operations management

1. Flexible
Manufacturing
Systems
Group 25

2. Metal
forming
Metal-
cutting
machines
Assembly
Joining-
welding,
gluing
Inspecti
on
Surface
treatmen
t
Testing
Weaving looms with
paper tapes
NC machines with
paper tapes
Hard wired NC
machines
Computer controlled
NC machines (CNC)
Direct Numerical
Control (DNC)
USES
HISTORY
Understanding FMS
 Flexible automation where a group of processing workstations
(usually CNC machine tools) are linked together by a material
handling system, all aspects of which are controlled by a
distributed computer system.

3. Features
Processes more than one
product style
independently
Each machine in the
system may process a
different part type
Changes can be made in
the production schedule
to meet demands on
different products
New product styles can
be introduced into
production
Distinguishing
Characteristics
Machines in the system
are linked by an
automatic machine
handling subsystems
Automatic continuous
cycling of machines
Complete control of the
manufacturing system by
the host computer
Lightly
manned/unmanned

4. Part variety test
Schedule change
test
Error recovery
test
The range of operations and part stylesBasic
Flexibilities
Machine flexibility
Material handling
flexibility
Expansion flexibility
Product flexibility
Volume flexibility
System
Flexibilities
Program Flexibility
Production Flexibility
Aggregate
Flexibilities
New part test
Tests of Manufacturing Flexibility
Ease and precision of Material Transport
Ability to produce parts in high and low
quantities
Ease with which the system can be
Expanded to increase total production
Ease with which new products can be
introduced
Ease of generating programs for new
machine sequences
The range or universe of part styles that
Can be produced on the system
Types and Tests of Manufacturing
Flexibility

5. Distinguishing FMS based on the
number of Machines
 Single machine cell (Type I A)
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 parts storage unit, and raw work
parts are loaded into it
 Flexible manufacturing cell (usually type II A, sometimes type III 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.
 Flexible manufacturing system (usually type II A, sometimes type III A)
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.

6. Levels of flexibility
Dedicated FMS
•Designed to produce a limited variety of part styles
•Complete universe of parts to be made on the
system is known in advance
Random-order
FMS
•Part family is large
•Substantial variations in part configurations
•New part designs introduced into the system and
engineering changes in parts currently produced
•Production schedule is subjected to change from
day-to-day

7. Components of FMS
1. Workstations
 Load/Unload Stations; Machining Stations;
Other processing Stations-
Punching, shearing, welding; Assembly Station
2. Material handling and storage
systems
 Primary handling system establishes the basic
layout of the FMS and is responsible for
moving work parts between stations in the
system
 Secondary handling system consists of transfer
devices, automatic pallet changing, and
similar mechanisms located at the
workstations
3. Computer control system
 uses a distributed computer system that is
interfaced with all workstations in the
system, as well as with the material handling
system and other hardware components
4. People
 required to manage and operate the
system – Basic setup, maintenance
1
2
3
4

8. FMS in real life
 Chrysler's Toluca plant, where the PT
Cruiser and Dodge Journey are
made interchangeably, though
they share few parts
 The way this works is by extensive
use of robots and computers; the
robots have tooling or spot welders
on the end of their "arms" and when
a new vehicle comes down the
line, they can quickly swap to
different tooling or welders, and
apply their arms in different ways
 This also works in the paint
shops, where robot arms are
programmed to act differently
depending on the vehicle that
shows up
Employees at Chrysler
Group LLC’ s Toluca
(Mexico) Assembly
Plant marry the
engine with the body
of an all-new Fiat 500
A robot tightens the lug nuts on the
wheel on the all-new Fiat 500

9. Advantages of FMS
• Reduced work in process
• Increased machine
utilization
• Better management
control
• Reduced direct and
indirect labor
• Reduced manufacturing
lead-time
• Consistent and better
quality
• Reduced inventory
Disadvantages of FMS
• Expensive, costing millions
of dollars
• Substantial pre-planning
activity
• Limited ability to adapt to
changes in product
• Technological problems
of exact component
positioning and precise
timing necessary to
process a component.
• Benefit of employee
suggestion lost

10. See FMS at
work!
Thank You 