UNIVERSITI TEKNOLOGI MARA

FACULTY OF MECHANICAL ENGINEERING

Computer Integrated Manufacturing: Flexible

Manufacturing & Material Handling System

CHAPTER 5:
5.1 Machine Centre
5.2 Flexible manufacturing cells & systems
5.3 Material flow & handling systems
5.4 Storage systems

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Chapter 19:

Where to Apply FMS Technology

The plant presently either:

Produces parts in batches or
Uses manned GT cells and management wants to
automate the cells
It must be possible to group a portion of the parts made in
the plant into part families
The part similarities allow them to be processed on
the FMS workstations
Parts and products are in the mid-volume, mid-variety
production range
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Flexible Manufacturing System Defined

A highly automated GT machine cell, consisting of a group

of processing stations (usually CNC machine tools),
interconnected by an automated material handling and
storage system, and controlled by an integrated computer
system
The FMS relies on the principles of GT
No manufacturing system can produce an unlimited
range of products
An FMS is capable of producing a single part family or
a limited range of part families
Flexibility to work on mixed-model
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Types of FMS

Kinds of operations

Processing vs. assembly

Type of processing

If machining, rotational vs. non-rotational

Number of machines (workstations):

1.

2.
3.

Single machine cell (n = 1)

Flexible manufacturing cell (n = 2 or 3)
Flexible manufacturing system (n = 4 or more)
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Single-Machine Manufacturing Cell (n=1)

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A single-machine CNC machining cell (n=1)

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Flexible Manufacturing Cell

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A two-machine flexible manufacturing cell

for machining (n = 2 or 3)

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A five-machine flexible manufacturing system

for machining (n = 5)

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Features of the Three Categories

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FMS Components / Elements:

1.
2.

3.
4.

Workstations (kinds of machines) & cells

Automated material and parts handling,
storage and transport system
Computer control system
Human labor

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1. Workstations

Load and unload station(s)

Factory interface with FMS

Manual or automated
Includes communication interface with
worker to specify parts to load, fixtures
needed, etc.

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1. Workstations

CNC machine tools in a machining type

system

CNC machining centers (3 to 5 axis)

Milling machines
Turning machines

Assembly machines

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2. Material-Handling and Storage

Systems

Functions:
Random, independent movement of parts between
stations
Capability to handle a variety of part styles: prismatic
& rotational
Standard pallet fixture base
Workholding fixture can be adapted
Temporary storage
Convenient access for loading and unloading
Compatibility with computer control
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2. Material Handling Equipment

Primary handling system establishes basic FMS layout

Secondary handling system - functions:
Transfers work from primary handling system to
workstations
Position and locate part with sufficient accuracy
and repeatability for the operation
Reorient part to present correct surface for
processing
Buffer storage to maximize machine utilization
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3. Computer Control System

A computer system is interfaced to all

elements / components.
Categories of functions:

Workstation control
Production control
Traffic control
Tool control

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4. Human Resource

Humans are needed to manage the operations of the

system.
Functions include:
Loading raw workparts into the system
Unloading finished parts from the system
Changing and setting of tools
Performing equipment maintenance and repair
Performing NC part programming, etc.
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FMS Benefits

Increased machine utilization

Reasons:
24 hour operation likely to justify investment
Automatic tool changing
Automatic pallet changing at stations
Queues of parts at stations to maximize utilization
Dynamic scheduling of production to account for
changes in demand
Fewer machines required
Reduction in factory floor space required
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FMS Benefits

Greater responsiveness to change

Reduced inventory requirements
Different parts produced continuously rather than in
batches
Lower manufacturing lead times
Reduced labor requirements
Higher labor productivity
Opportunity for unattended production
Machines run overnight ("lights out operation")
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Storage Systems

Function to store materials (e.g., parts, work-inprocess, finished goods) for a period of time and
permit retrieval when required
Used in factories, warehouses, distribution centers,
wholesale dealerships, and retail stores
Important supply chain component
Automation available to improve efficiency

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Conventional Storage Methods

Bulk storage - storage in an open floor area

Problem: achieving proper balance between storage
density and accessibility
Rack systems - structure with racks for pallet loads
Permits vertical stacking of materials
Shelving and bins - horizontal platforms in structural
frame
Steel shelving comes in standard sizes
Finding items can be a problem
Drawer storage - entire contents of each drawer can be
viewed
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Bulk Storage

Bulk storage arrangements: (a) high-density bulk storage

provides low accessibility, (b) bulk storage with loads forming
rows and blocks for improved accessibility

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Pallet Rack System

Pallet loads placed
on racks in
multi-rack structure

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Drawer Storage

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Automated Storage Systems

Mechanized and automated storage equipment to reduce
the human resources required to operate a storage
facility
Significant investment
Level of automation varies
In mechanized systems, an operator participates in
each storage/retrieval transaction
In highly automated systems, loads are entered or
retrieved under computer control
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Objectives and Reasons for

Automating Storage Operations

To increase storage capacity

To increase storage density
To recover factory floor space currently used for WIP
To improve security and reduce pilferage
To reduce labor cost and/or increase productivity
To improve safety
To improve inventory control
To improve stock rotation
To improve customer service
To increase throughput
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Types of Automated Storage System

1.

Automated Storage/Retrieval System

(AS/RS)

2.

Rack system with mechanized or automated

crane to store/retrieve loads

Carousel Storage System

Oval conveyor system with bins to contain

individual items

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AS/RS
Unit load AS/RS
with one aisle

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CNC Machining Center with Automatic Pallet

Changer - Stores One Part (single station
manufacturing cells)
Automatic
pallet changer
integrated with
a CNC
machining
center for
manual load
and unloading
of workparts.

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Storage Capacities Greater Than

One

Machining centers:

Various designs of parts storage unit

interfaced to automatic pallet changer (or
other automated transfer mechanism)

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Storage Capacities Greater Than

One

Machining center and automatic pallet changer with pallet

holders arranged radially; parts storage capacity = 5

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Storage Capacities Greater Than

One

Machining center and in-line shuttle cart system with pallet

holders along its length; parts storage capacity = 16

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Automated Guided Vehicles (AGVs)

An Automated Guided Vehicle System (AGVS) is a

material handling system that uses independently
operated, self-propelled vehicles guided along defined
pathways in the facility floor
Types of AGV:
Driverless trains
Pallet trucks
Unit load AGVs

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Automated Guided Vehicles:

Driverless Automated Guided Train
Common
application is
moving heavy
payloads over
long distances
in warehouses
and factories
without
intermediate
stops along the
route
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Automated Guided Vehicles:

AGV Pallet Truck

Used to move
palletized loads
along predetermined
routes
Vehicle is backed
into loaded pallet by
worker; pallet is then
elevated from floor
Worker drives pallet
truck to AGV guide
path and programs
destination

Automated Guided Vehicles:

Unit Load Carrier

Used to move unit

loads from station to
station
Often equipped for
automatic
loading/unloading of
pallets and tote pans
using roller conveyors,
moving belts, or
mechanized lift
platforms

FMS: machine centres, measuring & inspection

station & AGV

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Terminologies:

Flexible manufacturing cell made flexible by using

machine centres, CNC machines, industrial robots,
handling systems, etc.
Flexible manufacturing system
Machine cell manually operated production machines
laid out in a line, L, U-shaped configuration (cellular
manufacturing). For family of parts that are similar.
Transfer line production line for mass production

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