The document outlines the essential concepts and components of Flexible Manufacturing Systems (FMS), including its capabilities, components, layout types, and benefits. It discusses different categories of automation and types of FMS, detailing their implementation challenges and advantages. A case study on Ford Motor Company's FMS implementation highlights the practical applications and improvements achieved through better technology and systems integration.

1. Flexible Manufacturing Systems
(FMS - Unit – Vi(a))
(FMS - Unit – Vi(a))
Presented By
Dr. Sivasankara Raju R
Associate Professor
Dept. of Mechanical Engg.
AITAM, Tekkali-532201
Andhra Pradesh

2. What Will Be Covered
• Specify the three primary capabilities of flexibility in the FMS.
• List the four tests for flexibility in FMS research.
• Explain how different types of FMS may be specified.
• List the basic components of an FMS.
• List the basic components of an FMS.
• State the five categories of FMS layout.
• Specify the benefits of a successful FMS implementation.
• Outline the Major issues of planning for the creation of FMS.
• Specify the types of quantitative analysis that may be used
with regard to FMS.

3. What Is A Flexible Manufacturing
System?
Flexible Manufacturing System:
- “A system that consists of numerous programmable
- “A system that consists of numerous programmable
machine tools connected by an automated material
handling system”

4. 4

5. Basic Components of FMS
The Basic components of FMS are:
1. Workstations.
2. Automated material Handling and Storage system.
2. Automated material Handling and Storage system.
3. Computer Control System.

6. Components of FMS Systems
 Robotics
 Material Handling / Transport
 Machines
 Manual / Automated Assembly Cells
6
Manual / Automated Assembly Cells
 Computers
 Controllers
 Software
 Networks

7. Factors Influencing the FMS
layouts
• Available of raw material
• Proximity to market
• Transport facilities
• Availability of efficient and cheap labor
• Availability of efficient and cheap labor
• Availability of Power ,Water and Fuel
• Atmospheric and climatic condition
• Social and recreation Facilities

8. Objective of FMS
• Decreased Lead Times
• Increased machine utilization
• Improved Due Date Reliability
• Decreased Store Inventors levels
• Decreased Store Inventors levels
• Decreased Work in Progress
• Increased Quality

9. Stand alone
NC machines
High
Application Characteristics of FMS
Flexible Manufacture
Systems
Transfer Lines
Medium
Low
Low Medium High
Production volume
Product
variety

10. 10

11. Automated Manufacturing Systems
Automation systems can be categorized based on the
flexibility and level of integration in manufacturing process
operations. Various automation systems can be classified
as follows
1. Fixed automation
1. Fixed automation
2. Programmable automation
3. Flexible automation
4. Integrated Automation

12. Fixed Automation: Used in high volume production with dedicated equipment, which has a fixed set of operation
and designed to be efficient for this set.
• Continuous flow and Discrete Mass Production systems use this automation. e.g. Distillation Process,
Conveyors, Paint Shops, Transfer lines etc.
Programmable Automation: Used for a changeable sequence of operation and configuration of the machines using
electronic controls.
• However, non-trivial programming effort may be needed to reprogram the machine or sequence of operations.
• Investment on programmable equipment is less, as production process is not changed frequently.
• It is typically used in Batch process where job variety is low and product volume is medium to high, and
sometimes in mass production also. e.g. in Steel Rolling Mills, Paper Mills etc.
Flexible Automation: It is used in Flexible Manufacturing Systems (FMS) which is invariably computer controlled.
• Human operators give high-level commands in the form of codes entered into computer identifying product and
its location in the sequence and the lower level changes are done automatically.
• These automatically loads/unloads required tools and carries out their processing instructions. After processing,
• These automatically loads/unloads required tools and carries out their processing instructions. After processing,
products are automatically transferred to next machine.
• It is typically used in job shops and batch processes where product varieties are high and job volumes are
medium to low. Such systems typically use Multi purpose CNC machines, Automated Guided Vehicles (AGV)
etc.
Integrated Automation: Complete automation of a manufacturing plant, with all processes functioning under
computer control and under coordination through digital information processing.
• It includes technologies such as CAD/M, CAPP, CNC machine tools, FMS, AS &AR, automated material
handling systems such as robots and automated cranes and conveyors, computerized scheduling and production
control.
• In other words, it symbolizes full integration of process and management operations using information and
communication technologies. Typical examples of such technologies are seen in Advanced Process Automation
Systems and Computer Integrated Manufacturing (CIM)

13. Types of Flexible Manufacturing
System
• Single machine cell

14. 2. Flexible manufacturing cell

15. 3. Flexible manufacturing system
(FMS)

16. Benefits of FMS
FMS systems are intended to solve the following
problems:
 Reduced work in process
 Increased machine utilization
 Better management control
16
Better management control
 Reduced direct and indirect labor
 Reduced manufacturing lead-time
 Consistent and better quality
 Reduced inventory

17. Flexibility in Manufacturing
• Basic Flexibility
Machine flexibility
Material handling flexibility
• System Flexibility
volume flexibility
Routing flexibility
Routing flexibility
Expansion flexibility
• Aggregate Flexibility
Program flexibility
production flexibility
market flexibility

18. Different Types of FMS
• Sequential FMS
• Random FMS
• Dedicated FMS
• Dedicated FMS
• Engineered FMS
• Modular FMS

19. Types of FMS Layouts
• Progressive or Line type
• Loop Type
• Ladder Type
• Ladder Type
• Open Field Type
• Robot centered type

20. • Progressive Layout:
– Best for producing a variety of parts
• Closed Loop Layout:
– Parts can skip stations for flexibility
– Used for large part sizes
Types of FMS Layouts
– Used for large part sizes
– Best for long process times

21. 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
― Most complex FMS layout
― Includes several support stations

22. FMS Layouts Continued
Robot
Robot centered Layout
centered Layout
•
• -
- Robot centered cell with one or more robots are
Robot centered cell with one or more robots are
•
• Used as the material handling systems
Used as the material handling systems.

23. Advantages of FMS Implementation
• 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.
number of workers.
• Reduced inventory.
• Consistent and better quality.
• Savings from indirect labors, from reduced errors ,
rework, repairs and rejects.

24. 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
• Technological problems of exact component
positioning.
• Sophisticated manufacturing systems.

25. Automated Material Handling
• Automated Guided Vehicle
(AGV)
• Automated Storage and
Retrieval System (ASRS)
• Conveyors

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

27. Flexible Automation
• Ability to adapt to
engineering changes in
parts
• Ability to accommodate
routing changes
parts
• Increase in number of
similar parts produced on
the system
• Ability to rapidly change
production set up

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

29. Common Uses of Robots
• Loading and unloading
• Spray painting
• Inspection
• Spray painting
• Welding
• Material handling
• Machine Assembly

30. 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
communications coupled with new managerial philosophies
that improve organizational and personnel efficiency.”

31. Components of CIM
• CAD Computer Aided Design
• CAM Computer Aided Manufacturing
• CAM Computer Aided Manufacturing
• CAE Computer Aided Engineering

32. Manufacturing Technology
• This part of FMS uses:
– NC Numerically Controlled Machine
– CNC Computer Controlled Machine
– DNC Direct Numerical Controlled

33. 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

34. Integration of FMS
FMS
Manufacturing Technology CAM Robotics

35. Making FMS Work
– By implementing the components of robotics,
manufacturing technology and computer
integrated manufacturing in a correct order one
integrated manufacturing in a correct order one
can achieve a successful Flexible Manufacturing
System

36. A Real World Example
The
Ford
Ford
Motor Company

37. Vought Aerospace plant in Dallas, US

38. Flexible fabricating system for automated sheet-metal processing

39. Ford’s Problem
• At Ford Powertrain they faced the following
challenges
- outdated cell controller
- outdated cell controller
- lack of flexibility because of it
- causing loss of efficiency

40. Solution
• Implemented a cell control based on
an open architecture, commonly
available tools, and industry
available tools, and industry
standard hardware, software, and
protocols. (3)
• G2 as they call it uses AGV’s, UNIX work station that
communicates via TCP/IP to an Oracle database on a VAX.

41. 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)
• The budget for the fully automatic closed-loop controller
• 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

42. THANK YOU
THANK YOU