FLEXFLEXIIBLEBLE MANUFACTURMANUFACTURIINGNG
SYSTEMSYSTEM
Presented by: Er. Fateh Singh
A.P
Deptt. of Mechanical Engineering
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At a Glance
 In the middle of the 1960s, market competition became
moreintense.
 During 1960 to 1970 cost was the primary concern.
Later quality became a priority. As the market became
more and more complex, speed of delivery became
something customer also needed.
 A new strategy was formulated: Custo mizability. The
companies have to adapt to the environment in which
they operate, to be more flexible in their operations and
to satisfy different market segments(customizability).
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 Thus the innovation of FMS became related to the effort of
gaining competitiveadvantage
 The first FMS was patented in 1965 by Theo Williamsonwho
made numerically controlled equipment. Examples of
numerically controlled equipment are like a CNC lathes or
millswhich iscalled varying typesof FMS.
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Flexible Manufacturing System is?
 A Flexible Manufacturing System (FMS) is a form of
flexible automation in which several machine tools are
linked together by a material-handling system, and all
aspects of the system are controlled by a central
computer.
 An FMS is a “reprogrammable” manufacturing system
capableof producing avariety of productsautomatically
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Equipments o f FMS
Primary equipments
 Work centers
• Universal machining centers
• Turning centers
• Grinding machines
 Processcenters
• Wash machines
• Coordinatemeasuring machines
• Robotic work stations
• Manual workstations
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Secondary Equipments
Supporting Stations
• Pallet/fixtureload/unload stations
• Tool commissioning/setting area
Supporting Equipments
• Robots
• Pallet/fixturestores
• Pallet buffer stations
• Toolsstores
• Raw material stores
• Transport system
• Transport units(pallets)
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What are the Features o f FMS??
 An FMS is distinguished from an automated production
line by its ability to process more than one product
stylesimultaneously.
 At any moment, each machine in the system may be
processing adifferent part type.
 FMS can let us make changes in production schedule
in order to meet thedemandson different product
 New product styles can be introduced into production
with an FMS, so long as they are to be used on the
productsthat thesystem can process.
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Distinguishing Characteristics
 An automatic materials handling subsystem links
machines in the system and provides for automatic
interchange of work piecesin each machine
 Automatic continuous cycling of individual machines
 Complete control of the manufacturing system by the
host computer
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3 Levels o f Manufacturing Flexibility
 1 -Basic Flexibilities
 Machine Flexibility - The ease with which a machine can
processvariousoperations
 Material Handling Flexibility -A measure of the ease
with which different part types can be transported and
properly positioned at thevariousmachinetoolsin asystem
 Operatio n Flexibility - A measure of the ease with which
alternative operation sequences can be used for processing a
part type
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2-System flexibilities
 Volume Flexibility : A measure of a system’s capability
to be operated profitably at different volumes of the existing
part types
 Expansion Flexibility: The ability to build a system and
expand it incrementally
 Routing Flexibility: A measure of the alternative paths that
a part can effectively follow through a system for a given
processplan
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 Process flexibility: a measure of the volume of the set of
part types that a system can produce without incurring any
setup
 Product flexibility: the volume of the set of part types
that can bemanufactured in asystem with minor setup
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•3-Aggregate Flexibilities
 Program Flexibility: the ability of a system to run for
reasonably long periodswithout external intervention
 Production Flexibility: the volume of the set of part
types that a system can produce without major investment
in capital equipment
 Market Flexibility: the ability of a system to efficiently
adapt to changing market conditions
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Co mpo nents o f FMS Systems
 Robotics
 Material Handling / Transport
 Machines
 Manual / Automated Assembly Cells
 Computers
 Controllers
 Software
 Networks
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Benefits o f FMS
FMS systems are intended to so lve the fo llo wing
pro blems:
 Reduced work in process
 Increased machineutilization
 Better management control
 Reduced direct and indirect labor
 Reduced manufacturing lead-time
 Consistent and better quality
 Reduced inventory
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The Disadvantages o f FMS
 Expensive, costing millionsof dollars
 Substantial pre-planning activity
 Sophisticated manufacturing systems
 Limited ability to adapt to changesin product
 Technological problems of exact component positioning
and precisetiming necessary to processacomponent
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Future Benefits o f FMS
 Technology will make100% inspection feasible
 Computer diagnosis will improve estimation of machine
failure, and guidework crewsrepairing failures
 Minimum human labor in manufacturing systems
 Varity of toolswith increased computing power
 Better management software, hardware, and fixturing
techniques
 Developed standards that will let us install new
machineseasily
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FMS acco rding to number o f Machines
 Flexible manufacturing systems can be distinguished
according to the number of machines in the system. The
following aretypical categories:
 Singlemachinecell (TypeI A)
 Flexible manufacturing cell (usually type II A,
sometimestypeIII A)
 Flexible manufacturing system (usually Type II A,
sometimestypeIII A)
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 Single machine cell(Type IA)
• 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
partsstorageunit, and raw workpartsareloaded into it
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 Flexible manufacturing cell
• A flexible manufacturing cell consists of two or three
processing workstations (typically CNC machining
centers) plusapart handling system.
• The part handling system is connected to a load/unload
station
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 Flexible manufacturing system
• 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.
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So me o f the distinguishing characteristics o f the three
catego ries o f flexible manufacturing cells and systems are
summarized in figure belo w
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Flexibility Criteria Applied to the Three
Types o f Manufacturing Cells and Systems
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FMS Layo ut Co nfiguratio ns
 Progressiveor LineType
 Loop Type
 Ladder Type
 Open field type
 Robot centered type
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• Pro gressive o r Line Type
• Lo o p Type
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• Ladder type Open Field Layo ut
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Ro bo t Centered Layo ut
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Differences Between FMS and FMC
F.M.System
 Hasfour or more
machines
 Larger and more
sophisticated computer
control system
 Minimized effect of
machinebreakdowns
F.M.Cell
 Hastwo or three
machines
 Simpler computer
control system
 Limited error recovery
by fewer machines
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Applicatio n o f FMS
 Metal-cutting machining
 Metal forming
 Assembly
 Joining-welding (arc , spot), glueing
 Surfacetreatment
 Inspection
 Testing
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Co nclusio ns
 FMSisarevolution in thefield of Manufacturing Technology.
 FMS can be designed to meet the specific demand of each
company
 FMSisused for multitask operation.
 FMSrequiressubstantial investment of timeand resources
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References
Books Referred:
 M.P. Groover: “Automation Production System and
Computer Integration Manufacturing”, Prentice-Hall of
IndiaPrivateLimited,2008,Pg.No.:538-560.
 R.K. Jain: “Production technology”, Khanna
Publications, 2009, Pg.No.:962-974.
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