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Flexible Manufacturing Systems
Introduction to FMS/FAS
Conventional Manufacturing
Consisted of 2 varieties1. Job Shop type systems were capable
of large variety of product, but at a high cost.
2. Transfer lines could produce large volumes of a product at a reasonable cost, but were limited to the production of one, two, or very few different parts.
What is FMS/FAS? A FMS/FAS is one manufacturing
machine, or multiple machines that are integrated by an automated material handling system, whose operation is managed by a computerized control system. An FMS can be reconfigured by computer control to manufacture various products.
What is CIM? CIM is the integration of the total
manufacturing enterprise through the use of integrated systems and data communications coupled with new managerial philosophies that improve organizational and personal efficiency.
What is a manufacturing Cell? A manufacturing cell usually consists of
two or three processing workstations (typically CNC Machining or turning centers) plus a part handling system.
The following two slides contain a CAD layout and picture of the RIT Mfg Eng Tech Class of 2000’s manufacturing work cell.
Manufacturing Workcell (CAD)
Manufacturing Workcell
Manufacturing Cells VS FMS A FMS/FAS is a manufacturing cell,
but a cell is not necessarily a FMS/FAS
A FMS/FAS is a complete system that runs automatically
A manufacturing cell has some or most of the components of a FMS/FAS, but not all of them.
History of FMS 1950’s NC machines first appear 1960’s Computers appear in industry Later 1960’s Flexible Manufacturing
Systems first appeared in the U.S.A. at companies like Ingersoll-Rand, Caterpillar, John Deere, and General Electric Co.
Volume Vs Variety
Flexibility in a FMS/FAS Machine flexibility Production flexibility Mix flexibility Product flexibility Routing flexibility Volume flexibility Expansion flexibility
Components of an FMS/FAS Workstations Material handling and storage
system Computer control system People to manage and operate the
system
Types of Workstations Load/unload Stations Machining Stations Other Processing Stations Assembly Other Stations and Equipment (like
Inspection)
Layout Configurations for Material Handling System
In-line layout In-line Transfer Conveyor Rail guided vehicle
Loop layout Conveyor system In-Floor towline carts
Layouts Continued Ladder layout
Conveyor System Automated Guided Vehicle (AGV) Rail guided Vehicle
Open field layout AGV In-line towline carts
Robot-centered layout
Computer Control Systems Workstation Distribution of control instructions
to workstations Production control Traffic control Shuttle control Workpiece monitoring
Computer Controls (cont) Tool control
Tool locations Tool life monitoring
Performance monitoring and reporting
Diagnostics
Why Implement a FMS/FAS? Increased machine utilization Fewer machines required Reduction in factory floor space
required Greater responsiveness to change Reduced inventory requirements Lower manufacturing lead times
Why Implement a FMS/FAS? (continued)
Reduced direct labor requirements and higher labor productivity
Opportunity for unattended production
FMS Implementation Issues Part family considerations Processing requirements Physical characteristics or workparts Production volume Scheduling and dispatching Machine loading Part routing
FMS Issues (cont) Part grouping Tool management Pallet and fixture allocation Requires management
commitment and planning Major invest of time and money