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Fms arun.k and santhosh.k

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  • 1. www.a2zmba.com
  • 2. Flexibility
    • The capability of the manufacturing system to adapt successfully to changing environmental conditions and process requirements.
    www.a2zmba.com
  • 3. Definition of FMS
    • A flexible manufacturing system (FMS) is an arrangement of machines.... interconnected by a transport system. The transporter carries work to the machines on pallets or other interface units so that work-machine registration is accurate, rapid and automatic. A central computer controls both machines and transport system...
    • It is a computer controlled process technology suitable for producing a moderate variety of products in moderate volumes.
    www.a2zmba.com
  • 4. www.a2zmba.com
  • 5. Characteristics of an FMS
    • All products are variations of a stable basic design.
    • All products utilize the same family of components.
    • The number of components is only moderate.
    • The volume of each component is moderate.
    www.a2zmba.com
  • 6. Requirements for FMS with Automation
    • Machine Attachments
    • Computer Integrated Manufacturing (CIM)
    • Computer Aided Design (CAD)
    • Computer Aided Manufacturing (CAM)
    • Robotics and Robots
    • Group Technology
    • N/C Machines
    • Automated Quality Control Systems
    • Automatic Storage and Retrieval Systems (ASRS)
    • Automatic Identification Systems (AIS)
    • Automatic Assembly Systems
    • Automatic Process Control
    www.a2zmba.com
  • 7. Machine Attachments
    • Attachments or inexpensive add-ons to machines that reduce human effort and time required to perform operations.
    • Eg: Magazine feed attachments, quick cutting and grasping devices for lathes, strip feeders for stamping machines etc.
    www.a2zmba.com
  • 8. Numerically Controlled (N/C) Machines
    • Machines with control systems that read instructions and translate them into machine operations.
    • Eg: Lathes, boring mills, curing machines, weaving machines etc.
    www.a2zmba.com
  • 9. Robotics
    • Robot is a programmable machine that is capable of moving materials and performing routine, repetitive tasks which have manipulators and possess human like physiological characteristics.
    • Robotics is the science of selecting Robots to various applications.
    • Eg: Machines that weld, paint, assemble, inspect for quality, grasp, transport and store.
    www.a2zmba.com
  • 10. Automated QC Inspection
    • Automated machines that perform part or all of the inspection process.
    • Eg: Electronic circuit checks, computer driven function checks, weighting robots, flexible inspection etc.
    www.a2zmba.com
  • 11. Automatic Identification Systems (AIS)
    • Technologies used in automatic acquisition of product data for entry into a computer.
    • Eg: Bar-Coding systems, inventory counting, data entry for shop floor control etc.
    www.a2zmba.com
  • 12. Automated Process Controls
    • Computer Systems that receive data on the production process and send adjustments to process settings.
    • Eg: Control Systems for rolling mills in manufacturing etc.
    www.a2zmba.com
  • 13. CAD/CAM
    • Computer Aided Design are the Computer software programs that allow a designer to carry out geometric transformations rapidly.
    • Computer Aided Manufacturing (CAM) are the Manufacturing systems utilizing computer software programs that control the actual machine on the shop floor.
    www.a2zmba.com
  • 14. Automated Storage and Retrieval Systems
    • ASRS are the systems meant for receiving orders for materials from anywhere in operations, collecting materials from locations within a warehouse and delivering the materials to work stations in operations.
    • Three major elements
      • Computer and communication Systems
      • Automated Material handling and Delivery Systems
      • Storage and Retrieval Systems in warehouse
    www.a2zmba.com
  • 15. Computer Integrated Manufacturing
    • Computer Information Systems utilizing a shared manufacturing database for engineering design, manufacturing engineering, factory production, and information management.
    www.a2zmba.com
  • 16. Group Technology
    • A way of organizing and using data for components that have similar properties and manufacturing requirements.
    • GT results in
      • Reduced item handling and movement times.
      • Reduced Change over times.
      • Reduced idle wait time of items at the machine.
      • Reduced work in process.
    www.a2zmba.com
  • 17. Advantages
    • Increased output and enhanced productivity.
    • Improved and uniform quality.
    • Reduced cost.
    • Fewer accidents.
    • Better production control.
    • Lost Prerogatives gained.
    • Dangerous and unpleasant tasks.
    www.a2zmba.com
  • 18. Advantages Contd…
    • Reduced Inventories
    • Greater operating flexibility
    • Reduced lead time and scrap
    • Improved reliability
    • Design freedom
    www.a2zmba.com
  • 19. Disadvantages
    • Heavy capital investment
    • Displacement of labour
    • Benefit of employee suggestion lost
    • Tighter specification may be needed
    • Costs of supply failure increases
    • Slack season would be disastrous
    • Dehumanization
    • Problems of developing countries
    www.a2zmba.com
  • 20. Flexibility Without Automation
    • It is usually referred to as “attaining the effect of automation
    • without the expense”
    • Preautomation
    • Modular Design
    • Standardization
    www.a2zmba.com
  • 21. Preautomation
    • This attacks one of the Shingo’s 7 wastes, the waste of processing itself.
    • It makes no sense in automating a stage of production process when that stage adds no value to the product.
    • Preautomation studies reveal unneeded equipment and activities that can be eliminated rather than automated.
    www.a2zmba.com
  • 22.
    • Modular Design:
    • The creation of products from some combination of basic, preexisting subsystems.
    • Standardization:
    • Use of uniform standardized components in the products. Eg: screws, spark plugs, nuts & bolts etc.
    www.a2zmba.com
  • 23. Industrial Examples
    • The General Motors Fairfax plant in Kansas city, Missouri, produces Pontiac Grand Prixs.
    • Earlier, for producing cars with different colours it took time for shutting down the painting area so that it could be cleared of dust and scrubbed.
    • Today GM has reduced the production line delays by using Technologies such as airtight chambers and high powdered vacuum suctions.
    www.a2zmba.com
  • 24. Industrial Examples Contd…
    • General Motors, in a joint venture with Toyota at the NUMMI (New United Motors Manufacturing Inc.) plant outside San Francisco.
    • NUMMI has installed a new press line with Exchange of die techniques like IED, OED, SMED and OTED.
    • It has reduced the time taken for die exchange from hours/days to minutes.
    www.a2zmba.com
  • 25. Conclusion
    • Factories of the future will have stress on high product quality, greater emphasis on flexibility, fast delivery of customer orders, extensive use of CAD/CAM for product design, structural changes etc.
    • To fulfill all these requirements Flexible Manufacturing Systems (FMS) has to play a very important role…
    www.a2zmba.com