A flexible manufacturing system (FMS) is an automated machine cell consisting of a group of processing workstations like CNC machine tools interconnected by an automated material handling and storage system and controlled by a distributed computer system. FMS allows manufacturers to produce a variety of different part styles simultaneously and adjust production mix in response to changing demand while maintaining good quality and low costs. It transfers workpieces between machining stations using automated equipment like conveyors.

1. FLEXIBLE
MANUFACTURING
SYSTEMS (FMS)
BY - SHIVAM JOSHI
[0131ME114]

2. What is FMS ?
 A flexible manufacturing
system is an automated
machine cell, consisting
of a group of processing
workstations,
interconnected with
automated material
handling and storage
system.

3. The issues such as reduction of inventories and market-response
time to meet customer demands, flexibility to adapt to changes in the
market, reducing the cost of products and services to grab more
market shares, etc have made it almost obligatory to many firms to
switch over to flexible manufacturing systems (FMSs) as a viable means
to accomplish the above requirements while producing consistently
good quality and cost effective products. FMS is actually an automated
set of numerically controlled machine tools and material handling
systems, capable of performing a wide range manufacturing operations
with quick tooling and instruction changeovers.

4. HOW FMS WORKS
• A flexible manufacturing system (FMS) is a highly automated GT
machine cell, consisting of a group or processing workstations (usually
CNC machine tools), interconnected by an automated material
handling and storage system, and controlled by a distributed computer
system.
• The FMS is most suited for the
mid-variety, mid-volume
production range
• The reason the FMS is called flexible is that it is capable of processing
a variety of different part styles simultaneously at the various
workstations, and the mix of part styles and quantities of production
can be adjusted in response to changing demand patterns.

5. Flexibility is an attribute that allows a mixed model manufacturing
system to cope up with a certain level of variations in part or
product style, without having any interruption in production due to
changeovers between models. Flexibility measures the ability to
adapt “to a wide range of possible environment”. To be flexible, a
manufacturing system must posses the following capabilities
• Identification of the different production units to perform the
correct operation
• Quick changeover of operating instructions to the computer
controlled production machines
• Quick changeover of physical setups of fixtures, tools and other
working units

7. The first FMS was patented in 1965 by Theo Williamson who
made numerically controlled equipment. Examples of
numerically controlled equipment are like a CNC lathes or mills
which is called varying types of FMS.
During the 1970s, with the ever-growing developments in the
field of technology, manufacturers started facing difficulties and
hence, FM systems became main-stream in manufacturing to
accommodate new changes whenever required. During the
1980s for the first time manufacturers had to take in
consideration efficiency, quality, and flexibility to stay in
business.

8. 1.Workstations
2. Automated Material Handling and Storage systems
3. Computer Control System
4. Human Resources

9. • Following are the types of workstations typically found in an FMS:
1. Load/Unload Stations.
2. Machining Stations.
3. Other processing Stations.
4. Assembly Station.
5. Other Stations and Equipment.

10. Functions
1.Independent movement of workparts between stations.
2.Handle a variety of workpart configurations.
Temporary storage.
3.Convenient access for loading and unloading
workparts.
4.Compatible with computer control.

11. Material Handling Equipment
• Primary handling system establishes the basic layout of the FMS and is
responsible for moving workparts between stations in the system.
(Conveyor)

12. • The FMS includes a distributed computer system that is interfaced to
 the workstations,
 Material handling system, and
 Other hardware components.
• A typical FMS computer system consists of
a central computer and microcomputers.
• Microcomputers controlling the individual
machines and other components.
• The central computer coordinates the activities of the components to
achieve smooth overall operation of the system

13. • Human are needed to manage the operations of the FMS. Functions
typically performed by human includes:
 Loading raw workparts into the system,
 Unloading finished parts (or assemblies) from the system,
 Changing and setting tools,
 Equipment maintenance and repair,
 NC part programming in a machining system, and
 Programming and operation the computer system.

14. Flexible manufacturing systems can be distingished according to the
number of machines in the system. The following are typical categories:
1.Single machine cell (Type I A)
• A single machine cell consists of
one CNC machining center combined
witha parts storage system for
unattended operation.
• Completed parts are periodically unloaded from
the parts storage unit, and raw workparts are loaded into it

15. 2. Flexible manufacturing cell (usually type II A)
• A flexible manufacturing
cell consists of two
or three processing
workstations (typically
CNC machining centers)
plus a part handling system.
• The part handling system
• is connected to a
• load/unload station.

16. • 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.

17.  Sequential FMS
 Random FMS
 Dedicated FMS
 Engineered FMS
 Progressive or Line
Type
 Loop Type
 Ladder Type
 Open field type
 Robot centered type

18. 1.Progressive Layout
2. Loop Layout

19. 3.Ladder Type Layout 4.Open Field Layout

20. 5. Robot Centered Layout

21. 1.External changes such as change in product design and
production system.
2.Optimizing the manufacturing cycle time
3.Reduced production costs
4.Overcoming internal changes like breakdowns etc.
5.Lower cost per unit produced
6.Greater labour productivity
7.Greater machine efficiency
8.Improved quality
9.Increased system reliability
10.Reduced parts inventories

22. 11.To reduce set up and queue times
12.Improve efficiency
13.Reduce time for product completion
14.Utilize human workers better
15.Improve product routing
16.Produce a variety of Items under one roof
17.Improve product quality
18.Serve a variety of vendors simultaneously
19.Produce more product more quickly
20.Adaptability to CAD/CAM operations
21.Shorter lead times

23. 1.Expensive.
2.Substantial pre-planning activity.
3.Cost to implement,
4.Substantial pre-planning
5.Requirement of skilled labour
6.Complicated system
CHALLENGES
1.Determining if FMS the best production system for
your company
2.Possible expansion costs associated with implementing
FMS

25.  Metal-cutting machining
 Metal forming
 Assembly
 Joining-welding (arc , spot), glueing
 Surface treatment
 Inspection
 Testing

26.  FMS is a 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.

27. T.Y