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FLEXIBLE MANUFACTURING SYSTEM (FMS)

Presented BySandeep Tajane

Abhinandan SawantRohan Mathkar

Rutuja Wagh

8 January 2016

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History• The FMS was first conceptualized for machining, and

it required the prior development of NC.• This concept is credited to David Williamson, a British

engineer during mid-1960s.• In late 1960s the first FMS machining system was

installed at Ingersoll-Rand company in Virginia.• Germany implemented its first FMS in 1969, in

cooperation with the university of Stuttgart.• Russia and Japan implemented FMS in 1972.

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Introduction of FMS• A FMS is a automated machine cell, consisting of a

group of processing workstations, interconnected with automated material handling and storage system.

• The FMS is most suited for the mid-variety, mid-volume production range.

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Why FMS ?• External changes such as change in product design

and production system.• Optimizing the manufacturing cycle time.• Reduced production costs.• Overcoming internal changes like breakdowns etc.

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What Makes It Flexible?• Three capabilities that a manufacturing system

must possess to be a flexible. The ability to identify and distinguish among the

different part styles processed by the system. Quick changeover of operating instructions. Quick changeover of physical setup.

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Manufacturing Flexibility1. Machine Flexibility 2. Production Flexibility3. Product Flexibility 4. Routing Flexibility5. Volume Flexibility6. Expansion Flexibility

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Classification of FMS• Flexible manufacturing systems can be distinguished

according to the number of machines in the system. • The following are typical categories:

1. Single Machine Cell (SMC) 2. Flexible Manufacturing Cell (FMC) 3. Flexible Manufacturing System (FMS)

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Single Machine Cell• A Single Machine Cell consists of one CNC machining

center combined with a parts storage system for unattended operation.

• Completed parts are periodically unloaded from the parts storage unit, and raw work parts are loaded into it.

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Single Machine Cell

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Flexible Manufacturing Cell• A Flexible Manufacturing Cell consists of two or three

processing workstations (typically CNC machining centers) plus a part handling system.

• The part handling system is connected to a load/unload station.

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Flexible Manufacturing Cell

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Flexible Manufacturing System • A Flexible Manufacturing System has four or more

processing workstations connected mechanically by a common part handling system and electronically by a distributed computer system.

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Flexible Manufacturing System

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Flexibility criteria applied to the 3 types of manufacturing cells and systems

System Type Part VarietySchedule Change Error Recovery

New Part

Single machine cell (SMC)

Yes, but processing sequential, not simultaneous

Yes Limited recovery due to only one machine

Yes

Flexible mfg cell (FMC)

Yes, simultaneous production of different parts

Yes Error recovery limited by fewer machines than FMS

Yes

Flexible mfg system (FMS)

Yes, simultaneous production of different parts

Yes Machine redundancy minimizes effect of machine breakdowns

Yes

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Elements of FMS1. Workstations2. Automated Material Handling & Storage Systems3. Computer Control PLC4. Human Resources

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Workstations• Consist of following Substations1. Load/Unload Stations2. Machining Stations3. Other Processing Stations4. Assembly

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Material Handling and Storage Systems

• Functions of the Handling System1. Independent movement of workparts between

stations.2. Handle a variety of workpart configurations.3. Temporary storage.4. Convenient access for loading and unloading

workparts.5. Compatible with Computer Control.

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Material Handling and Storage Systems

• Material Handling Equipment Primary Handling System establishes the basic

layout of the FMS and is responsible for moving worksparts between the stations in the system (Conveyor).

Secondary Handling System consist of transfer devices, automatic pallet changing, and similar mechanism located at the workstation in the FMS.

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Automated Fork lifting Automated Rail Traveler

Material Handling and Storage Systems

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Computer Control PLC• The FMS includes a distributed computer system that

is interfaced to The Workstations Material handling system Other hardware components

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Computer Control PLC• A typical FMS computer system consists of a central

computer and microcomputer Microcomputers controlling the individual

machines and other components. The central computer coordinates the activities of

the components to achieve smooth overall operation of the system

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Computer Control PLC

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Human Resources• Human are needed to manage the operations of the

FMS.• Functions performed by human includes:

Loading raw work parts into the system Unloading finished parts (or assemblies) from the

system Changing and setting tools Equipment maintenance and repair NC part programming in a machining system Programming and operation the computer system

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Allied Signal’s FMS

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LAYOUTS OF FMS1. Line Type2. Loop Type3. Ladder Type4. Robot Centered Type

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1. Line Layout• An Automated guided vehicle is most efficient when

the movement is in straight-lines along the AGV path in a single-row machine layout.

• Machines are arranged only on one side of AGV path, and in double row machine layout, machines are arranged on both sides.

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2. Loop Layout• The loop layout uses conveyor systems that allow

unidirectional flow of parts around the loop. • A secondary material handling system is provided at

a workstation which permits the flow of parts without any obstruction.

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3. Ladder Type Layout• Ladder type layout consists of rungs on which

workstations are located. • This reduces the average travel distance thereby

reducing the transfer time between workstations.

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4. Robot Centered Layout• If a handling robot is used in a Flexible manufacturing

system cell , the machines are laid out in a circle, such a layout is called circular layout.

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Advantages of FMS• Faster, low cost changing of one part to another, with

capital gain.• Lower labor cost, with reduction of labor force

needed.• Less inventory, because of planning and

programming precision.• Consistent and greater quality, with automated

controls.• Gain Saving from lower labor needs, reduced errors,

repairs and rejects.

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Disadvantages of FMS• Expensive, sometimes costing millions of Dollars.• A great amount of pre-planning activity.

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THANK YOU