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Flexible Manufacturing
Systems (FMS)

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What Is A Flexible Manufacturing System?
Flexible Manufacturing System:
"An automated, mid-volume, mid-variety, central
computer-controlled manufacturing system
Nanua Singh, Computer-Integrated Design and Manufacturing", John Wiley & Sons, 1996

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Basic Components of FMS

The Basic components of FMS are:
1. Workstations.
2. Automated material Handling and Storage
system.
3. Computer Control System.

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1. Workstations:
Typically computer numerical control (CNC) machine tools that
perform machining operation on families of parts.
Machining centers
Robots
Load and unload stations
Assembly work stations
Inspection stations (image processing)

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CNC

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Robots

2. Automated Material
Handling and Storage system:
The various automated material handling systems
are used to transport work parts and subassembly
parts between the processing stations, sometimes
incorporating storage into function.
Automated Guided Vehicle (AGV)
Automated Storage and Retrieval System (ASRS)
Conveyors

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Automated Guided Vehicle (AGV)

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Automated Storage and Retrieval System (ASRS)

3. Computer Control System:

It is used to coordinate the activities of the processing
stations and the material handling system in the FMS.
Control of each work station
Distribution of control instruction to work station
Production control
Traffic control
Work handling system and monitoring
System performance monitoring and reporting

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FMS

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FMS

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Slide 15

Sum up
FMS: Flexible Manufacturing Systems
CNC: Computer numerical control
Robot
AGV: Automated Guided Vehicle
ASRS: Automated Storage and Retrieval System
Pallet
Buffered

Slide 16

When to use FMS

High

Stand alone
NC machines

Flexible Manufacture
Systems

Medium
Product
variety

Transfer Lines
Low
Low

Medium

High

Production volume

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Flexibility in Manufacturing
Basic Flexibility
Machine flexibility
Material handling flexibility
System Flexibility
volume flexibility
Routing flexibility
Expansion flexibility
Accumulated Flexibility
Program flexibility
production flexibility
market flexibility

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Advantages of FMS
* Ability to meet varying customer demands in terms of
numbers (seasonality) and choices.
* Less scrap
* Reduced downtime
* Improved quality through better control over it
* Increase in machine efficiency
* Faster production
* Increased system reliability
* Adaptability to CAD/CAM operations
* Reduced Inventories
* Less of Storage Space. Plant Layout gets simplified. The
space is freed up for other activities.

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Disadvantages of FMS
Complexity: These sophisticated manufacturing systems
are extremely complex and involve a lot of substantial pre
planning activity before the jobs are actually processed.
Cost of equipment: Equipment for a flexible
manufacturing system will usually initially be more
expensive than traditional equipment. Maintenance costs
are also usually higher than traditional manufacturing
systems.
Equipment Utilization: Increased machine utilization can
result in faster deterioration of equipment, providing a
shorter than average economic life.
Product/Job Costing.

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Different Types of FMS

Sequential FMS
Random FMS
Dedicated FMS
Engineered FMS
Modular FMS

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Task for you

Factors Influencing the FMS layouts

Available of raw material
Proximity to market
Transport facilities
Availability of efficient and cheap labor
Availability of Power ,Water and Fuel
Atmospheric and climatic condition
Social and recreation Facilities

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Challenges with FMS

Determining if FMS the best production system for your
company (economically and socially)
Possible expansion costs associated with implementing FMS
Day to day maintenance of FMS operations

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Integration of FMS

FMS

Manufacturing
Technology

CIM

Robotics

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Manufacturing Technology
This part of FMS uses:
NC Numerically Controlled Machine
CNC Computer Controlled Machine
DNC Direct Numerical Controlled

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CIM: Computer Integrated
Manufacturing
The Integration of the total manufacturing through the use of
integrated systems and data communications coupled with
new managerial philosophies that improve organizational and
personnel efficiency.

Components of CIM:
CAD Computer Aided Design
CAM Computer Aided Manufacturing
CAE Computer Aided Engineering

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Robots

Robots: Programmable Manipulators

Can tolerate hostile environments
Can work much longer hours than humans
Can perform redundant jobs more consistently

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Common Uses of Robots

Loading and unloading

Inspection

Spray painting

Machine Assembly

Welding
Material handling

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FMS Nuts and Bolts

Visible:
1) CNC machine tools
2) Pallet
3) Material handling equipment
4) Robots
5) Tooling systems
6) Part cleaning stations
7) Computer hardware equipment
Invisible:
1) NC programs
2) Traffic management software
3) Tooling information
4) Sophisticated FMS software

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FMS computer control system
Workstation control
Supervisory control among workstations (workstation coordination)
Production control (part rate and mix)
Traffic control (manage part delivery systems)
Workpiece monitoring (status of various systems)
Tool control (location and tool life)
Performance monitoring and reporting (report operational data)
Diagnostics (identify sources of error, preventive maintenance)

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Manufacturing Simulation Software

AnyLogic
SCADA
FlexSim
Wolfram
Simio

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Sample questions:
1) List out the components of FMS and explain their role in FMS.
2) What are the objectives of FMS?
3) How to achieve different types of flexibilities in FMS.
4) Explain the applications of FMS.
5) What are the benefits of FMS?
6) What is meant by FMS?
7) List out the types of material handling systems.
8) What are the advantages of FMS?
9) Mention the applications of FMS?