UNIT-1&2

1) Explain the economic justification of FMS and

integration of FMS components in the data
processing system.
Ans. The basic reasons for designing and
implementation of FMS. At the present time systems
worldwide have an exponential growth.
FMS provides the following benefits if designed and
used successfully:
1) Greater productivity which means a greater output
and a lower unit cost, on 45%-85% smaller floor
space.
2) Quality is improved because the product is more
uniform and consistent.
3) The intelligent self correcting system (machines
equipped with sensors and feedback system) increase
the overall reliability of product.
4) The expenses are smaller because the overall capital
investment is 5%-10% lower, 45%-85% less
machining facility are required compared to
conventional stand alone CNC controlled machine
 tools and also because the flexible material handling
and storage system provides an automated inventory
system with considerable lower levels of stock and
materials handling.
5) Parts can be randomly provided in batches of one or
reasonably high numbers and the lead time can be
reduced by 50%-75%.
6) FMS is the only available manufacturing
environment to data where the time spent on the
machine tool can be as high as 90% and the time
spent cutting can again be over 90%.
7) Compare this stand alone NC machine where the part
from stock to finished the item, spends only 5% on its
time on the machine tool, and where the actual
productive work takes only 30% of this 5%.
8) The time resulting in useful work where stand alone
machines are used as therefore as little as 1%-1.5%of
the time the parts are takes to be proceeding to the
shop.
9) One another important fact ought to be mentioned.
While FMS requires fewer machine operators or none
at all the remaining staff.
 2) Explain in detail the JIT manufacturing, its benefits
and relationship to FMS.

Just in time is a key element of Lean

production
i-Producing the quantity of units that is
needed
ii-Producing them on the
date\time required
iii-Supplier delivers the exact quantity
demanded at the scheduled time and date
Three fundamental concept of JIT are
i- Elimination of waste and variability
ii-‘Pull’ verses ‘Push’ system
iii- Manufacturing cycle time (throughput
time)
Objectives of JIT
i. Produces only the product/services that
customer wants.
ii. Produce products only as quickly as possible
customers want to use them
iii. Produce products with perfect quality
iv. Produce in minimum possible time
 v. Produce products with features only what
customer want
vi. Produce with no waste of labour
\materials\equipments
vii. Produce with methods that reinforce the
occupational development of workers.

Requirements of JIT:
Before implementing JIT system, certain changes to
the factory and the way it is managed must occur
before benefits of JIT are realized.
i- Stabilize production schedule
ii- Make the factories focused.
iii- Increase the production characteristics of
manufacturing centres.
iv- Improve Product quality.
v- Cross train workers so that they are multi
skilled and competent in several jobs.
Vi Reduce equipment breakdowns through
preventive maintenance.
vi- Develop long term supplier relationship that
avoids interruptions in material flows.
3) Discuss the need for automation and the work piece
transport systems in FMS.
FMS is a manufacturing cell or system consisting of
one or more CNC machines, connected by automated
material handling system, pick-and-place robots and
all operated under the control of a central computer.
It also has auxiliary sub-systems like component
load/unload station, automatic tool handling system,
tool pre-setter, component measuring station, wash
station etc. Each of these will have further elements
depending upon the requirement as given below:

A. Workstations
o CNC machine tools o Assembly equipment
o Measuring Equipment

B. Material handling Equipment

Load unload stations (Palletizing)
 Robotics
 Automated Guided Vehicles (AGVs)
 Automated Storage and retrieval Systems
(AS/RS)
 C. Tool systems
• Tool setting stations
• Tool transport systems
D. Control system
• Monitoring equipments
• Networks

4) Explain in detail the parts classification and coding

systems and benefits of group technology.

1) This method is the most time consuming of the three

methods.
2) In parts classification and coding, similarities among
parts are identified and these similarities are related
in a coding system.
3) To accomplish parts classification and coding
requires examination and analysis of the design
and/or manufacturing attributes of each part. The
examination is sometimes done by looking in tables.
4) An alternative and more productive approach
involves interaction with a computerized
classification and coding system, in which the user
responds to questions asked by the computer.
5) On the basis of the responses, the computer assigns
the code number to part. Whichever method is used,
the classification results in a code number that
uniquely identifies the part’s attributes.
In terms of the meaning of the symbols in the code,
there are three structures used in classification and
coding schemes.
1) Hierarchical structure, or monocode
2) Chain type structure or polycode
3) Hybrid, or mixed.

Part classification and coding system:

1) Optiz system
2) MI CLASS system
3) CODE system

Optiz system:
1) This is the most common and widely used coding
system .
2) It is generally a 9 digit code with 5 forming the
primary code while the last 4 are secondary code.
3) It represents one of the pioneering efforts in GT
and is probably the best known, if not the most
 frequently used, of the parts classification and
coding systems.
4) It is intended for machine parts.
5) The Optiz coding scheme uses the following digit
sequences.
12345 6789 ABCD
6) The basic code consists of nine digits, which can
be extended by adding four more digits.
7) The first nine are intended to convey both design
and manufacturing data.
8) The interpretation of the first nine digits is defined.
9) The first five digits, 12345 are called the form
code. This describes the primary design attributes
of the part. Such as external shape (For example,
rotational vs rectangular) and machined features
(for example, holes, threads, gear teeth, and so
forth)
10) The next four digits ,6789, constitute the
supplementary code , which indicates some of the
attributes that would be useful in manufacturing.
(for example, dimensions, work material, starting
shape, and accuracy.)
 11) The extra four digits ,ABCD, are referred to as
secondary code and are intended to identify the
production operation type and sequence.

MI CLASS:
1) The MICLASS ( Metal Institute Classification)was
developed by organisation for Applied Scientific
Research in Netherlands in 1960s and 1970s to
develop a system for both design and manufacture
needs for OIR (Organisation for Industrial
Research).
2) The various functions MICLASS was developed
for are
• Standardise engineering drawings
o Retrieve drawings based on classification
o Standardise process routing
o Automate process planning
3) MICLASS is an expandable hybrid code system of
up to 30 digits, while the first 12 digits have been
standardised
1 2 3 4 5 6 7 8 9 10 11 12
Basic form primary dimensions
tolerance material
 4) The system can be enlarged to thirty digits to
cover any classification attribute desired by the
user.
5) Computer software is provided by OIR for
deriving the part code after the user goes through
series of questions and answers them interactively.
6) The built in logic is in the form of decision tree.
13 14 15 16 17 18 19 20 21
lot size secondary dimension general mfg
process supplementary design and mfg
22 23 24

Coding system:
1) This is a code developed by the Japan Society
for the promotion of the Machine industry
(JSPMI) and was presented first in 1976.
2) Manufacturing Data Systems, Incorporated
(MDSI) has developed this classification and
coding system called CODE.
It is an 8 digit hybrid code used primarily to classify and
code mechanical piece parts.
5 Discuss in detail the FMS design criteria, Modeling
and simulation of FMS.
 FMS design criteria, having analysed a few of
designer problems. Let us see what the major design
criteria are in the case of FMS.
1) The FMS data processing system should be linked to
the company’s overall distribution information
management system, incorporating the CAD/CAM
data bases, and should be used not only as large and
fast information centre, but also a decision making
machine operating in real time.
2) Both the mechanical and electrical hardware has to
be modular and compatible, otherwise further
developments will have higher capital investment
effects, or be impossible.
3) The control software, the production planning
system, the stock control system, the FMS part
programming aids and the data base management
system (DBMS)should also be modular to provide
potential for further development and relatively
simple software debugging.
4) the FMS machining stations should provide
automated tools and parts changing facilities and the
necessary standard interface to other material
handling systems. Other FMS stations must also be
 capable of integration with the all over data
processing and material handling system.
5) The material storage system should communicate
with the material handling and data processing
system. It should be able to store rough materials,
semi finished and finished work pieces, tools fixtures
adn clamping devices and the other necessary
components, together with separate parts.
6) Sensor based diagnostic feedback system should be
operate in each cell providing a real time facility,
analysis and error recovery in case of brake downs.
Each cell should be able t report the failures
automatically to one of the integrated nodes of the
computer network.
7) The part programme and scheduling system should
enable the FMS part programmers alternative routes
of manufacturing, inspection and assembly.

Simulation of FMS:
1) The reason for using simulation is that direct
experimentation with FMS is impossible either
because it does not yet exist or else it is too
expensive and time consuming or even dangerous
2) Simulation techniques used for complex materials
handling and machining systems identify queue
build –ups in the buffer stores or in the automated
ware house their by indicating the required
capacities of various FMS modules.
3) In some cases, the capacities of individual pieces of
equipment may seen adequate consider that as a
single system but when integrated into FMS they
can produce bottle like points. Simulation should
avoids such occurrence.
4) The FMS simulation should be dynamic because the
system behaviour and the results are time
dependent. Parameters which build-up FMS
simulation models are either deterministic or
stochastic.
5) Stochastic variables such as material failures,
machine break downs, tool breakages, the demand
for spare parts etc..., rely on probability calculations.
However, statistical relationships can often be found
and at the vary least, their minimum and maximum
values and an experimental or assumed distribution
can be determined
The FMS simulation model is always an abstract and
simplified representation of real system. It is therefore,
important that is sufficiently complete.
 UNIT 3&4

1) Describe the Data base management systems and

their application in FMS.

A data base can be defined as a collection of data in a

single location designed to be used by different
programmers for a variety of applications. The term
database denotes a common base of data collection
designed to be used by different programmers. More
specifically it is a collection of logically related data
stored together in a set of files intended to serve one or
more applications in an optimal fashion. Data are stored
such that they are independent of the data. A database
must also have a predetermined structure and
organization suitable for access, interpretation, or
processing either manually or automatically. A database
not only stores the data but also provides several ways to
view the data depending upon the needs of the user.
There are several classifications of data.
i. Physical data: These are data stored in the
computer’s storage device. The volume of data
required by a manufacturing company is so large that
secondary storage devices such as hard discs, tapes,
 CD-ROMs, and other digital storage devices of
several gigabyte capacities will be used.
ii. Logical data: This indicates how a user views the
physical data. The distinction between the physical
data and the corresponding logical view is that the
user conceptualizes certain meaningful relationships
among the physical data elements. For example, we
may have a set of items and quantities recorded in
files. The logical view or interpretation of these sets
of data can be that the items represent components
available in stores and that the quantities recorded
correspond to their inventory.
iii. Data independence: Database management systems
(DBMS) are used by the users to manage the
physical data. DBMS makes a distinction between
the two namely, the user and the physical data.
Changes in the organization of physical data and or
in the storage device parameters are absorbed by
DBMS and therefore do not affect the user or more
accurately, the application program. This flexibility
is absent in the traditional file systems.

Objectives of Database
1. A database serves the following objectives:
2. • Reduce or eliminate redundant data
3. • Integrate existing data
4. • Provide security
5. • Share data among users
6. • Incorporate changes quickly and effectively
7. • Exercise effective control over data
8. • Simplify the method of using data
9. • Reduce the cost of storage and retrieval of data
10. • Improve accuracy and integrity of data
Applications of DBMS in FMS:
1. FMS tooling system
2. CNC & DNC part program not only for machining
but for all other necessary operations, such as
inspection, robotized welding, etc…
3. Information required by the FMS process control
system.
 2) Describe what distributed system is and discuss in
detail the components of a distributed DBMS in
FMS.

A distributed system is a network that consists of

autonomous computers that are connected using
a distribution middleware. They help in sharing
different resources and capabilities to provide users
with a single and integrated coherent network
Distributed Database Management System (DDBMS)
is a type of DBMS which manages a number of
databases hoisted at diversified locations and
interconnected through a computer network. It provides
mechanisms so that the distribution remains oblivious
to the users, who perceive the database as a single
database.

DDBMS components:
1. Computer workstations (sites or nodes) that form the
network system.
2. Network hardware and software components that reside
in each workstation.
3. Communications media that carry the data from one
workstation to another.
4. The transaction processor (TP), which is the software
component found in each computer that requests data.
The transaction processor receives and processes the
application’s data requests (remote and local). The TP
is also known as the application processor (AP) or the
transaction manager (TM).

5. The data processor (DP). which is the software

component residing On each computer that stores
and retrieves data located at the site. The DP is also
known as the data manager (DM). A data processor
may even be a centralized DBMS.

The protocols determine how the distributed database

system will:
• Interface with the network to transport data and
commands between
data processors (DPs) and transaction processors (TPs).
• Synchronize all data received from DPs (TP side) and
route retrieved
data to the appropriate TPs (DP side).
• Ensure common database functions in a distributed
system . Such
functions include security, concurrency control,
backup, and recovery.
ADVANTAGES OF DDBMS:
a. Faster data access
b. Faster data processing
c. Growth facilitation
d. Improved communications
e. Reduced operating costs
f. User-friendly interface
g. Less danger of a single-point failure
h. Processor independence
i. Data are located near “greatest demand” site
DISADVANTAGES OF DDBMS:
a) Complexity of management and control
b) Security
c) Lack of standards
d) Increased storage requirements
e) Increased training cost

4) Explain working of automated guide vehicles and

benefits of using AGV’s in FMS?
Automated guided vehicles are vehicles that are equipped
with automated guidance systems and are capable of
following prescribed path
These are driverless vehicles that are programmed to
follow a guide path
There are different navigation system that is used bu
AGV’s
 Wired navigation:
 Guide tape navigation
 Laser target navigation
 Wired navigation

The wired sensor is placed on bottom of AGV’s and

is placed facing the ground.A slot is cut in ground
and a wire is placed approximately 1 inch below the
ground.The sensor detect the radio frequency being
transmitted from wire and follows it.
 Guide tape navigation:
The AGV’s use magnetic tape for guide path
The AGV’s is fitted with appropriate guide sensors to
follow path of tape. It is considered a passive system
since it does not require the guide medium to be
energized as wire does.
 Laser target navigation:
The AGV’s carries a laser transmitter and receiver on
rotating turret
The laser is sent off then received again the angle and
distance are automatically calculated and stored into
AGV’s memory. The AGV’s has map stored in
memory and can correct its position based on errors
between expected and received measurements

Types of AGV’s:
 Driverless trains:
• It consists of a towing vehicle that pulls one or
more trailers to form a train.
• This type is applicable in moving heavy pay
loads over large distance in warehouses or
 factories with or without intermediate pickup and
drop off points along the route.
• It consists of 5-10 trailers and is an efficient
transport system.

 AGV’s pallet trucks:

• Pallet trucks are used to move palletized loads
along predetermined routes.
• The capacity of an AGV pallet truck ranges up
to several thousand kilograms and some are
capable of handling two pallets.
• It is achieved for vertical movement to reach
loads on racks and shelves.

 Unit load carriers:

• These are used to move unit loads from one
station to another.
• It is also used for automatic loading and
unloading of pallets by means of rollers.
• Load capacity ranges up to 250 kg or less
Especially these vehicles are designed to move
small loads.
 5) Discuss in detail the different applications of
industrial robots in FMS.
Robots are mainly used in three types of applications:
1. material handling;
2. processing operations; and
3. assembly and inspection.
Material handling
In material handling, robots move parts between various
locations by means of a gripper type end effector.
Material handling activity can be sub divided into
material transfer and machine loading and/or unloading.
 Processing Operations:
In processing operations, the robot performs some
processing activities such as grinding, milling, etc. on the
workpart. The end effector is equipped with the
specialized tool required for the respective process.

Assembly and inspection:

Assembly operation typically include components to

bluid up the product and to perform material handling
operations
 Inspection operations are perform by industrial robots
can usually divided into three following techquines
a. By using feeler guage
b. By using robotic vision
c. By involving the use of optics and ligh

9)& 7) Explain about FMS clamping devices and fixtures

database and mating surface description method for
automated design and robotized assembly?

FMS CLAMPING DEVICES AND FIXTURE

DATABASE

The task is to design a data structure capable of

describing, storage the data related to elements,
subassemblies of fixtures and clamping devices and the
pallet itself.

It must incorporate graphics information and mating

surfaces description for each surface element involved.
1-fixture element identifier
2-graph code, pointing to graphic data base where all
other important data can be formed
3-mating code for describing mating surface for robotized
assembly
4-length(breadth )
5- length (height)
6- length (length)
7 & 8 - adjustable values when using element, elements in
sub assembly.
Errors when loading pallet onto machine tools should also
be handled and stored so that they can be used by FMS
control system for error compensation purpose.
The fixture and clamping device data base has to serve the
stack control and order processing system
Achieving of such data base is not easy task
One solution for defining and storing base elements,
pallets, supporting elements, positioning elements,
guiding elements, fastening elements, sub assemblies and
others.
Mating:
when working on clamping device and fixture design with
cad facilities or when assembling such components
automatically, it is essential to check which surfaces can
be mounted together either by viewing them in a graphics
screen or by trying them out on a robot. Such intelligent
tasks are solved by human operator within seconds. It use
however very difficult to teach cad system or robots how
to solve this kind of task.
One way is to use a coding system where by a code is
allocated to all those surfaces which could be mates.
These codes are stored in the database in each Element
description record in the form of a string or a Boolean
matrix. When the designer decides to mount more fixtures
elements on each other, for example, the system can
automatically check whether or not the codes match each
other L, can send a warning message to the designer to
avoid unrealistic designs. Some typical fixtures elements
are those surfaces coded as mating.
It is not difficult to implement such a coding system. if
the FMS is using a properly standardized set fixture and
clamping devices elements and sub assemblies, coding
does take time and cannot be easily automated.
A more elegant solution to this problem is now becoming
possible with wider application of solid graphics design
packages which capable of checking any interference of
volumes. Once all components tools clamping devices
and fixtures assemblies are designed using such solid
modeling systems the mating surface description will be
provided automatically this rendering coding work
unnecessary an experimental design of a fixture assembly
using solid modeling system.

8) Explain about computer network topologies used

in FMS and the seven layer network protocol
model.

COMPUTER NETWORK TOPOLOGY :

Computer network topology is the way various

components of a network (like nodes, links,
peripherals, etc) are arranged. Network topologies
define the layout, virtual shape or structure of
network, not only physically but also logically. The
way in which different systems and nodes are
connected and communicate with each other is
determined by topology of the network.
 Topology can be physical or logical

• Physical Topology is the physical layout of nodes,

workstations and cables in the network.
• Logical topology is the way information flows
between different components.

Types of physical network topologies

• Bus Topology:
In the bus topology, the computers are connected
through a common communication media. A special
type of central wire is used as communication media.
This central wire is called Bus. The computer are
attached through the bus the ends of the bus are
closed with the terminator .The terminators are used

to absorb signals.
• Star Topology:
The star topology uses a separate cable for each work
station. The cable connects the work station to a
central device typically a HUB. The configuration
provides a more reliable network that is easily
expended. With star there is no central point of
failure in the cable .

• Ring Topology:
Every computer is connected to the next computer in
the ring and each transmits what it receives from the
previous computer. The messages flow around the
ring in one direction.

• Mesh Topology:
A mesh network or mesh topology uses separate
cable to connect each device to every other device on
the network, providing a straight communication
path.
• Tree Topology
A tree topology is a special type of structure in which
many connected elements are arranged like the
branches of a tree.

• Hybrid Topology :
Hybrid networks use a combination of any two or
more topologies in such a way that the resulting
network does not exhibit one of the standard
topologies (e.g., bus, star, ring, etc.).
 The seven layers are:
 Application Layer
 Presentation Layer Session Layer
 Transport Layer
 Network Layer
 Link Layer
 Physical Layer

Basic functionality of each of them is as follows:

7. Application Layer: Provides Applications with
access to network services.

6. Presentation Layer: Determines the format used to

exchange data among networked computers.

5. Session Layer: Allows two applications to

establish, use and disconnect a connection between
them called a session. Provides for name recognition
and additional functions like security, which are
needed to allow applications to communicate over the
network.

4. Transport Layer: Ensures that data is delivered error

free, in sequence and with no loss, duplications or
 corruption. This layer also repackages data by
assembling long messages into lots of smaller
messages for sending, and repackaging the smaller
messages into the original larger message at the
receiving end.

3. Network Layer: This is responsible for addressing

messages and data so they are sent to the correct
destination, and for translating logical addresses and
names (like a machine name FLAME) into physical
addresses. This layer is also responsible for finding a
path through the network to the destination computer.

2. Data-Link Layer: This layer takes the data frames

or messages from the Network Layer and provides
for their actual transmission. At the receiving
computer, this layer receives the incoming data and
sends it to the network layer for handling. The Data-
Link Layer also provides error-free delivery of data
between the two computers by using the physical
layer.
1. Physical Layer: Controls the transmission of the
actual data onto the network cable. It defines the
 electrical signals, line states and encoding of the data
and the connector types used.
UNIT 5
1) With the help of neat sketch, discuss different FMS
layout configuration and applications of FMS?
TYPES OF F.M.S LAYOUT:

1. PROGRESSIVE OR LINE TYPE

2. LOOP TYPE
3. LADDER TYPE
4. OPEN FIELD TYPE
5. ROBOT CENTERED TYPE
1. PROGESSIVE OR LINE TYPE

The machines and handling system are arranged in a

line.
• It is most appropriate for a system in which the part
progress from one workstation to the next in a
welldefined
sequence with no back flow.
• The operation of this type of system is very similar to
transfer type.
• Work always flows in unidirectional path as shown in
Figure.
• Straight line flow, well-defined processing sequence
similar for all work units
• Work flow is from left to right through the same
Workstations.
2. LOOP TYPE:

• The parts usually move in one direction around the

loop, with the capability to stop and be transferred
to any station.
• The loading and unloading stations are typically
located at one end of the loop.
• One direction flow, but variations in processing
sequence possible for different part types.
• Secondary handling system at each workstation.
• Parts can skip stations for flexibility
• Used for large part sizes
• Best for long process times.
4. LADDER TYPE:

• The loading and unloading station is typically located at

the same end.
• The sequence to the operation/transfer of parts from
one machine tool to another is in the form of ladder steps.
• Loop with rungs to allow greater variation in processing sequence
• Parts can be sent to any machine in any sequence
• Parts not limited to particular part families.

5. OPEN FIELD TYPE:

• The open field layout is also an adoption of the loop
configuration.
• The open field layout consists of loops and ladders
organized to achieve the desired processing requirements.
This is used for the processing of a large family of parts.
The number of different machines may be limited, and the
parts are routed to different workstations depending on
availability of machines.
• A possible arrangement of this layout is shown in fig
6. ROBOT CENTERD TYPE:

• If a handling robot is used in a Flexible manufacturing

system cell , the machines are laid out in a circle, such a
layout is called circular layout.
 3) Describe the importance of part cleaning in
automated manufacturing and wash station types and
its operations?

 It plays important role in FMS.

 Wash stations are automated high technology
washing machine that uses high pressure coolant
to removing dirt, and chips, oil from part pallet
and fixtures
Classification of wash stations
 Batch type
 In line type
Batch type:

 Batch washers handle work piece of thousands

of pounds and 72 inches large cubes.
 It is used flow to mid volume application to
provide clean work piece for inspection,
assembly, or further process.
In line type:

 It is used for high volume products for high

and repair production rate.
 Work piece is located at one end of system,
the work piece are cleaned as they pass
through machine and removed at other end.
  Separate roller conveyors are added at load
and unload station for interfacing.
 Multi stages can be added for running rust
preventions or blow dry.
Process:
Both batch and in line type used spray nozzle
which is to be sized, located and directed to clean external
and internal area of work piece
Both batch and inline require significant volume and
pressure for complete flushing of chips from work piece,
fixtures and pallets. The high pressure wash station
operate at 28 bars or even more.
Blow of is another important wash station option. It
reduces drying time of the washed work piece by blowing
of the excess coolant or wash solution. Some wash
stations uses convector heated air blow off generated by
gas, steam, or electrically to speed up blow off and to
reduce moisture. In line type have their Individual best
solution storage tank equipped for chip recovery coolant
recirculation, where as the batch type the chip and coolant
blow directly into flume system and through to be
circulate back into central coolant storage tank.
 A sludge conveyor can be used on any type of wash
station.
Importance of part cleaning:
 Cleaning To perform past machining operation
but automated process add value.
 Part must be cleaning before they can attempt to
be accurately inspection, assembly or stocked.
4) Explain in detail the components and operation of
flexible machining cell and flexible assembly
system?