FLEXIBLE MANUFACTURING SYSTEM

Prepared By
NEGESA BEKUMA Submitted : Dr.k.Balasundaram
Post Graduate Program in Manufacturing Engineering
MEng. 7037Production and Operation Management
Seminar presentation on
Title: FLEXIBLE MANUFACTURING SYSTEM
11/24/2021

TABLE OF CONTENTS
Introduction to FMS
History of FMS
Why FMS?
Basic Components of FMS
FMS Equipment
Types of FMS
Layouts of FMS
Flexibility in FMS
Applications of FMS
Advantages
Disadvantages
Conclusion
 References
Wednesday, November 24, 2021
FMS

Types of manufacturing systems
FMS
1

FLEXIBLE MANUFACTURING SYSTEM:
 Flexible manufacturing system (FMS) is a manufacturing asset
that can adapt to changing requirements. It allows for the
production of more than one type of part or a “family” of
parts, as needed.
It is a collection of production equipment logically organized under
a host computer and physically connected by a central transport
system.
FMS: is a production method that is designed to easily adapt to
changes in the type and quantity of the product being
manufactured.
11/24/2021

FMS :has four or more processing workstation connection
mechanically by a common part handling systems and
electronically by a distributed computer system.
“ A system that consists of numerous programmable machine
tools connected by an automated material handling system”.
The objective of an FMS is to carry out on a single system the
fabrication of several types of parts that can change over time
with small conversion time, at the required volume and quality,
with the aim of achieving productivity and flexibility at the same
time.

 FMS first proposed in England in 1960’s.
 The concept is credited to David Williamson. a British
Engineer employed by Molins during the mid‐l96Os.
 “System 24” operates 24 hours a day.
 Automation is main purpose in beginning.
 The first physical FMS was established around 1967 in the
United States.
HISTORY OF FMS:
FMS 3

WHY FMS?
 External changes such as change in product design and
production system.
 Optimizing the manufacturing changes like cycle time.
 Overcoming internal breakdowns etc.
 Reduced production costs
FMS 4

In addition, even though an FMS is highly automated people are
required to manage and operate the system.
Basic Components of FMS:
FMS 8

1)Workstations:
FMS are being designed with other type of processing
equipment‘s including inspection stations, assembly works and
sheet metal presses. The main elements of FMS.
The various workstations are:
1. Machining centers
2. Load and unload stations
3. Assembly work stations
4. Inspection stations
5. Forging stations
6. Sheet metal processing, etc.

.
2, Material handling and Storage system:
The various functions of automated material handling and storage
system are:
1. Random and independent movement of work parts
between workstations
2. Handling of a variety of work part configurations
3. Temporary storage
4. Convenient access for loading and unloading of work parts
5. Compatible with computer control.

3, computer control system.
It is used to coordinate the activities of the processing stations and
the material handling system in the FMS. It’s the brain of FMS.
The various functions of computer control system are:
 Control of each work station.
 Distribution of control instruction to work station.
 Production control.
 Traffic control.
 Shuttle control.
 Work handling system and monitoring.
 System performance monitoring and reporting.
FMS 11

Types of FMS:
Based on the flexibility of the system.
1. Sequential FMS
2. Random FMS
3. Dedicated FMS
4. Engineered FMS
5. Modular FMS
 Sequential FMS : It manufactures one-piece part
batch type and then planning and preparation is
carried out for the next piece part batch type to be
manufactured.
 Random FMS : It manufactures any random mix of
piece part types at any one time.
 Dedicated FMS :It continually manufactures, for
extended periods, the same but limited mix of piece
part batch types.
 Engineered FMS :It manufactures the same mix of
part types throughout its lifetime.
 Modular FMS :A modular FMS, with a sophisticated
FMS host, enables and FMS user to expand their FMS
capabilities in a stepwise fashion into any of the
previous four types of FMS. Wednesday, November 24, 2021
FMS
12

Factors Influencing FMS :
The various factors influencing the layouts of FMS are:
 Availability of raw material
 Proximity to market
 Transport facilities
 Availability of efficient and cheap labor
 Availability of power, water and fuel
 Atmospheric and climatic condition
 Social and recreation facilities
 Business and economic conditions
FMS 13

Layouts of FMS:
1. Progressive or Line Type
2. Loop Type
3. Ladder Type
4. Open field Type
5. Robot centered Type
FMS 14

1,Progressive or Line Type:
The machines and handling system are arranged in a line in this type of system.
It is most appropriate for a system in which the part progress from one
workstation to the next in a well-defined sequence with no back flow.
Work always flows in unidirectional path as shown in the figure below.
FMS
15

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 station are typically located at one end of the loop as
shown in the figure below.
2,Loop Type :
FMS 16

 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 as shown in the figure below.
3,Ladder Type:
FMS 17

 The loading and unloading station is typically located at the same end.
The parts will go through all the substations, such as CNC machines,
coordinate measuring machines and wash station by the help of AGV’s
from one substation to another.
4,Open Field Type :
FMS 18

 Robot centered cell is a relatively new form of flexible system in which one or
more robots are used as the material handling systems.
Industrial robots can be equipped with grippers that make them well suited for
handling of rotational parts.
5,Robot Centered Type :
FMS 19

Flexibility in FMS:
Flexibility in manufacturing means the ability to deal with slightly or
greatly mixed parts, to allow variation in parts assembly and variations
in process sequence, change the production volume and change the
design of certain product being manufactured.
The flexibility in F.M.S. is achieved with the help of software controlling
the hardware.
 Three capabilities that a manufacturing system must possess to
 be flexible:
 (I) The ability to identify and distinguish among the different
 part or product styles processed by the system,
 (II) Quick changeover of operating instructions, and Wednesday, November 24, 2021
FMS 20

CONT’...nd
Three capabilities that a manufacturing system must possess to be flexible:
(I) The ability to identify and distinguish among the different part or
product styles processed by the system,
(II) Quick changeover of operating instructions, and
(III) Quick changeover of physical setup.
FMS 21

FMS 22

The main advantage of FMS is its high flexibility in managing
manufacturing resources.
The resulting gains are numerous including:
 Reduced manufacturing cost.
 Greater labor productivity.
 Greater machine efficiency.
 Improved quality.
 Increased system reliability.
 Shorter lead times.
ADVANTAGE:
FMS 23

FMS 24
 Expensive.
 Complexity in setup.
 Requirement of skilled labor.
DISADVANTAGES:

Conclusion
FMS is revolution in the field of manufacturing Technology.
FMS can be designed to meet the specific demand of each company.
FMS is used for multitask operation.
FMS requires substantial investment of time and resources.
FMS 25

[1] Sethi, A. K., and S. P. Sethi. 1990. “Flexibility in Manufacturing: A Survey.”
InternationalnJournal of Flexible Manufacturing System, Services and Operations
Management 2 (4): 289–328
[2] Browne, J., Dubois, D., Rathmill, K., Sethi, S. P., and Stecke, K. E., 1984,Classification of
flexible manufacturing systems.The FMS Magazine, April1984, 114-1117.
references
FMS 26

FLEXIBLE MANUFACTURING SYSTEM

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