Flexible manufacturing systems (FMS) consist of programmable machine tools connected by an automated material handling system. The basic components of an FMS are workstations, an automated material handling and storage system, and a computer control system. An FMS provides flexibility in manufacturing by allowing for machine flexibility, material handling flexibility, volume flexibility, routing flexibility, and expansion flexibility. Common FMS layouts include progressive, loop, ladder, open field, and robot-centered layouts. FMS implementations can result in decreased lead times, increased machine utilization, and improved quality.

1. Flexible
Manufacturing
Systems (FMS)

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

16. Components of Flexible
Manufacturing Systems
 NC
 CNC
 DNC
 Robotics
 AGV
 ASRS
 Automated
Inspection
 Cells and Centers

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

18. FMS Nuts and Bolts
Robots

19. Robots
Robots: Programmable Manipulators
― Can tolerate hostile environments
― Can work much longer hours than humans
― Can perform redundant jobs more consistently

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.”

22. Components of CIM
 CAD Computer Aided Design
 CAM Computer Aided Manufacturing
 CAE Computer Aided Engineering

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

25. Flexible
Manufacturing
How Does It Work ?

26. Integration of FMS
FMS
Manufacturing Technology CAM Robotics

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

28. A Real World Example
The
Ford
Motor Company

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

33. THANK YOU