FLEXIBLE MANUFACTURING

SYSTEM

LECTURE :

PREPARED BY

PROF. CHIRAG P PATEL

U. V. PATEL COLLEGE OF

ENGINEERING

FLEXIBLE MANUFACTURING SYSTEM

Definition: FMS is a highly automated GT machine cell,

consisting of a group of processing

workstations(usually CNC machine tools),

interconnected by an automated material handling and

storage system, and controlled by a distributed

computer system.

WHAT MAKES IT FLEXIBLE?

Part Variety test:

Schedule change test

Error recovery test

New Part test

CLASSIFICATION OF FMS

Flexibility type Definition Depends on Factors such As:

Machine Flexibility Capability to adapt a given

machine(workstation) in the system

to a wide range of production

operations and part styles. The

greater the range of operations and

part styles, the greater the machine

flexibility.

-Setup or changeover time

-Ease of machine

reprogramming

-Tool storage capacity of

machines.

-Skill and versatility of workers

in the system.

Production Flexibility The range of universe of part styles

that can be produced on the system.

-Machine flexibility of

individual stations.

-Range of machine flexibilities

of all stations in the system

Mix Flexibility Ability to change the product mix

while maintaining the same total

production quantity; that is,

producing the same parts only in

different proportions

-similarity of parts in the mix.

-Relative work content times of

parts produced,

-Machine flexibility.

Flexibility type Definition Depends on Factors such As:

Product Flexibility Ease with which design changes can

be accommodated. Ease with which

new products can be introduced.

-How closely the part design

matches the existing part family.

-off-line part program

preparation.

-Machine flexibility

Routing Flexibility Capacity to produce parts through

alternative workstation sequences in

response to equipment breakdowns,

tool failures, and other interruptions

at individual stations.

-Similarity of in the mix.

-Similarity of workstation.

-Duplication of workstations.

-Cross-training of manual

workers.

-Common tooling.

Volume Flexibility Ability to economically produce

parts in high and low total

quantities of production, give the

fixed investment in the system.

-Level of manual labor

performing production.

-Amount of invested in capital

equipment.

Expansion Flexibility Ease with which the system can be

expanded to increase total

production quantities.

-Expense of adding workstation.

-Ease with which layout can be

expanded,

-Type of part handling system

used.

Number of Machine

Single Machine cell

Flexible manufacturing cell

Flexible manufacturing system

Level of Flexibility

Dedicated FMS

Random-order FMS

SINGLE MACHINE CELL

FLEXIBLE MANUFACTURING CELL

FLEXIBLE MANUFACTURING SYSTEM

COMPARISON OF DEDICATED AND RANDOM-

ORDER FMS TYPES

FMS COMPONENTS

Work Stations

Material Handling & Storage System.

Computer Control System.

Human Resources.

FMS COMPONENTS

Work Stations

Load/Unload Stations.

Machining Station.

Other processing station

Assembly

Other stations and equipment.

Material Handling & Storage System.

Function of Handling System. Random, independent movement of work-parts

between stations.

Handle a variety of work-part configuration.

Temporary storage.

Convenient access for loading and unloading work-parts.

Compatible with computer control

FMS Layout Configurations in line, loop Layout, Ladder, Open field, Robot-

Centered

IN-LINE LAYOUT

LOOP LAYOUT

LADDER LAYOUT

OPEN FIELD LAYOUT

Computer Control System: Work station control,

Distribution of control instruction to workstation,

Production control,

Traffic Control,

Shuttle control,

Work-piece monitoring,

Tool control

-Tool location,

-Tool life monitoring,

Performance monitoring and reporting,

Diagnostics

Human Resources:

STRUCTURE OF FMS APPLICATION

SOFTWARE SYSTEM

FMS APPLICATION AT INGERSOLL-

RAND IN VIRGINIA.

FMS AT AVCO-LYCOMING

FMS AT VOUGHT AEROSPACE

FLEXIBLE FABRICATION SYSTEM.

FMS BENEFITS

1.Increased Machine utilization.

2.Fewer machine required

3.Reduction in factory floor space required

4.Greater responsiveness to change.

5.Reduced inventory requirement.

6.Lower manufacturing lead times.

7.Reduced direct labor requirements and high labor productivity.

8.Opportunity for unattended production.

9.The inspection cost is a significant portion of the total cost

FMS PLANNING & DESIGN ISSUES

Planning:1.Part family considerations.

2.Processing requirements

3.Physical characteristics of the work-part.

4.Production volume.

Design:5.Types of work-stations

6.Variations in process routing and FMS Layout.

7.Material handling system.

8.Work in process and storage capacity.

9.Tooling.

10.Pallet fixtures.

FMS OPERATIONS ISSUES

1.Scheduling and dispatching.

2.Machine loading

3.Part routing

4.Part grouping

5.Tool Management.

6.Pallet and fixture allocation.