This document discusses Toyota's flexible manufacturing system (FMS). It provides background on Toyota and defines an FMS. The objectives of Toyota's FMS are listed as improving efficiency, maintaining flexibility for different products, optimizing cycle time, and more. Key components of Toyota's FMS are described, including CNC machines, material handling robots, and computer control. Findings note productivity and profitability gains from Toyota's FMS.

1. A MINI PROJECT
SUBMITTED
IN PARTIAL FULFILMENT OF THE REQUIREMENT
FOR THE DEGREE OF
MASTER OF BUSINESS ADMINISTRATION
IN
OPERATIONS MANAGEMENT
PRESENTED BY:
NEHA KHAN
MBA 2ND SEM
UNDER THE SUPERVISION OF:
DR. SWATI SRIVASTAVA
DEPARTMENT OF BUSINESS
ADMINISTRATION
TO STUDY FLEXIBLE MANUFACTURING SYSTEM
OF TOYOTA

2. TOYOTA
• A Japanese multinational automotive manufacturer.
• Founded by Kiichiro Toyoda on August 28, 1937.
• It is one of the most innovative car manufacturers
in terms of its production.
• They continue to evolve and revitalize their
production system.
• Toyota had a Flexible Body Line back in 1985.
• They have modified their production lines which
they now call the Global Body Line or GBL.
• GBL incorporates a completely different aspect of
flexibility.

3. FLEXIBLE MANUFACTURING SYSTEM
• A Flexible Manufacturing System (FMS) is a type of
industrial process that allows equipment to be used for
more than one purpose, or that may be related.
• Machines are often used to make customized parts, or
to make different parts of different product models.
• This type of system can be changed manually, but may
be controlled by a computer, and modified by a
completely automated process.
• A flexible manufacturing system is an automated
machine cell, consisting of a group of processing
workstations, interconnected with automated material
handling and storage systems.

4. OBJECTIVES
• To improve efficiency and economies of scale associated with mass
production.
• To maintain the flexibility in order to manufacture variety of products.
• Optimizing the manufacturing cycle time.
• To develop an automated material handling system.
• Reduce downtime and improve control over quality.
• Improve work-in-process inventory.
• Eliminate labour dependence on highly skilled machines.
• Reduce production costs.
• External changes such as change in product design and production system.

5. WHAT
MAKES IT
FLEXIBLE???
• Four capabilities that a manufacturing
system must possess to be a flexible.
– Process different part styles in a
non-batch mode.
– Accept changes in production
schedule.
– Respond gracefully to equipment
malfunctions and breakdowns in
the system.
– Accommodate the introduction of
new part designs.

6. CLASSIFICATION OF FMS
Based on the kinds of operations they perform-
• Processing operation
• Assembly operation
Based on the number of machines in the system-
• Single machine cell (SMC)
• Flexible machine cell (FMC)
• Flexible manufacturing system (FMS)
Based on the level of flexibility associated with the system-
• Dedicated FMS
• Random order FMS

7. BASIC COMPONENTS OF FMS
FLEXIBLE SYSTEM
WORKSTATION
CNC M/C
MATERIAL
HANDLING
ROBOT
TRANSFER
EQUIPMENT
AS/R EQUIPMENT
COMPUTER
CONTROL
REAL TIME CONTROL
(CONTROL DIFFERENT
ACTIVITIES)

8. LAYOUT
OF FMS
IN
TOYOTA

9. ADVANTAGES OF FMS
• To reduce set up and queue times
• Improve efficiency
• Reduce time for product completion
• Utilize human workers better
• Improve product routing
• Produce a variety of Items under one
roof
• Improve product quality
• Serve a variety of vendors
simultaneously
• Produce more product more quickly
DISADVANTAGES OF FMS
• Expensive • Substantial pre-planning activity

10. FINDINGS
• Toyota has gained more productivity and profitability
• Computer controlled robots in the FMS enabled in achieving a mixed fund
of profits ranging from high usage to high production capacity.
• FMS has a great adaptability of changing the sequences of manufacturing
and utilize the idle time.
• Reduced the lead time by 40%, improved machine utilization by 30%,
reduced the labour times by 30%, and also reduced the direct and
indirect labour costs.

11. CONCLUSION
• Flexible manufacturing system has the ability to respond quickly to any design changes
in a product. It has the natural flexibility of finding new types of piped product without
major modifications.
• The Flexible Manufacturing System uses a number of robotic equipment and systems.
Software developed to integrate CNC control machine and management system.
• Flexibility in manufacturing has improved:
– Lower labor costs,
– Decreased inventory costs,
– Consistent and better quality,
– Low cost/output unit,
– Savings from indirect work, from reduced errors, recycling, repairs and disposal.

12. BIBLIOGRAPHY
• https://www.machinedesign.com/news/article/21815035/chrysler-shifting-to-
japanese-method-of-flexible-manufacturing
• https://doi.org/10.1016/j.ijpe.2008.12.02
• https://scholar.google.com
• www.google.com
• https://www.toyotabharat.com/
• https://global.toyota/en/
• www.linkedin.com
• https://www.researchgate.net/publication/350809207
• https://hwacheonasia.com/how-to-build-a-flexible-manufacturing-system-with-cnc-
machine-tool-automation/
• https://www.l2l.com/blog/flexible-manufacturing-systems-now-more-than-ever