2. What Will Be Covered
Flexible Manufacturing is Defined
How “you” can use FMS
Nuts and Bolts
How FMS works
A real world example
Summary
3. What Is A Flexible
Manufacturing System?
Flexible Manufacturing System:
- “A system that consists of numerous
programmable machine tools connected by an
automated material handling system”
4. Basic Components of FMS
The Basic components of FMS are:
1. Workstations.
2. Automated material Handling and Storage
system.
3. Computer Control System.
5. Stand alone
NC machines
Flexible Manufacture
Systems
Transfer Lines
High
Medium
Low
Low Medium High
Production volume
Product
variety
Application Characteristics of FMS
6. Flexibility in Manufacturing
Basic Flexibility
Machine flexibility
Material handling flexibility
System Flexibility
volume flexibility
Routing flexibility
Expansion flexibility
Aggregate Flexibility
Program flexibility
production flexibility
market flexibility
7. Different Types of FMS
Sequential FMS
Random FMS
Dedicated FMS
Engineered FMS
Modular FMS
8. Progressive Layout:
Best for producing a variety of parts
Closed Loop Layout:
Parts can skip stations for flexibility
Used for large part sizes
Best for long process times
Types of FMS Layouts
• Robot centered Layout
- Robot centered cell with one or more robots are
Used as the material handling systems.
9. FMS Layouts Continued
• Ladder Layout:
― Parts can be sent to any machine in any sequence
― Parts not limited to particular part families
• Open Field Layout:
― Most complex FMS layout
― Includes several support stations
10. Types of FMS Layouts
Progressive or Line type
Loop Type
Ladder Type
Open Field Type
Robot centered type
11. Factors Influencing the FMS
layouts
Available 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
12. Objective of FMS
Decreased Lead Times
Increased machine utilization
Improved Due Date Reliability
Decreased Store Inventors levels
Decreased Work in Progress
Increased Quality
13. Advantages and disadvantages
of FMS Implementation
Advantages
Faster, lower-cost changes from one part to
another which will improve capital utilization.
Lower direct labor cost, due to the reduction in
number of workers.
Reduced inventory.
Consistent and better quality.
Savings from indirect labors, from reduced
errors , rework, repairs and rejects.
14. Disadvantages
Limited ability to adapt to changes in product or
product mix .
Substantial pre-planning activity
Expensive , costing millions of Dollars.
Technological problems of exact component
positioning.
Sophisticated manufacturing systems.
15. Automated Material Handling
Automated Guided
Vehicle (AGV)
Automated Storage and
Retrieval System
(ASRS)
Conveyors
17. Flexible Automation
Ability to adapt to
engineering changes in
parts
Increase in number of
similar parts produced
on the system
Ability to accommodate
routing changes
Ability to rapidly change
production set up
20. Common Uses of Robots
Loading and unloading
Spray painting
Welding
Material handling
Inspection
Machine Assembly
21. Computer Integrated
Manufacturing
CIM: “The Integration of the total manufacturing
enterprise through the use of integrated systems and
data communications coupled with new managerial
philosophies that improve organizational and personnel
efficiency.”
23. Manufacturing Technology
This part of FMS uses:
NC Numerically Controlled Machine
CNC Computer Controlled Machine
DNC Direct Numerical Controlled
24. Challenges with FMS
Determining if FMS the best production system for your
company (economically and socially)
Possible expansion costs associated with
implementing FMS
Day to day maintenance of FMS operations
27. Making FMS Work
By implementing the components of
robotics, manufacturing technology and
computer integrated manufacturing in a
correct order one can achieve a successful
Flexible Manufacturing System
29. Ford’s Problem
At Ford Powertrain they faced the
following challenges
- outdated cell controller
- lack of flexibility because of it
- causing loss of efficiency
30. Solution
Implemented a cell control based
on an open architecture,
commonly available tools, and
industry standard hardware,
software, and protocols. (3)
31. Benefits
Enabled Ford to mix and match machine
tools from different vendors (3)
Reduced the number of man-years
required to implement the application (3)
32. Benefits Continued
The budget for the fully automatic closed-
loop controller was less than 1/10th the
cost for a system built in language.
No formal training was required for the
floor shop operators