Flexible Manufacturing SystemsFlexible Manufacturing SystemsFlexible Manufacturing SystemsFlexible Manufacturing Systems
Dr.Ravinder Kumar
Core Transformation Process for a
Manufacturing Company
ENVIRONMENT
Organization
Raw Material
Inputs
Product or Service
OutputsCore
Work Processes
Materials
Handling
Milling Inspection
Assembly
Dr.Ravinder Kumar
Classification Based on System of Production� Group I
� Small-batch and unit production
� Group II� Large-batch and mass production
� Group III� Continuous process production
Dr.Ravinder Kumar
Flexible Manufacturing Systems� Computer-aided design
� (CAD)
� Computer-aided manufacturing� (CAM)� (CAM)
� Integrated Information Network
Dr.Ravinder Kumar
NEW CHOICES
Small batchFlexible
ManufacturingMass
Customization
Relationship of Flexible Manufacturing Technology
to Traditional Technologies
Customized
Mass
Production
Continuous
Process
BATCH SIZESmall Unlimited
Standardized
PRODUCT FLEXIBILITY
Source: Based on Jack Meredith, “The Strategic Advantages of New
Manufacturing Technologies For Small Firms.” Strategic Management
Journal 8 (1987): 249-58; Paul Adler, “Managing Flexible Automation,”
California Management Review (Spring 1988): 34-56; and
Otis Port, “Custom-made Direct from the Plant.”
Business Week/21st Century Capitalism, 18 November 1994, 158-59.
Dr.Ravinder Kumar
Comparison of Organizational Characteristics Associated with
Mass Production and
Flexible Manufacturing Systems
CharacteristicCharacteristic Mass ProductionMass Production FMSFMS
Structure:Structure:
Span of ControlSpan of Control WideWide NarrowNarrow
Hierarchical levelsHierarchical levels ManyMany FewFewHierarchical levelsHierarchical levels ManyMany FewFew
TasksTasks Routine, repetitiveRoutine, repetitive Adaptive, Adaptive,
craftcraft--likelike
SpecializationSpecialization HighHigh LowLow
Decision makingDecision making CentralizedCentralized DecentralizedDecentralized
OverallOverall Bureaucratic, Bureaucratic,
mechanisticmechanistic
SelfSelf--regulating, regulating,
organicorganic
Source: Based on Patricia L. Nemetz and Louis W. Fry, “Flexible
Manufacturing Organizations: Implications for Strategy Formulation
and Organization Design.” Academy of Management Review 13
(1988); 627-38; Paul S. Adler, “Managing Flexible Automation,”
California Management Review (Spring 1988); 34-56; Jeremy Main,
“Manufacturing the Right Way,” Fortune, 21 May 1990, 54-64.
Comparison of Organizational Characteristics Associated with
Mass Production and
Flexible Manufacturing Systems (cont.)
CharacteristicCharacteristic Mass ProductionMass Production FMSFMS
Human Human
Resources:Resources:
InteractionsInteractions StandaloneStandalone TeamworkTeamwork
TrainingTraining Narrow, one timeNarrow, one time Broad, frequentBroad, frequent
ExpertiseExpertise Manual, Manual,
technicaltechnical
Cognitive, socialCognitive, social
Solve problemsSolve problems
Source: Based on Patricia L. Nemetz and Louis W. Fry, “Flexible
Manufacturing Organizations: Implications for Strategy Formulation
and Organization Design.” Academy of Management Review 13
(1988); 627-38; Paul S. Adler, “Managing Flexible Automation,”
California Management Review (Spring 1988); 34-56; Jeremy Main,
“Manufacturing the Right Way,” Fortune, 21 May 1990, 54-64.
Flexible Manufacturing Systems (FMS)
� An FMS is a “reprogrammable” manufacturing system capable of producing a variety of products automatically.
� Conventional manufacturing systems have been marked by one of two distinct features:� The capability of producing a variety of different product types, but at a high cost (e.g., job shops).
� The capability of producing large volumes of a product at a lower cost, but � The capability of producing large volumes of a product at a lower cost, but very inflexible in terms of the product types which can be produced (e.g., transfer lines).
� An FMS is designed to provide both of these features.
Dr.Ravinder Kumar
FMS Components
� Numerical Control (NC) machine tools� Automated material handling system (AMHS)
� Automated guided vehicles (AGV)� Conveyors� Automated storage and retrieval systems (AS/RS)� Automated storage and retrieval systems (AS/RS)
� Industrial Robots� Control Software
Dr.Ravinder Kumar
Flexible Manufacturing System
Computer
control
room
Machine Machine
Tools
Conveyor
Pallet
PartsFinished
goods
Load Unload
Terminal
Pallet
Dr.Ravinder Kumar
Classification of FMS-related Problems
� Strategic analysis and economic justification, which provides long-range, strategic business plans.
� Facility design, in which strategic business plans are integrated into a specific facility design to accomplish long-term managerial objectives.
� Intermediate-range planning, which encompasses decisions related to master � Intermediate-range planning, which encompasses decisions related to master production scheduling and deals with a planning horizon from several days to several months in duration.
� Dynamic operations planning, which is concerned with the dynamic, minute-to-minute operations of FMS.
Dr.Ravinder Kumar
FMS Problems
� Part type selection (Askin) - selecting parts that will be produced in the FMS over some relatively long planning horizon.
� Part selection (Stecke) - from the set of parts that have current production requirements and have been selected for processing in the FMS, select a subset for immediate and simultaneous processing.
� Machine grouping (Stecke) - partition machines into groups where each machine in a group can perform the same set of operations.group can perform the same set of operations.
� Loading (Stecke) - allocate the operations and required tools of the selected part types among the machine groups.
� Control - provide instructions for, and monitor the equipment in the FMS so that the production goals identified by the above problems are met.
Dr.Ravinder Kumar
Information Technology
� Management information system (MIS)�move large amounts of data
� Decision support system (DSS)�add decision making support
� Expert system� Expert system�recommend decision based on expert knowledge
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Decision Support System
Information:
Personnel
AccountingManagement Information System
ManagementDecision Support System
Information:reportsmodel resultswhat if?analysis
Computersystem:dataprocessing
Data
Quantitativetechniques
Production
Marketing
Distribution
Other areas
Decisions
What -if? analysis
Dr.Ravinder Kumar
Artificial Intelligence
� Neural networks�emulate interconnections in brain
� Genetic algorithms�based on adaptive capabilities in nature
� Fuzzy logic� Fuzzy logic�simulate human ability to deal with ambiguity
Dr.Ravinder Kumar
Advanced Communications
� Electronic data interchange (EDI)
� Internet
� Wireless communications
� Teleconferencing
& telecommuting
� Bar coding
� Virtual reality
Dr.Ravinder Kumar
Manufacturing Technology
� Numerically controlled (NC) machines�controlled by punched tape
� Computer numerical controlled (CNC)�controlled by attached computer
� Direct numerical control (DNC)� Direct numerical control (DNC)� several NC machines controlled by single computer
Dr.Ravinder Kumar
Automated Material Handling
� Conveyors
� Automated guided vehicle (AGV)
� Automated storage & retrieval system (ASRS)
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Flexible Manufacturing Systems (FMS)
� Programmable machine tools
� Controlled by common computer network
� Combines flexibility with efficiency
� Reduces setup & queue times
Dr.Ravinder Kumar
Robotics
� Programmable manipulators
� Follow specified path
� Better than humans with respect to �hostile environments
�long hours�long hours
�consistency
Dr.Ravinder Kumar
Robot Parts
� Controller�hardware, software, power source
� Manipulator�robot arm
� End-effector� End-effector�“hand”
Dr.Ravinder Kumar
Computer Integrated Manufacturing
(CIM) � Integration of design, manufacture & delivery via computer technology
� CAD - uses software to create & modify designs
� CAM - uses programmable automation in manufacturing
� CAE - links functional design to CAD form design
� CAPP - creates processing instructions for CAM
GT- classifies designs to benefit from prior experience� GT- classifies designs to benefit from prior experience
Dr.Ravinder Kumar
Components Of CIM
Product
design
TQM
Bar codes,
EDI
MRP
GTCAECAD
IGES,
PDES,
DMIS
DFM
CAD/CAM
CAPP
CIM
Manufacture
Process
planning
Systems
management
RoboticsFMSNC/CNC/
DNC
Cells
and centers
Automated
inspection
AGV,
ASRS
JIT/
kanban
DSS/ES/
AI
LAN, TOP,
satellites
MRP
Cellular
manufacturing
MAP,
STEP
CAPP
Dr.Ravinder Kumar
Adoption Of Technology
� Technology Readiness� Need well-designed products & efficient processes
� Technology Design� Know what to automate
� Technology Selection� Technology Selection� Choose the right level
� Technology Integration� Have a strategy for incremental automation
Dr.Ravinder Kumar
An Example
Dr.Ravinder Kumar
And also
Dr.Ravinder Kumar