALLY REPROGRAMMABLE MACHINES.MACHINES.

►AUTOMATED TOOL DELIVERY AND AUTOMATED TOOL DELIVERY AND CHANGINGCHANGING

►AUTOMATED MATERIAL HANDLINGAUTOMATED MATERIAL HANDLING►COORDINATED CONTROLCOORDINATED CONTROL

FMS FEATURESFMS FEATURES

►MANY PART TYPES CAN BE LOADEDMANY PART TYPES CAN BE LOADED►PARTS CAN ARRIVE AT MACHINES IN PARTS CAN ARRIVE AT MACHINES IN

ANY SEQUENCEANY SEQUENCE►PARTS IDENTIFIED BY CODESPARTS IDENTIFIED BY CODES►MANY MACHINES CAN BE INCLUDEDMANY MACHINES CAN BE INCLUDED►SMALL FMS LEAD TO FLEXIBLE CELLSSMALL FMS LEAD TO FLEXIBLE CELLS

►EXPENSIVE TO IMPLEMENT BUT EXPENSIVE TO IMPLEMENT BUT SAVINGS CAN BE SIGNIFICANTSAVINGS CAN BE SIGNIFICANT

►FLOOR SPACE REDUCIBLE BY 1/3FLOOR SPACE REDUCIBLE BY 1/3►EQUIPMENT UTILIZATION UP TO EQUIPMENT UTILIZATION UP TO

85% OR MORE85% OR MORE►DETAILED PRODUCTION DETAILED PRODUCTION

SEQUENCE NOT NEEDED WELL IN SEQUENCE NOT NEEDED WELL IN ADVANCEADVANCE

MANUFACTURING MANUFACTURING FLEXIBILITYFLEXIBILITY

►BASICBASIC MACHINEMACHINE (VARIETY OF OPERATIONS) (VARIETY OF OPERATIONS) MATERIAL HANDLING MATERIAL HANDLING (PART MOBILITY (PART MOBILITY

AND PLACEMENT)AND PLACEMENT) OPERATION OPERATION (VARIETY OF OPERATIONS (VARIETY OF OPERATIONS

PRODUCING SAME PART FEATURES)PRODUCING SAME PART FEATURES)

►SYSTEMSYSTEM PROCESSPROCESS (VARIETY OF PARTS (VARIETY OF PARTS

PRODUCIBLE WITH SAME SETUP)PRODUCIBLE WITH SAME SETUP) ROUTINGROUTING (ABILITY TO USE DIFFERENT (ABILITY TO USE DIFFERENT

MACHINES UNDER SAME SETUP)MACHINES UNDER SAME SETUP) PRODUCTPRODUCT (CHANGEOVER) (CHANGEOVER) VOLUMEVOLUME (PRODUCTION LEVEL) (PRODUCTION LEVEL) EXPANSIONEXPANSION (ADDED CAPACITY) (ADDED CAPACITY)

►AGGREGATEDAGGREGATED PROGRAMPROGRAM (UNATTENDED RUNNING) (UNATTENDED RUNNING) PRODUCTIONPRODUCTION (RANGES OF PARTS, (RANGES OF PARTS,

PRODUCTS, PROCESSES, VOLUME, PRODUCTS, PROCESSES, VOLUME, EXPANSION)EXPANSION)

MARKETMARKET (COMBINATION OF (COMBINATION OF PRODUCT, PROCESS, VOLUME AND PRODUCT, PROCESS, VOLUME AND EXPANSION)EXPANSION)

COMMENTSCOMMENTS

THE PART TYPES ASSIGNED TO THE THE PART TYPES ASSIGNED TO THE FMS SHOULD HAVE SUFFICIENT FMS SHOULD HAVE SUFFICIENT PRODUCTION VOLUMES TO MAKE PRODUCTION VOLUMES TO MAKE AUTOMATION ATTRACTIVE BUT AUTOMATION ATTRACTIVE BUT INSUFFICIENT TO JUSTIFY DEDICATED INSUFFICIENT TO JUSTIFY DEDICATED PRODUCTION LINESPRODUCTION LINES

ORIGINS OF FMSORIGINS OF FMS

►LINK LINES (1960’S)LINK LINES (1960’S)►NC MACHINES AND NC MACHINES AND

CONVEYORSCONVEYORS►BATCH PROCESSINGBATCH PROCESSING

FMS PRIORITIESFMS PRIORITIES

►MEETING DUE DATESMEETING DUE DATES►MAXIMIZING MACHINE MAXIMIZING MACHINE

UTILIZATIONUTILIZATION►MINIMIZE THROUGHPUT TIMESMINIMIZE THROUGHPUT TIMES►MINIMIZE MINIMIZE WIPWIP LEVELS LEVELS

FMS COMPONENTSFMS COMPONENTS

►MACHINESMACHINES►PART MOVEMENT SYSTEMSPART MOVEMENT SYSTEMS►SUPPORTING WORKSTATIONSSUPPORTING WORKSTATIONS►SYSTEM CONTROLLERSYSTEM CONTROLLER

MACHINESMACHINES

►PRISMATIC VS ROTATIONAL PARTSPRISMATIC VS ROTATIONAL PARTS►HORIZONTAL MACHINING HORIZONTAL MACHINING

CENTERS (HMC) AND HEAD CENTERS (HMC) AND HEAD INDEXERS (HI)INDEXERS (HI)

►TOOL MAGAZINES AND TOOL MAGAZINES AND AUTOMATIC TOOL CHANGERSAUTOMATIC TOOL CHANGERS

PART MOVEMENTPART MOVEMENT

►CONVEYORSCONVEYORS►TOW CARTSTOW CARTS►RAIL CARTSRAIL CARTS

SUPPORTING WORKSTATIONSSUPPORTING WORKSTATIONS

►LOAD/UNLOAD STATIONSLOAD/UNLOAD STATIONS►AUTOMATIC PART WASHERSAUTOMATIC PART WASHERS►COORDINATE MEASURING COORDINATE MEASURING

MACHINESMACHINES

CONTROLLERCONTROLLER

►COMPUTERCOMPUTER►WORKER (ATTENDANT)WORKER (ATTENDANT)►TRACKING SYSTEM FORTRACKING SYSTEM FOR

PARTSPARTS MACHINESMACHINES

COMPONENTS OF THE COMPONENTS OF THE MANUFACTURING FACILITYMANUFACTURING FACILITY

FACILITYFACILITY SHOPSHOP CELLCELL WORKSTATIONWORKSTATION EQUIPMENTEQUIPMENT

BASIC STEPS IN DECISION BASIC STEPS IN DECISION HIERARCHYHIERARCHY

►LONG TERM PLANNING OR LONG TERM PLANNING OR SYSTEM DESIGN SYSTEM DESIGN (PART TYPES & (PART TYPES & EQUIPMENT SELECTION)EQUIPMENT SELECTION)

►MEDIUM RANGE PLANNING OR MEDIUM RANGE PLANNING OR SETUP SETUP (DAILY DECISIONS ABOUT (DAILY DECISIONS ABOUT PARTS & TOOLING)PARTS & TOOLING)

►SHORT TERM OPERATION SHORT TERM OPERATION (SCHEDULING & CONTROL)(SCHEDULING & CONTROL)

SYSTEM DESIGNSYSTEM DESIGN

►PROBLEM: SELECTING SYSTEM SIZE, PROBLEM: SELECTING SYSTEM SIZE, HARDWARE, SOFTWARE AND PARTS HARDWARE, SOFTWARE AND PARTS FOR THE FOR THE FMSFMS

►SIZE & SCOPE ARE SELECTED SIZE & SCOPE ARE SELECTED ACCORDING TO CORPORATE ACCORDING TO CORPORATE STRATEGYSTRATEGY

►HARDWARE & SOFTWARE SELECTED HARDWARE & SOFTWARE SELECTED TO FIT SCOPETO FIT SCOPE

SCHEDULING AND CONTROLSCHEDULING AND CONTROL

►BASIC PROBLEM AREASBASIC PROBLEM AREAS SEQUENCING AND TIMING OF PART SEQUENCING AND TIMING OF PART

RELEASES TO THE SYSTEMRELEASES TO THE SYSTEM SETTING OF INTERNAL PRIORITIES IN SETTING OF INTERNAL PRIORITIES IN

THE SYSTEMTHE SYSTEM ABILITY OF SYSTEM TO TAKE ABILITY OF SYSTEM TO TAKE

CORRECTIVE ACTION WHEN CORRECTIVE ACTION WHEN COMPONENTS FAILCOMPONENTS FAIL

Flexible Assembly SystemsFlexible Assembly Systems

►For the combination of raw materials For the combination of raw materials and components into products with and components into products with functional characteristics.functional characteristics.

►Automated vs manned systemsAutomated vs manned systems►Example: Vibratory bowl feeders and Example: Vibratory bowl feeders and

vision systemsvision systems►Role of Design for AssemblyRole of Design for Assembly

FLEXIBLE FLEXIBLE MANUFACTURING MANUFACTURING

SYSTEMSSYSTEMS

……Thank you…Thank you…