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  • 1. Flexible Manufacturing Systems Group 25
  • 2. Metal forming Metal- cutting machines Assembly Joining- welding, gluing Inspecti on Surface treatmen t Testing Weaving looms with paper tapes NC machines with paper tapes Hard wired NC machines Computer controlled NC machines (CNC) Direct Numerical Control (DNC) USES HISTORY Understanding FMS  Flexible automation where a group of processing workstations (usually CNC machine tools) are linked together by a material handling system, all aspects of which are controlled by a distributed computer system.
  • 3. Features Processes more than one product style independently Each machine in the system may process a different part type Changes can be made in the production schedule to meet demands on different products New product styles can be introduced into production Distinguishing Characteristics Machines in the system are linked by an automatic machine handling subsystems Automatic continuous cycling of machines Complete control of the manufacturing system by the host computer Lightly manned/unmanned
  • 4. Part variety test Schedule change test Error recovery test The range of operations and part stylesBasic Flexibilities Machine flexibility Material handling flexibility Expansion flexibility Product flexibility Volume flexibility System Flexibilities Program Flexibility Production Flexibility Aggregate Flexibilities New part test Tests of Manufacturing Flexibility Ease and precision of Material Transport Ability to produce parts in high and low quantities Ease with which the system can be Expanded to increase total production Ease with which new products can be introduced Ease of generating programs for new machine sequences The range or universe of part styles that Can be produced on the system Types and Tests of Manufacturing Flexibility
  • 5. Distinguishing FMS based on the number of Machines  Single machine cell (Type I A) A single machine cell consists of one CNC machining center combined with a parts storage system for unattended operation. Completed parts are periodically unloaded from the parts storage unit, and raw work parts are loaded into it  Flexible manufacturing cell (usually type II A, sometimes type III A) A flexible manufacturing cell consists of two or three processing workstations (typically CNC machining centers) plus a part handling system. The part handling system is connected to a load/unload station.  Flexible manufacturing system (usually type II A, sometimes type III A) A flexible manufacturing system has four or more processing workstations connected mechanically by a common part handling system and electronically by a distributed computer system.
  • 6. Levels of flexibility Dedicated FMS •Designed to produce a limited variety of part styles •Complete universe of parts to be made on the system is known in advance Random-order FMS •Part family is large •Substantial variations in part configurations •New part designs introduced into the system and engineering changes in parts currently produced •Production schedule is subjected to change from day-to-day
  • 7. Components of FMS 1. Workstations  Load/Unload Stations; Machining Stations; Other processing Stations- Punching, shearing, welding; Assembly Station 2. Material handling and storage systems  Primary handling system establishes the basic layout of the FMS and is responsible for moving work parts between stations in the system  Secondary handling system consists of transfer devices, automatic pallet changing, and similar mechanisms located at the workstations 3. Computer control system  uses a distributed computer system that is interfaced with all workstations in the system, as well as with the material handling system and other hardware components 4. People  required to manage and operate the system – Basic setup, maintenance 1 2 3 4
  • 8. FMS in real life  Chrysler's Toluca plant, where the PT Cruiser and Dodge Journey are made interchangeably, though they share few parts  The way this works is by extensive use of robots and computers; the robots have tooling or spot welders on the end of their "arms" and when a new vehicle comes down the line, they can quickly swap to different tooling or welders, and apply their arms in different ways  This also works in the paint shops, where robot arms are programmed to act differently depending on the vehicle that shows up Employees at Chrysler Group LLC’ s Toluca (Mexico) Assembly Plant marry the engine with the body of an all-new Fiat 500 A robot tightens the lug nuts on the wheel on the all-new Fiat 500
  • 9. Advantages of FMS • Reduced work in process • Increased machine utilization • Better management control • Reduced direct and indirect labor • Reduced manufacturing lead-time • Consistent and better quality • Reduced inventory Disadvantages of FMS • Expensive, costing millions of dollars • Substantial pre-planning activity • Limited ability to adapt to changes in product • Technological problems of exact component positioning and precise timing necessary to process a component. • Benefit of employee suggestion lost
  • 10. See FMS at work! Thank You 