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Flexible Manufacturing Systems

(FMS)
by Ed Red
an automated, mid-volume, mid-variety, central computer-controlled
manufacturing system Nanua Singh, Computer-Integrated Design and
Manufacturing, John Wiley & Sons, 1996
References:
1. Nanua Singh, Computer-Integrated Design and Manufacturing, John Wiley &
Sons, 1996
2. Mikell Groover, Automated Production Systems and Computer-Integrated
Manufacturing, Prentice-Hall, 2nd edition, 2001
ME 482 - Manufacturing Systems

Objectives
Toreviewmodernflexiblemanufacturingsystems(FMS):
Grouptechnology(GT)
Manufacturingcells
Automatedparthandlingequipment(AGVs,etc.)
Controlsoftware
Analysismodels
Toconsiderapplicationconditions(studentpresentations)
Totestunderstandingofthematerialpresented

ME 482 - Manufacturing Systems

FMS characteristics
A manufacturing cell used to implement group technology
(GT)
robotsmachinetools
Independent machines performing multiple operations and
having automated tool interchange capabilities
Automated material-handling between stations (move parts
between machines and fixturing stations)
Hierarchical computer control architectures
Often include CMM, inspection and part washing devices
ME 482 - Manufacturing Systems
ME 482 - Manufacturing Systems

GTrequirement:
Partscanbegroupedintopartfamilies!
Similarmanufacturingprocess
requirements(manufacturing
attributes),butwithdifferent
designattributes
Turned,drilled,milled..

Cylindrical,hole,thread,chamfer,
tolerance,dimension..
ME 482 - Manufacturing Systems

GTrequirement:Productionmachines
canbearrangedintocells!

Grouptechnologylayout

Processtypeplantlayoutdashed
linesindicatesdepartments!
ME 482 - Manufacturing Systems

GTpartclassificationandcoding
Partsdistinguished(classified)bydesignattributesand
manufacturingattributes.
Partdifferentiatedbycodingmethodsfor

designretrieval
automatedprocessplanning
machinecelldesign

Basicstructure
ofOpitzcoding
system

ME 482 - Manufacturing Systems

GTOpitzformcode

ME 482 - Manufacturing Systems

GTexample
Forthepartshowndeterminetheform
codeintheOpitzpartsclassificationand
codingsystem..
Solution:
WithreferencetoFigure15.6,thefivedigitcodeisdevelopedasfollows:
Lengthtodiameterratio,L/D=1.5
Digit1=1
Externalshape:steppedonbothendswithscrewthreadononeendDigit2=5
Internalshape:partcontainsathroughhole
Digit3=1
Planesurfacemachining:none
Digit4=O
Auxiliaryholes,gearteeth,etc.:none
Digit5=O
ThepartssformcodeintheOpitzsystemis
ME 482 - Manufacturing Systems

15100

FMS
HighlyautomatedGTmanufacturingcell,consistingofagroupof
processingworkstations,interconnectedbyanautomatedmaterial
handlingandstoragesystem,andcontrolledbyadistributed
computersystem(Grooverdefn)
Whatdoesflexiblemean?
1.Canidentifyandoperateondifferentpart/productstyles
2.Quickchangeoverofprocess/operatinginstructions
3.Quickchangeoverofphysicalsetup
FMSoperations:
1.Processingoperations,or
2.Assemblyoperations
ME 482 - Manufacturing Systems

FMSautomatedparthandling

Conveyo
r
AGV
AS/RS
ME 482 - Manufacturing Systems

Singlemachine

FMStypeDistinguishbynumberofmachines
1.

Singlemachinecell*canoperateinbatchmode(sequentiallyprocess
partsofasinglestyleindefinedlotsizes) orflexiblemode(process
differentpartstylesandadapttodifferentproductionschedules)

*Noerrorrecoveryifmachinebreaksdownsinceproductionwillstop
2.

Flexiblemachinecell(FMC)consistsof23machinesplusparthandling
FlexibleManufacturingCell
equipmentandlimitedpartstorage.simultaneousproductionofdifferent
partsanderrorrecovery.

3.

Flexiblemanufacturingsystemconsistsof4ormoreworkstationsconnected
bycommonparthandlingsystemanddistributedcomputersystem.Other
stationsmaysupporttheactivities,suchasacoordinatemeasuringmachine
(CMM)orwashingstation..simultaneousproductionofdifferentpartsand
errorrecovery.

ME 482 - Manufacturing Systems

Looplayout

FMSlayouts

Ladder
Openfield
layout
layout
Inlinelayout

1. Inlinelayout
2. Looplayout(secondaryparthandlingsystems)
3. Ladderlayout
4. Openfieldlayout

ME 482 - Manufacturing Systems

FMScomputercontrolsystem
1.

Workstationcontrol

2.

Supervisorycontrolamongworkstations(workstationcoordination)

3.

Productioncontrol(partrateandmix)

4.

Trafficcontrol(managepartdeliverysystems)

5.

Shuttlecontrol(parthandlingbetweenmachineandprimaryhandling
system)

6.

Workpiecemonitoring(statusofvarioussystems)

7.

Toolcontrol(locationandtoollife)

8.

Performancemonitoringandreporting(reportoperationaldata)

9.

Diagnostics(identifysourcesoferror,preventivemaintenance)

ME 482 - Manufacturing Systems

FMSdesignissues
1. Workstationtypes
2. VariationsinprocessroutingsandFMSlayout(increasing
productvarietymoveyoufrominlinelayoutstoopenfieldlayouts)

3. Materialhandlingsystem
4. Workinprocess(WIP)andstoragecapacity(FMSstorage
capacitymustbecompatiblewithWIP)

5. Tooling(numbersandtypesoftoolsateachstation,toolduplication)
6. Workpiecemonitoring(statusofvarioussystems)
7. Palletfixtures(numbersinsystem,flexibility)
ME 482 - Manufacturing Systems

FMSoperationalissues
1. Scheduling(masterproductionschedule)anddispatching
(launchingofpartsintothesystem)

2. Machineloading
3. Partrouting
4. Partgrouping
5. Toolmanagement
6. Palletandfixtureallocation
ME 482 - Manufacturing Systems

FMSquantitativeanalysis
Fourmodels:
1. Deterministicmodels(dontincludeoperatingcharacteristics,

includingqueues,thatmaydegradeperformance,thusarealittleoptimistic)

2. Queueingmodels
3. Discreteeventsimulation
(simulation)
DiscreteeventsimulationUsedtomodelmanufacturingcell
4.

DiscreteeventsimulationUsedtomodelmanufacturingcell
ormaterialhandlingsystem,aseventsoccuratdiscrete
Heuristicapproaches
momentsintimeandaffectthestatusandperformanceofthe
system,e.g.,partsarrivingatthemachine.

ME 482 - Manufacturing Systems

FMSbottleneckmodel
Bottleneckoutputofaproductionsystemhasanupper
limit,givenanupperboundsontheproductmixflowing
throughthesystem
IntroducethebottleneckmodeltoprovideinitialFMS
parameterestimates
Introduceterminologyandsymbols
Demonstrateonexamples
ME 482 - Manufacturing Systems

FMSterminologyandsymbols
Partmix
pj=fractionofsystemoutputthatisofstylej
P=totalnumberofpartstylesmadeinFMSingiven
timeperiod
P

p j 1.0
jj11

Workstationsandservers(workstationthatcanduplicateprocess
capabilitiesofanotherworkstation)

n=numberofworkstations
si=numberofserversateachstationi(i=1,2,n,andwe

includetheload/unloadstationasanFMSworkstation)
ME 482 - Manufacturing Systems

FMSterminologyandsymbols
Processroutingforeachpartorproduct,defines
operationalsequence,assignedworkstations,and
associatedprocesstimes,includingloadingand
unloadingtimes
tijk=processingtimeforapart/productinagiven
server,notincludingwaitingtime,where
i=stationi
j=part/productj
k=particularoperationinprocessroutingsequenceofoperations
ME 482 - Manufacturing Systems

FMSterminologyandsymbols
Workhandlingsystemmaterialhandlingsystemis
consideredaspecialworkstationanddesignateitas
stationn+1;then
sn+1=numberofcarriers(servers)inhandlingsystem
(conveyors,carts,AGVs,etc.)
Transporttime
tn+1=meantransporttimerequiredtomoveapartfrom
oneworkstationtothenextstationintheprocess
routing

ME 482 - Manufacturing Systems

FMSterminologyandsymbols
Operationfrequencyexpectednumberoftimesagiven
operationintheprocessroutingisperformedforeach
workunit,e.g,aninspectionofadimension
fijk=operationfrequencyforoperationkforpartjat
stationi
Thisparameter(fijk)isusuallyonesinceeachoperationis
usuallyperformedonceonadifferentworkstation!
Exceptionsmightexistforpartinspectionstations.Notethat
therearemanyzerovaluessincenotallpartsandoperations
gothrougheverymachine.
ME 482 - Manufacturing Systems

FMSquantitativemodels

Averageworkload(Li)meanoperationaltimeofstationiperpart,
calculatedas(unitsareinmin.)

Li=jktijkfijkpj

i=stationi
j=part/productj(processrouting)
k=operationinroutingsequence

Workloadofthehandlingsystemisthemeantransporttime(tn+1)
multipliedbytheaveragenumberoftransportstocompletepart
process.
Averagenumberoftransports(nt)isthemeannumberofoperationsin
theprocessroutingminus1:

nt=ijkfijkpj1
WorkloadofhandlingsystemisLn+1=nttn+1

ME 482 - Manufacturing Systems

difficultinterpretation!

FMSexampledeterminent
Simplesystemhasmachiningstationandload/unloadstation.
Ifsystemprocessessinglepart,determinen t.
Onepart(j=1)so
p1=1.0

Load

Unload

fi1k=1.0
3routingoperations:loadpartat1>routetostation2formachining>
returntostation1forunloading
Then
nt=1=2
loadmachineat2unload
ME 482 - Manufacturing Systems

FMSquantitativemodels
FMSproductionisusuallyconstrainedbyabottleneck
station(considerthehandlingstationalso),whichisthe
stationiwiththehighestworkloadperserverasmeasured
byLi/si.Designatei=bthebottleneckstationandcalculate
themaximumproductionratefrom
Rmax=sb/Lb

(numberofpartspertimeforstationb)

Note:Thisisvalidevenforpartsnotpassingthroughthebottleneckstation
becausethepartmixratiosarefixedandlimitedbythebottleneckstation.

Individualproductionratesare
Rj=pjsb/Lb
ME 482 - Manufacturing Systems

FMSquantitativemodels

Meanworkstationutilizationistheproportionoftimethatstationsare
activeasdeterminedfrom
Ui=RmaxLi/si(Ub=1)
Theaveragestationutilizationis
U=iUi/(n+1)
TheoverallFMSutilizationisweightedbythenumberofserversat
eachstation(notincludinghandlingstations)
Us=isiUi/isi
Numberofbusyserversatotherthanthebottleneckstation
determinedfrom
Bi=RmaxLi
ME 482 - Manufacturing Systems

FMSexample(fromGroover)
AnFMSwith4stationsisdesignedsothatstation1isload/unload,station2
performsmillingoperationswith3servers,station3performsdrillingoperations
with2servers,whilestation4performspartinspectiononpartsamples.Thepart
handlingsystemhasameantransporttimeof3.5minand2carriers.TheFMS
producespartsA,B,C,andDwithpartmixfractionsandroutingsshowninthe
table.
Determine:
1.FMSmaxproductionrate
2.Productionrateofeachpart
3.Eachstationutilization
4.OverallFMSutilization
ME 482 - Manufacturing Systems

FMSexamplesolution
First,determinebottleneckstationbycalculatingworkloads:
L1=(4+2)(1.0)(0.1+0.2+0.3+0.4)=6.0min.
L2=(20)(1.0)(0.1)+25(1.0)(0.2)+(30)(1.0)(0.4)=19.0min.
Similarly,

L3=14.4min.;

L4=4.0min.

nt=(4.51)(0.1)+(5.21)(0.2)+(3.51)(0.3)+(3.3331)(0.4)=2.783
L5=(2.873)(3.5)=10.06min.
parthandlingstation!
NowcalculateLi/sitoidentifybottleneck:
L1/s1=6.0/1=6.0
L2/s2=19.0/3=6.333
L3/s3=14.4/2=7.2thebottleneck!Rmax=2/14.4=0.1389pc/min.(8.333
pc/hr)
L4/s4=4.0/1=4.0L5/s5=10.06/2=5.03
ME 482 - Manufacturing Systems

FMSexamplesolution
Productionrateforeachpart:
RA=8.333(0.1)=0.8333pc/hr.
RB=8.333(0.2)=1.667pc/hr.
RC=8.333(0.3)=2.500pc/hr.
RD=8.333(0.4)=3.333pc/hr.
Stationutilization:
U1=(6.0/1)(0.1389)=0.8333
U2=(19.0/3)(0.1389)=0.879
U3=(14.4/2)(0.1389)=1.0
U4=(4.0/1)(0.1389)=0.555
U5=(10.06/2)(0.1389)=0.699

(83.33%)

OverallFMSutilization(excludeparthandling):
U1=[1(0.833)+3(0.879)+2(1.0)+1(0.555)]/7=0.861
ME 482 - Manufacturing Systems

(86.1%)

FMSfollowonexample(fromGroover)
DeterminetheproductionrateofpartDthatwillincreasetheutilization
ofstation2to100%.NotethatthisispossiblesincepartDdoesnotgo
throughstation3,thebottleneckstation,andstation2isunderutilized.
Solution:
SetU2=100%andsolveU2=1.0=L2(0.1389)/3togetL2=21.6min.as
comparedto19.0min.previously.
PartsA,BandDareprocessedbystation2.PartsAandBare
constrainedintheirproductionratebytheotherstations,butnotpartD
whichisonlyprocessedbystation2.
Wefirstdeterminetheportionofthestation2workloadtakenupbyA
andB:
L2(byA+B)=20(0.1)(1.0)+25(0.2)(1.0)=7.0min.
ME 482 - Manufacturing Systems

FMSfollowonexample
At100%utilizationtheworkloadforpartDincreasesto21.67.0=14.6
min.,whereitwas19.07.0=12.0min.at87.9%utilization.Theproduction
rateforpartDisnowincreasedto14.6(3.333)/12.0=4.055pc/hr.
NotethatincreasingthethroughputforpartDwillchangethepartmixratios
previouslypresented.

ME 482 - Manufacturing Systems

Optimizingoperationsallocationinan
FMSwithnegligiblesetup
Soundfamiliar?

Twocriteria:
productionofpartswithminimumcost
productionofpartsatmaxproductionrate
Define:

Kparttypeshavingdemanddk

(k=1,......K)

Mmachinetypeseachhavingcapacitybm

(m=1,.....M)

Jkoperationsperformedonparttypek

(j=1,.......Jk)

ckjm=unitprocessingcosttoperformjthoperationonkthpart
onmthmachine;else,setthecosttoinfinity(sethigh)
tkjm=unitprocessingtimetoperformjthoperationonkthpart
onmthmachine;else,setthetimetoinfinity(sethigh)

ME 482 - Manufacturing Systems

Optimizingoperationsallocationin
anFMSwithnegligiblesetup
Defineflexibilityfactor,akljm:
Assumeoperationscanbeperformedonalternativemachines.Partcan
bemanufacturedalonganumberofroutes.Forexample,ifaparthas
threeoperationsandifthefirst,second,andthirdoperationscanbe
performedas:
operation1ontwomachines
operation2onthreemachines
operation3ontwomachines
thenasetofalternativeprocessplans(lL,whereListhetotal
numberofalternativeplans)wouldinclude2x3x2=12possible
processingroutes.Define
akljm=1ifinplanlthejthoperationonthekthpartisperformedon
th
ME 482 - Manufacturing
Systems
them
machine;else,setthefactorto0

Optimizingoperationsallocationin
anFMSwithnegligiblesetup
Minimumcosttomanufactureallparts:
MinimizeZ1= kljmakljmckjmXkl

Linearprogramming

whereZ1istheobjectivefunctionandXklisadecisionvariablerepresenting
thenumberofunitsofpartktobeprocessedusingplanl.
Constraints:
Demandforpartsmustbemet:

lXkldk

Cannotexceedmachinecapacity: kljakljmtkjmXklbm
Positivenumberofunitsproduced: Xkl0k,l
ME 482 - Manufacturing Systems

Optimizingoperationsallocationinan
FMSwithnegligiblesetup
Maximizethroughput(minimizetotalprocesstimeforparts):
MinimizeobjectivefunctionZ2= kljmakljmtkjmXkl
Constraints:
Demandforpartsmustbemet:

lXkldk

Cannotexceedmachinecapacity: kljakljmtkjmXklbm
Positivenumberofunitsproduced: Xkl0k,l

ME 482 - Manufacturing Systems

Optimizingoperationsallocationin
anFMSwithnegligiblesetup
Balanceworkloadonmachines(minimizethemaximumoftheprocesstimes):
MinimizeobjectivefunctionZ3=maximum{ kljmakljmtkjmXkl}

Constraints:

Minimizedmax>otherworkloads: Z3 kljmakljmtkjmXkl0m
Demandforpartsmustbemet:

lXkldk

Cannotexceedmachinecapacity: kljakljmtkjmXklbm
Positivenumberofunitsproduced: Xkl0k,l
ME 482 - Manufacturing Systems

Linearprogrammingexample
Considerthemanufactureof5parttypeson4machinetypes,eachpart
requiringseveraloperations.Table12.18listthepertinentdata.Developa
productionplanfor:1)mincostmodel;2)maxthroughput(minprocessing
time);and3)workloadbalancing.

ME 482 - Manufacturing Systems

Linearprogrammingexample
The3modelsweresolvedusingLINDO,alinearprogrammingpackage,
withtheresultsshowninTable12.19.Thetableshowsthatpartscanbe
producedthroughanumberofalternativeprocessplans.Anothertable(next
slide)canbegeneratedtoshowthemachineloadingforvariousoperations
allocationstrategies.

ME 482 - Manufacturing Systems

Linearprogrammingexample
Notethatallthreemodelsresultin100%utilizationofmachinesm 2andm3,
makingthesebottleneckmachines.Considermachinem 1.Itsresource
utilizationforthe3modelsare2400,2400,and2045unitsoftime,
respectively.Thisinformationisusefulforproductionschedulingandalso
forpreventivemaintenance.

ME 482 - Manufacturing Systems

Tocalculatethese
valuessimplymultiply
alltheoperationson
eachmachine(each
partthroughthe
machineisan
operation)bythetime
requiredforeach
operationasgivenin
Table12.18.

FMS

Whathavewelearned?

ME 482 - Manufacturing Systems

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