2.

FLEXIBLE MANUFACTURING SYSTEMS (FMS)

A Flexible Manufacturing System (FMS) is a reprogrammable manufacturing system capable of producing a variety of products automatically. 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 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. Conventional manufacturing

Figure 2.1: Flexible Manufacturing System

FMS Components Numerical Control (NC) machine tools Automated material handling system (AMHS) Automated guided vehicles (AGV) Conveyors Automated storage and retrieval systems (AS/RS)

Industrial Robots Control Software

2.1

Equipment of FMS

Primary equipment Work centers Universal machining centers (prismatic FMSs) Turning centers (rotational FMSs) Grinding machines Nibbling machines

Process centers Wash machines Coordinate measuring machines Robotic work stations Manual workstations

Secondary equipment Support stations Pallet/fixture load/unload stations Tool commissioning/setting area

Support equipment Robots Pallet/fixture/stillage stores Pallet buffer stations Tools stores Raw material stores Transport system(AGVs,RGVs,robots) Transport units(pallets/stillages)

2.2

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 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-tominute operations of FMS.

2.3

Types of FMS Sequential FMS Random FMS Dedicated FMS Engineered FMS Modular FMS

2.4

Application of FMS Metal-cutting machining Metal forming Assembly Joining-welding (arc , spot), glueing Surface treatment Inspection Testing

2.5

FMS different approaches The capability of producing different parts without major retooling A measure of how fast the company converts its processes from making an old line of products to produce a new product The ability to change a production schedule, to modify a part, or to handle multiple parts

2.6

Advantages of using FMS To reduce set up and queue times Improve efficiency Reduce time for product completion Utilize human workers better Improve product routing Produce a variety of Items under one roof

Improve product quality Serve a variety of vendors simultaneously Produce more product more quickly

2.7

Disadvantage of using FMS Limited ability to adapt to changes in product or product mix (ex:machines are of limited capacity and the tooling necessary for products, even of the same family, is not always feasible in a given FMS) Substantial pre-planning activity Expensive, costing millions of dollars Technological problems of exact component positioning and precise timing necessary to process a component Sophisticated manufacturing systems

Figure 2.2: Illustration example of a FMS cell

2.8

FMS Layouts Progressive Layout:

o Best for producing a variety of parts Closed Loop Layout: o Parts can skip stations for flexibility o Used for large part sizes o Best for long process times Ladder Layout: o Parts can be sent to any machine in any sequence o Parts not limited to particular part families Open Field Layout: o Most complex FMS layout o Includes several support stations

2.9

FMS Problems Part type selection - selecting parts that will be produced in the FMS over some relatively long planning horizon. Part selection - 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 - partition machines into groups where each machine in a group can perform the same set of operations. Loading - 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.