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.