SELECTION OF MANUFACTURING SYSTEMS FOR DIFFERENT

MANUFACTURING SCENARIOS

Manufacturing System

A manufacturing system can be defined as a system in which raw

materials are processed from one form into another, known as a
product, gaining a higher or added value in the process and thus
creating wealth in the form of a profit.

Dedicated Manufacturing System (DMS)

A machining system designed for production of a specific part, and

which uses transfer line technology with fixed tooling and automation.

The economic objective of a DMS is to cost-effectively produce one

specific part type at the high volumes and the required quality.

Each dedicated line is typically designed to produce a single part (e.g.,

specific engine block) at high production rate.

When the volume is high, the cost per part is relatively low. Therefore,
DMS is cost effective as long as market demand matches the supply;
but with increasing pressure from global competition, there are many
situations in which dedicated lines do not operate at full capacity, and
thereby create losses.

Producing product variety is impossible with a DMS, and therefore their

role in modern manufacturing is decaying.
Flexible Manufacturing System (FMS)

A flexible manufacturing system (FMS) is a manufacturing system in

which there is some amount of flexibility that allows the system to
react in case of changes, whether predicted or unpredicted

It is a method for producing goods that is readily adaptable to changes

in the product being manufactured, both in type and quantity.

A flexible manufacturing system (FMS) gives manufacturing firms an

advantage to quickly change a manufacturing environment to improve
process efficiency and thus lower production cost.
A Flexible Manufacturing System (FMS) is a group of numerically-
controlled machine tools, interconnected by a central control system..
It has been described as an automated job shop and as a miniature
automated factory. In other words, it is an automated production
system that produces one or more families of parts in a flexible
manner.

Unfortunately the cost of investment to acquire an FMS is very high and

it considerably affects the cost to produce a part; indeed its flexibility is
frequently too high and expensive for needs of a producer of parts.

Advantages

 Reduced manufacturing cost

 Lower cost per unit produced,
 Greater labor productivity,
 Greater machine efficiency,
 Improved quality,
 Increased system reliability,
 Reduced parts inventories,
 Adaptability to CAD/CAM operations.
 Shorter lead times
 Improved efficiency
 Increase production rate
 High flexibility in managing manufacturing

Disadvantages

 Initial set-up cost is high,

 Substantial pre-planning
 Requirement of skilled labor
 Complicated system

Limitations of Flexible Manufacturing System

It has fixed hardware and fixed, but programmable, software. This type
of architecture does not allow changes to be made on the system
structure. Therefore, FMSs have limited capabilities in terms of
upgrading, add-ons and customization.

Cellular Manufacturing System (CMS)

Cellular manufacturing is a manufacturing process that produces

families of parts within a single line or cell of machines operated by
machinists who work only within the line or cell. A cell is a small scale,
clearly-defined production unit within a larger factory. This unit has
complete responsibility for producing a family of like parts or a product.
All necessary machines and manpower are contained within this cell,
thus giving it a degree of operational autonomy. Each worker is
expected to have mastered a full range of operating skills required by
his or her cell. Therefore, systematic job rotation and training are
necessary conditions for effective cell development. Complete worker
training is needed to ensure that flexible worker assignments can be
fulfilled.

In traditional manufacturing environments, similar machines are placed

close together (e.g. lathes, mills, drills, presses, painting, cleaning, etc.).
Cellular Manufacturing systems machines are grouped together
according to the families of parts produced, which provides a distinct
advantage in that material flow is significantly improved, which reduces
the distance traveled by materials, inventory, people which increases
the overall lead times.

Cellular manufacturing considerably reduces total manufacturing cost,

time and area of manufacturing industries. Manufacturing industries
who adopt cellular manufacturing get improvement in profit,
productivity and production quality. Cellular manufacturing also helps
manufacturers in defeating their competitors in global business
scenario. If manufactures implement cellular manufacturing system in
their manufacturing industries then they can fully satisfy their
customers by selling high quality products quickly in reasonable price.

In cellular manufacturing, objective of machine layout is to minimize

the intra-cell movement of various parts within the cell and it is
obtained by properly arranging machines within the cell. Objective of
cell layout is to minimize the inter-cell movement within the floor space
and it is achieved by properly arranging cells within the factory or shop
floor.
Cellular manufacturing can be implemented in four stages as per the
following:
1. Cell formation: Grouping parts into part families and corresponding
machines into machine cells by using the parts production process.
2. Intra-cell layout: Layout of machines within each cell.
3. Inter-cell layout: Layout of cells within the factory or shop floor.
4. Scheduling: Scheduling of jobs in each cell.

Reconfigurable Manufacturing System (RMS)

A reconfigurable manufacturing system (RMS) is one designed at the

outset for rapid change in its structure, as well as its hardware and
software components, in order to quickly adjust its production capacity
and functionality within a part family in response to sudden market
changes or or regulatory requirements.

Reconfigurable manufacturing system promises customized flexibility in

a short time, while the other manufacturing system provides
generalized flexibility designed for anticipation variations.

A reconfigurable manufacturing system (RMS) having an adjustable

structure is designed based upon market demand and can be readily
changed from a first desired production capacity to a second desired
production capacity to manufacture a desired amount of product from
a family of products.

As distinguished from flexible manufacturing system (FMS), an RMS has

the structure which allows for rapid adjustment of production capacity
and functionality, in response to new market circumstances, by basic
change of its hardware and software components.

This system can be continuously improved by integrating new

technology.

It can be rapidly reconfigured to accommodate future products and

changes in product demand rather than scrapped and replaced.