The adjusted flow matrix is obtained as:
F = [[0, 40, 490, 250, 180],
[40, 0, 70, 200, 120],
[490, 70, 0, 280, 210],
[250, 200, 280, 0, 150],
[180, 120, 210, 150, 0]]
The heuristic algorithm provides the following sequence:
3 - 1 - 4 - 2 - 5
Hence, the recommended linear single row layout is:
3 1 4 2 5
This minimizes the total material handling cost by placing machines with highest flow between them closest. The clearance between machines must also be ensured as per the data provided.
1. Automated assembly systems use mechanized devices to perform assembly tasks and are designed for large production quantities of a specific product.
2. They are well-suited for high demand, stable designs, and limited component assembly. Advantages include high production rates, quality, and low costs.
3. Common configurations include in-line machines, dial indexing machines, carousels, and single-station cells. Parts delivery systems rely on feeders, tracks, and placement devices to orient and position components.
The proper implementation and role of flexible manufacturing system in current scenario. Better understanding of different types of flexible manufacturing system layouts and types of flexible manufacturing system.
Other than these, brief introduction of flexibility and types of flexibility in manufacturing and other industries.
Automated storage and retrieval systemPrasanna3804
Automated Storage and Retrieval Systems (ASRS) consist of computer-controlled systems that automatically place and retrieve loads from defined storage locations. ASRS are chosen to address issues like orders taking too long in factories, wasted time searching for items, lost/damaged products, inaccurate records, and safety hazards. The basic structure of an ASRS includes a storage structure, storage/retrieval machine, storage modules, pickup/deposit stations, and an external handling system. SSI Schafer is a leading provider of ASRS and other logistics systems, having been founded in 1937 and now operating globally with over 50 subsidiaries.
Introduction ,FMS Equipment,FMS Layouts ,Analysis Methods for FMS,,advantages of fms,comparison of fms to conventional methods,applications.Benefits of fms.
This document discusses computer aided quality control (CAQC). It introduces CAQC and explains that it uses computers to inspect and test manufactured products to ensure they meet defined quality standards. The objectives of CAQC are listed as increasing inspection and production productivity, reducing lead times and waste. The main components of CAQC are computer aided inspection (CAI) and computer aided testing (CAT). CAI uses 3D scanning and CAD modeling to check part specifications, while CAT simulates stresses and other factors to test attributes like strength. The advantages of CAQC include data harvesting, allowing 100% inspection and testing, using non-contact sensors, and providing computerized feedback control.
Flexible manufacturing systems (FMS) consist of interconnected computer-controlled machines and automated material handling systems. An FMS allows for mixed production and variation in parts, assembly, and processes. It includes processing workstations, an automated transport and storage system, and a computer control system that coordinates the activities. FMS provides benefits like decreased lead times, increased throughput and quality, and reduced costs. However, FMS implementation requires substantial investment and planning to address technological and coordination challenges.
The document is a presentation on automated material handling. It discusses material handling and different types of material handling equipment such as conveyors and automated guided vehicles (AGVs). It describes AGVs in detail, including their components, guidance technologies, and types. It provides an example of calculating the number of AGVs needed based on delivery rate, cycle time, and vehicle availability. The presentation also discusses using simulation to model AGV systems and limitations of automated material handling systems.
1. Flexible manufacturing systems (FMS) allow companies to efficiently produce a variety of products without major retooling. An FMS consists of processing workstations interconnected by an automated material handling and storage system and controlled by a central computer.
2. The key components of an FMS are workstations, an automated material handling and storage system, and a computer control system. Workstations can include machining centers, assembly stations, and inspection stations.
3. FMS provides several benefits such as decreased lead times, increased output and machine utilization, and reduced inventory levels. However, FMS also requires substantial upfront planning and costs millions of dollars to implement.
1. Automated assembly systems use mechanized devices to perform assembly tasks and are designed for large production quantities of a specific product.
2. They are well-suited for high demand, stable designs, and limited component assembly. Advantages include high production rates, quality, and low costs.
3. Common configurations include in-line machines, dial indexing machines, carousels, and single-station cells. Parts delivery systems rely on feeders, tracks, and placement devices to orient and position components.
The proper implementation and role of flexible manufacturing system in current scenario. Better understanding of different types of flexible manufacturing system layouts and types of flexible manufacturing system.
Other than these, brief introduction of flexibility and types of flexibility in manufacturing and other industries.
Automated storage and retrieval systemPrasanna3804
Automated Storage and Retrieval Systems (ASRS) consist of computer-controlled systems that automatically place and retrieve loads from defined storage locations. ASRS are chosen to address issues like orders taking too long in factories, wasted time searching for items, lost/damaged products, inaccurate records, and safety hazards. The basic structure of an ASRS includes a storage structure, storage/retrieval machine, storage modules, pickup/deposit stations, and an external handling system. SSI Schafer is a leading provider of ASRS and other logistics systems, having been founded in 1937 and now operating globally with over 50 subsidiaries.
Introduction ,FMS Equipment,FMS Layouts ,Analysis Methods for FMS,,advantages of fms,comparison of fms to conventional methods,applications.Benefits of fms.
This document discusses computer aided quality control (CAQC). It introduces CAQC and explains that it uses computers to inspect and test manufactured products to ensure they meet defined quality standards. The objectives of CAQC are listed as increasing inspection and production productivity, reducing lead times and waste. The main components of CAQC are computer aided inspection (CAI) and computer aided testing (CAT). CAI uses 3D scanning and CAD modeling to check part specifications, while CAT simulates stresses and other factors to test attributes like strength. The advantages of CAQC include data harvesting, allowing 100% inspection and testing, using non-contact sensors, and providing computerized feedback control.
Flexible manufacturing systems (FMS) consist of interconnected computer-controlled machines and automated material handling systems. An FMS allows for mixed production and variation in parts, assembly, and processes. It includes processing workstations, an automated transport and storage system, and a computer control system that coordinates the activities. FMS provides benefits like decreased lead times, increased throughput and quality, and reduced costs. However, FMS implementation requires substantial investment and planning to address technological and coordination challenges.
The document is a presentation on automated material handling. It discusses material handling and different types of material handling equipment such as conveyors and automated guided vehicles (AGVs). It describes AGVs in detail, including their components, guidance technologies, and types. It provides an example of calculating the number of AGVs needed based on delivery rate, cycle time, and vehicle availability. The presentation also discusses using simulation to model AGV systems and limitations of automated material handling systems.
1. Flexible manufacturing systems (FMS) allow companies to efficiently produce a variety of products without major retooling. An FMS consists of processing workstations interconnected by an automated material handling and storage system and controlled by a central computer.
2. The key components of an FMS are workstations, an automated material handling and storage system, and a computer control system. Workstations can include machining centers, assembly stations, and inspection stations.
3. FMS provides several benefits such as decreased lead times, increased output and machine utilization, and reduced inventory levels. However, FMS also requires substantial upfront planning and costs millions of dollars to implement.
This document provides an overview of group technology (GT) in manufacturing. It defines GT as an approach that groups similar parts into families to take advantage of their common design and production processes. The key benefits of GT include reduced setup times and inventory costs through specialized machine cells for each part family. While identifying appropriate part families and rearranging production equipment into cells can be challenging initially, GT aims to improve manufacturing efficiency through standardization and reduced material handling.
This document discusses different layout configurations for flexible manufacturing systems (FMS). It describes five types of FMS layouts: progressive or line type, loop type, ladder type, open field type, and robot centered type. For each type, it provides a brief explanation of the layout and flow of parts. It also lists some factors that influence the selection of an FMS layout, such as availability of materials and labor, transportation infrastructure, and local business conditions.
Flexible manufacturing system (fms) and automated guided vehicle system (agvs)mathanArumugam
This document discusses flexible manufacturing systems (FMS) and automated guided vehicle systems (AGVS). It defines FMS as a highly automated group of CNC machine tools interconnected by an automated material handling system. It describes the types, components, and benefits of FMS, including flexibility types like machine flexibility. It also discusses automated guided vehicle systems for material transport, including guidance technologies and vehicle management.
1. Numerical control (NC) systems were developed to automate machine tools using programmed sequences of instructions to control machine motions and functions.
2. NC systems use machine control units to read part programs containing coded instructions and translate them into mechanical actions to control machine tools.
3. Modern computer numerical control (CNC) systems provide greater flexibility over early NC systems by using computers to generate part programs and allow real-time adjustments to machine operations.
Computer application for testing (contact and non-contact)Ghassan Alshahiri
This document discusses computer applications in manufacturing measurement systems. It covers topics like contact and non-contact measurement tools, techniques, and considerations when choosing tools. It also discusses how computer systems perform measurements using sensors, analog to digital conversion, and programming. The document compares contact and non-contact methods, describing technologies like CMMs, laser scanners, and structured light scanners. It notes advantages and disadvantages of different methods and considerations for software for inspection.
The document summarizes the history and development of numerical control, including its evolution from mechanized machining in the 15th century to computerized numerical control (CNC) in the 20th century. It describes the basic components and functions of NC machines, including the machine control unit, machine tool, control loops unit, and data processing unit. It also discusses the different types of numerical control systems such as conventional NC, direct NC, and computer NC.
The document discusses various computer-aided design (CAD) standards used for data exchange, including graphics standards like GKS and OpenGL, as well as data exchange standards like IGES, DXF, and STEP. It provides details on the purpose and requirements of each standard, explaining concepts like layers, entities, and file structure. The key standards discussed are IGES for shape data exchange, DXF for CAD file interchange, and STEP for comprehensive product data across the design and manufacturing lifecycle.
This document discusses transfer devices and feeders used in mass production. It describes transfer systems that move workpieces between machining stations, including linear mechanisms like conveyors and rotary indexing tables. Transfer devices outlined include inline and rotary configurations. Feeders are also discussed, which control the rate of material flow from bins to equipment, differing from conveyors in modulating flow rate. Common part feeding devices to move individual pieces are also listed.
This document discusses automated production lines, also called transfer lines or transfer machines. It provides three key points:
1. Automated production lines consist of multiple linked workstations that perform processing operations like machining on parts. Parts are transferred between stations by a mechanized material handling system.
2. Transfer lines are appropriate for high production demand of parts requiring multiple operations, with stable designs and long product lives. They provide benefits like low labor costs and high production rates.
3. Storage buffers between workstations can reduce the impact of breakdowns and allow production to continue. The effectiveness of buffers depends on their capacity, providing some protection even with small buffers but maximum benefits with unlimited capacity buffers.
Introduction to flexible manufacturing system (fms)Nilraj Vasandia
This document provides an introduction and overview of flexible manufacturing systems (FMS). It discusses the key components of an FMS, including workstations, material handling and storage systems, and a computer control system. The objectives of an FMS are described as flexibility in production, automation and integration, reduced lead times, higher productivity, lower manpower needs, and reduced material handling. Different classifications of FMS are presented based on the number of machines, flexibility, and layout type. Advantages include higher utilization rates and flexibility, while limitations include high costs. FMS are applied to products with medium quantities and variety.
6 CHAPTER SIX - COMPUTER AIDED INSPECTION.pptfahamkhan7
The document discusses computer-aided inspection technologies. It defines inspection as examining products and components to determine if they conform to design specifications. There are two main types of inspection: inspection for variables which measures quality characteristics, and inspection for attributes which determines if a product meets accepted standards. A typical inspection procedure involves presenting an item, examining it for defects, making an acceptance decision, and taking appropriate action. The document focuses on computer-aided inspection tools like coordinate measuring machines (CMMs) and machine vision systems which allow engineers to quickly and precisely assess physical properties of manufactured objects.
This document discusses group technology and computer aided process planning. It defines group technology as identifying and grouping similar parts to take advantage of their common design and production characteristics. The key benefits of group technology are outlined. Implementation involves identifying part families and rearranging production machines into cells dedicated to each family. Various part classification and coding systems used in group technology are also described.
This document discusses automated guided vehicles (AGVs) which are programmed to move materials between workstations on a factory floor. It describes the components, classifications, navigation methods, and control systems of AGVs. It also provides two case studies, one on developing an AGV to change sprinklers in irrigation and another on implementing an AGV system to transport goods in a hospital. The document aims to provide an overview of AGVs, their applications, and examples of their use.
This document provides information on Flexible Manufacturing Systems (FMS) and Automated Guided Vehicle Systems (AGVS). It defines FMS and describes its key components, types, flexibility, planning and control. It also defines AGVS, discusses its applications and benefits, and describes vehicle guidance technologies and management systems used to control traffic and dispatch vehicles.
Introduction
Types of Material Handling Equipment
Material Transport Equipment
Storage Systems
Unitizing Equipment
Identification and Tracking Systems
Principles of Material Handling
Automated Guided Vehicles (AGVs)
Components of AGVS
Types of AGVs
Driverless Trains
Automated Guided Pallet Trucks
AGV Unit Load Carriers
Vehicle Guidance
Imbedded Guide Wires
Paint Strips
Self-guided Vehicles
Vehicle Routing
Frequency Select Method
Path Switch Select Method
Traffic Control
On-board Vehicle Sensing
Zone Control
Benefits of AGV
Applications of AGV
difference of NC and CNC ,Part programming,Methods of manual part programming,Basic CNC input data,Preparatory Functions ,Miscellaneous Functions,Interpolation:Canned cycles:part programming on component,Tool length compensation,Cutter Radius,Task compensation:Types of media of NC
The document discusses shop floor control and flexible manufacturing systems (FMS). It describes the key components and functions of shop floor control including order release, scheduling, and progress phases. It also explains the components, types, layout configurations and applications of FMS, including automated workstations, material handling systems, computer control, and benefits like increased flexibility and productivity.
This document provides an overview of flexible manufacturing systems (FMS). It defines FMS as an automated machine cell consisting of interconnected processing workstations and automated material handling. It discusses the history and purpose of FMS in optimizing manufacturing cycle times and reducing costs. The basic components of FMS are described as workstations, automated material handling systems, and computer control systems. The document outlines different types of FMS layouts and how flexibility is achieved. It provides examples of FMS applications and discusses the advantages of FMS in improving efficiency and reducing production time, while also noting the high expenses associated with implementation.
A flexible manufacturing system (FMS) is a set of numerically controlled machine tools and supporting workstations connected by an automated material handling system and controlled by a central computer, allowing it to process multiple product styles simultaneously. An FMS provides benefits like reduced cycle times, lower inventory levels, improved quality and quicker response to market changes. It uses elements like robotics, material handling equipment, machines, assembly cells, computers and software. Planning and optimization is important to maximize efficiency through approaches like minimizing cycle times, balancing workloads, and incorporating quality inspections.
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.
This document provides an overview of group technology (GT) in manufacturing. It defines GT as an approach that groups similar parts into families to take advantage of their common design and production processes. The key benefits of GT include reduced setup times and inventory costs through specialized machine cells for each part family. While identifying appropriate part families and rearranging production equipment into cells can be challenging initially, GT aims to improve manufacturing efficiency through standardization and reduced material handling.
This document discusses different layout configurations for flexible manufacturing systems (FMS). It describes five types of FMS layouts: progressive or line type, loop type, ladder type, open field type, and robot centered type. For each type, it provides a brief explanation of the layout and flow of parts. It also lists some factors that influence the selection of an FMS layout, such as availability of materials and labor, transportation infrastructure, and local business conditions.
Flexible manufacturing system (fms) and automated guided vehicle system (agvs)mathanArumugam
This document discusses flexible manufacturing systems (FMS) and automated guided vehicle systems (AGVS). It defines FMS as a highly automated group of CNC machine tools interconnected by an automated material handling system. It describes the types, components, and benefits of FMS, including flexibility types like machine flexibility. It also discusses automated guided vehicle systems for material transport, including guidance technologies and vehicle management.
1. Numerical control (NC) systems were developed to automate machine tools using programmed sequences of instructions to control machine motions and functions.
2. NC systems use machine control units to read part programs containing coded instructions and translate them into mechanical actions to control machine tools.
3. Modern computer numerical control (CNC) systems provide greater flexibility over early NC systems by using computers to generate part programs and allow real-time adjustments to machine operations.
Computer application for testing (contact and non-contact)Ghassan Alshahiri
This document discusses computer applications in manufacturing measurement systems. It covers topics like contact and non-contact measurement tools, techniques, and considerations when choosing tools. It also discusses how computer systems perform measurements using sensors, analog to digital conversion, and programming. The document compares contact and non-contact methods, describing technologies like CMMs, laser scanners, and structured light scanners. It notes advantages and disadvantages of different methods and considerations for software for inspection.
The document summarizes the history and development of numerical control, including its evolution from mechanized machining in the 15th century to computerized numerical control (CNC) in the 20th century. It describes the basic components and functions of NC machines, including the machine control unit, machine tool, control loops unit, and data processing unit. It also discusses the different types of numerical control systems such as conventional NC, direct NC, and computer NC.
The document discusses various computer-aided design (CAD) standards used for data exchange, including graphics standards like GKS and OpenGL, as well as data exchange standards like IGES, DXF, and STEP. It provides details on the purpose and requirements of each standard, explaining concepts like layers, entities, and file structure. The key standards discussed are IGES for shape data exchange, DXF for CAD file interchange, and STEP for comprehensive product data across the design and manufacturing lifecycle.
This document discusses transfer devices and feeders used in mass production. It describes transfer systems that move workpieces between machining stations, including linear mechanisms like conveyors and rotary indexing tables. Transfer devices outlined include inline and rotary configurations. Feeders are also discussed, which control the rate of material flow from bins to equipment, differing from conveyors in modulating flow rate. Common part feeding devices to move individual pieces are also listed.
This document discusses automated production lines, also called transfer lines or transfer machines. It provides three key points:
1. Automated production lines consist of multiple linked workstations that perform processing operations like machining on parts. Parts are transferred between stations by a mechanized material handling system.
2. Transfer lines are appropriate for high production demand of parts requiring multiple operations, with stable designs and long product lives. They provide benefits like low labor costs and high production rates.
3. Storage buffers between workstations can reduce the impact of breakdowns and allow production to continue. The effectiveness of buffers depends on their capacity, providing some protection even with small buffers but maximum benefits with unlimited capacity buffers.
Introduction to flexible manufacturing system (fms)Nilraj Vasandia
This document provides an introduction and overview of flexible manufacturing systems (FMS). It discusses the key components of an FMS, including workstations, material handling and storage systems, and a computer control system. The objectives of an FMS are described as flexibility in production, automation and integration, reduced lead times, higher productivity, lower manpower needs, and reduced material handling. Different classifications of FMS are presented based on the number of machines, flexibility, and layout type. Advantages include higher utilization rates and flexibility, while limitations include high costs. FMS are applied to products with medium quantities and variety.
6 CHAPTER SIX - COMPUTER AIDED INSPECTION.pptfahamkhan7
The document discusses computer-aided inspection technologies. It defines inspection as examining products and components to determine if they conform to design specifications. There are two main types of inspection: inspection for variables which measures quality characteristics, and inspection for attributes which determines if a product meets accepted standards. A typical inspection procedure involves presenting an item, examining it for defects, making an acceptance decision, and taking appropriate action. The document focuses on computer-aided inspection tools like coordinate measuring machines (CMMs) and machine vision systems which allow engineers to quickly and precisely assess physical properties of manufactured objects.
This document discusses group technology and computer aided process planning. It defines group technology as identifying and grouping similar parts to take advantage of their common design and production characteristics. The key benefits of group technology are outlined. Implementation involves identifying part families and rearranging production machines into cells dedicated to each family. Various part classification and coding systems used in group technology are also described.
This document discusses automated guided vehicles (AGVs) which are programmed to move materials between workstations on a factory floor. It describes the components, classifications, navigation methods, and control systems of AGVs. It also provides two case studies, one on developing an AGV to change sprinklers in irrigation and another on implementing an AGV system to transport goods in a hospital. The document aims to provide an overview of AGVs, their applications, and examples of their use.
This document provides information on Flexible Manufacturing Systems (FMS) and Automated Guided Vehicle Systems (AGVS). It defines FMS and describes its key components, types, flexibility, planning and control. It also defines AGVS, discusses its applications and benefits, and describes vehicle guidance technologies and management systems used to control traffic and dispatch vehicles.
Introduction
Types of Material Handling Equipment
Material Transport Equipment
Storage Systems
Unitizing Equipment
Identification and Tracking Systems
Principles of Material Handling
Automated Guided Vehicles (AGVs)
Components of AGVS
Types of AGVs
Driverless Trains
Automated Guided Pallet Trucks
AGV Unit Load Carriers
Vehicle Guidance
Imbedded Guide Wires
Paint Strips
Self-guided Vehicles
Vehicle Routing
Frequency Select Method
Path Switch Select Method
Traffic Control
On-board Vehicle Sensing
Zone Control
Benefits of AGV
Applications of AGV
difference of NC and CNC ,Part programming,Methods of manual part programming,Basic CNC input data,Preparatory Functions ,Miscellaneous Functions,Interpolation:Canned cycles:part programming on component,Tool length compensation,Cutter Radius,Task compensation:Types of media of NC
The document discusses shop floor control and flexible manufacturing systems (FMS). It describes the key components and functions of shop floor control including order release, scheduling, and progress phases. It also explains the components, types, layout configurations and applications of FMS, including automated workstations, material handling systems, computer control, and benefits like increased flexibility and productivity.
This document provides an overview of flexible manufacturing systems (FMS). It defines FMS as an automated machine cell consisting of interconnected processing workstations and automated material handling. It discusses the history and purpose of FMS in optimizing manufacturing cycle times and reducing costs. The basic components of FMS are described as workstations, automated material handling systems, and computer control systems. The document outlines different types of FMS layouts and how flexibility is achieved. It provides examples of FMS applications and discusses the advantages of FMS in improving efficiency and reducing production time, while also noting the high expenses associated with implementation.
A flexible manufacturing system (FMS) is a set of numerically controlled machine tools and supporting workstations connected by an automated material handling system and controlled by a central computer, allowing it to process multiple product styles simultaneously. An FMS provides benefits like reduced cycle times, lower inventory levels, improved quality and quicker response to market changes. It uses elements like robotics, material handling equipment, machines, assembly cells, computers and software. Planning and optimization is important to maximize efficiency through approaches like minimizing cycle times, balancing workloads, and incorporating quality inspections.
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.
This document provides an introduction to flexible manufacturing systems (FMS). It defines an FMS as a highly automated manufacturing cell consisting of CNC machine tools and an automated material handling system controlled by a distributed computer system. An FMS is capable of processing different part styles simultaneously and adjusting production in response to demand changes. The document discusses what gives manufacturing systems flexibility, types of flexibility, components of an FMS including workstations, material handling systems, computer control, and human resources, and characteristics of single machine cells, flexible manufacturing cells, and flexible manufacturing systems.
The document discusses flexible manufacturing systems (FMS). It provides a history of FMS, describing how the concept originated in the 1960s and was first implemented by companies in the US, Germany, Russia, and Japan. It defines an FMS as an automated machine cell consisting of interconnected processing workstations and automated material handling. FMS offers benefits like reduced costs, optimized cycle times, and flexibility to handle different part styles and quick changeovers. It classifies FMS based on the number of machines and describes common components and layouts of FMS. Potential applications and advantages are also outlined, along with challenges associated with implementing FMS.
This document provides an overview of flexible manufacturing systems (FMS). It defines an FMS and describes its key elements, features, and components. These include numerically controlled machines, automated material handling systems, coordinated control, reduced costs and space requirements, and increased equipment utilization. The document also discusses modeling approaches for FMS design, including selecting part types and equipment, batch formation, and scheduling and control.
A flexible manufacturing system (FMS) is defined as a set of numerically controlled machine tools and supporting workstations connected by an automated material handling system and controlled by a central computer. An FMS allows for multiple part types to be loaded and processed in any sequence through automated tool changing and material handling. Key benefits include reduced costs, improved equipment utilization, and the ability to easily changeover to new product lines. Effective FMS design requires determining the optimal system size, hardware, software and part selection to maximize savings subject to system capacity.
This document discusses CAD and CAM considerations for flexible manufacturing systems (FMS). For CAD, it describes library of parts, group technology, and special requirements for FMS data preparation including geometry, attributes, and design cycle data. For CAM, it notes that adding a new part to an FMS is a multi-step process considering machining, material, handling, and inspection requirements. It also discusses developing NC programs within a FMS's limited product range and using robot simulators for offline programming.
The document discusses discrete process control systems and the use of programmable logic controllers (PLCs) and personal computers for discrete control. It covers ladder logic diagrams, the basic way that PLCs are programmed to perform logic and sequencing functions. Ladder logic uses rungs of logic elements connected between power rails to represent the control circuits. PLCs and ladder logic are widely used in industry due to their ability to clearly represent control functions in a way that is familiar to plant technicians.
Group technology is a manufacturing philosophy that groups similar parts into families based on their attributes. Parts in a family are processed by a group of dissimilar machines called a machine cell. There are three main methods to form part families: manual visual inspection, production flow analysis, and classification/coding. Classification/coding systems assign symbols to parts to represent design/manufacturing attributes, with the three main types being monocode (hierarchical), polycode (attribute-based), and hybrid codes.
Group Technology is a manufacturing process that produces families of parts within a single production line or cell of machines. A manufacturing cell is a cluster of machines grouped together to produce a similar part family. Techniques like tacit judgment, visual inspection, classification and coding systems, and production flow analysis are used to form part families by identifying parts that require similar manufacturing processes or equipment. Rank order clustering analyzes a machine-part incidence matrix to group similar machines and components into production cells to minimize material handling needs. While cellular manufacturing offers benefits like reduced work-in-process inventory and lead times, it also faces challenges like loss of routing flexibility and difficulty balancing cells over time.
This document discusses coding style guidelines for logic synthesis. It begins with basic concepts of logic synthesis such as converting a high-level design to a gate-level representation using a standard cell library. It then discusses synthesizable Verilog constructs and coding techniques to improve synthesis like using non-blocking assignments in sequential logic blocks. The document also provides guidelines for coding constructs like if-else statements, case statements, always blocks and loops to make the design easily synthesizable. Memory synthesis approaches and techniques for designing clocks and resets are also covered.
A flexible manufacturing system (FMS) is an automated machine cell consisting of a group of processing workstations interconnected by an automated material handling and storage system. It is suited for mid-variety, mid-volume production. An FMS has the ability to identify different part styles, complete quick changeovers of operating instructions and physical setups, and satisfy tests of flexibility including part variety, schedule changes, error recovery, and production of new parts. The basic components of an FMS are workstations, automated material handling and storage systems, and a computer control system.
An FMS integrates highly automated manufacturing systems including flexible automation, CNC machines, distributed computer control, automated material handling and storage to produce a variety of parts simultaneously. It is the most automated and sophisticated type of GT cell. An FMS relies on group technology principles and consists of processing workstations like CNC machines interconnected by an automated material handling system and controlled by a distributed computer system. It is suited for mid-variety, mid-volume production and differentiates itself through its ability to change part mix and quantities in response to demand while maintaining production.
This document discusses cellular manufacturing. It begins by explaining that cellular manufacturing involves grouping similar products together based on their manufacturing requirements and producing them in dedicated manufacturing cells. Each cell contains the necessary machines and resources to produce a family of similar parts. The document then discusses the advantages of cellular manufacturing, such as reduced setup times, inventory, and material handling. It also notes potential disadvantages like issues balancing cell production volumes. The remainder of the document provides details on implementing cellular manufacturing, including identifying part families, designing cell layouts, and arranging machines within each cell for efficient production flow.
Group technology (GT) is a manufacturing philosophy that involves grouping similar parts and products to improve productivity. It aims to form production cells with machines and processes for dissimilar product families. GT implementation involves three phases: actions on manufacturing processes like part simplification, changes to production like tighter part controls, and organizational results like higher quality levels and reduced setup times. GT coding systems classify parts which facilitates communication, cost estimation, and quality improvements through design standardization. While GT provides benefits, organizations may face obstacles like management resistance to change and high startup costs that require training and support to overcome.
This is our first assignment in our English Class at Point College. Assume that this product is going to launch in Malaysia and try to promote this product to your customer.
Our product: Google Driverless Car
Group 3 Members:
- Lee Sweet Wan
- Martin
- Vivy
- Jojo
- Joyce Teoh
- Derrick
This document provides an overview of supply chain management concepts from the first chapter of the textbook "Supply Chain Management (3rd Edition)". It defines a supply chain, outlines the key decision phases of supply chain strategy, planning and operations. It also describes how supply chains can be viewed through either their cycles between stages or their push/pull processes. Key goals of supply chain management are maximizing overall value and profitability across the entire supply chain network.
This document discusses flexible manufacturing systems (FMS). It defines FMS as an automated set of numerically controlled machine tools and material handling systems capable of performing a wide range of manufacturing operations with quick tooling and instruction changeovers. The key components of an FMS are described as numerical control machine tools, work holding and tooling, material handling equipment, inspection equipment, and other ancillary systems. FMS provides several types of flexibility including machine, production, mix, product, routing, volume, and expansion flexibility. The document also outlines the physical and control subsystems that make up an FMS.
The document discusses Group Technology (GT), which is a manufacturing philosophy that increases production efficiency by grouping similar parts together based on their design and production characteristics. GT justifies batch production by capitalizing on similarities among component parts. This grouping results in manufacturing efficiencies such as reduced setup times, lower inventories, better scheduling and quality. The history of GT is outlined, showing it has been applied for over five decades, with early concepts in the 1920s-1930s and widespread adoption in the 1950s and 1960s in the Soviet Union, Western Europe, and later in the United States and Japan.
JIT, Kanban, Kaizen, Muda in TPS (Toyota Production System)Abdul Qadir Master
Prepared by Abdul Qadir, for Proj Procurement and Contracts Subject taken by Sir Usman Khalid, if anyone needs its report in document form can approach me at abdulqadirmail@gmail.com
This document discusses different types of manufacturing systems. It describes manufacturing systems as consisting of production machines, material handling systems, computer control systems, and human resources. The document outlines different types of production machines based on level of automation, from manually operated to fully automated machines. It also discusses different types of manufacturing system layouts including single station cells, multi-station systems with fixed routing along an assembly line, and multi-station systems with variable routing to different workstations. The document provides examples and advantages of different manufacturing system configurations.
Automation involves the use of technology and computers to automate production processes. There are different types of automation based on the level of flexibility, including fixed, programmable, and flexible automation. Flexible manufacturing systems (FMS) are highly automated systems that can produce different product varieties with minimal changeover time. An FMS uses a physical subsystem with workstations, material handling systems, and storage to process parts, along with a control subsystem. Common layout configurations for an FMS include line, loop, ladder, carousel, robot cell, and open field layouts. Benefits of FMS include reduced costs, lead times, and inventories, while limitations include high initial costs and need for skilled labor and pre-
An FMS is a highly automated manufacturing system consisting of CNC machine tools and an automated material handling system controlled by a distributed computer system. It is suited for mid-volume, mid-variety production between 5,000-75,000 parts per year. Advantages include increased efficiency and flexibility to process different part styles and respond to changing production needs. FMS can be classified based on the number of machines, level of flexibility, and type of operations performed.
A flexible manufacturing system (FMS) uses numerically controlled machine tools connected by an automated material handling system and controlled by a central computer. An FMS can process multiple product styles simultaneously unlike an automated production line. It allows changes to production schedules to meet varying product demands. Key components of an FMS include workstations, an automated material handling system, computer control system, and human labor. Common FMS layouts are progressive, loop, ladder, open field, and robot-centered.
Flexible manufacturing systems (FMS) are automated production systems comprised of multiple computer-controlled machines linked together by an automated material handling and transport system and controlled by a distributed computer system. An FMS allows for flexible production of different part types by easily changing production schedules and introducing new product styles. FMS range from single machine cells to larger systems with multiple workstations. They provide benefits like reduced costs and lead times but also have disadvantages like high initial costs and limited ability to adapt to product changes.
What is FMS?
Types of Flexibility
Types of FMS
FMS Components
Workstations
Material Handling and Storage Systems
Computer Control System
Human Recourses
FMS Layout
Applications
Benefits
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.
• The FMS is most suited for
the mid-variety, mid-volume
production range
Flexible manufacturing systems (FMS) provide the ability to produce a variety of parts at non-uniform rates with small batch sizes. An FMS consists of programmable machines interconnected by an automated material handling and storage system controlled by an integrated computer system. It is characterized by variety of products, small volumes, less lead time, high quality, and low cost. The core components of an FMS include the manufacturing system, tool handling/storage, material handling/storage, and computer control system. FMS offers benefits like flexibility, higher efficiency, reduced lead times and costs, and increased productivity.
FMS is a manufacturing philosophy based on the concept of effectively controlling material flow through a network of versatile production stations using an efficient and versatile material handling and storage system.
The FMS is most suited for the mid-variety, mid-volume production range
A flexible manufacturing system (FMS) is an automated machine cell consisting of a group of processing workstations interconnected by an automated material handling and storage system. An FMS is suited for mid-variety, mid-volume production and provides benefits like reducing production costs and cycle times. An FMS must be able to identify different part styles, quickly change operating instructions, and quickly change physical setups. The basic components of an FMS are workstations, automated material handling and storage systems, and a computer control system. [/SUMMARY]
Flexible manufacturing systems (FMS) were first conceptualized in the 1960s and allow for automated production with interchangeable parts. An FMS consists of multiple automated workstations like CNC machines connected by an automated material handling system. This automation allows for flexibility in production, including the ability to produce different part styles and quick changeovers. While offering advantages like improved efficiency and quality, implementing an FMS presents challenges around costs, maintenance, and adapting to production changes.
This document provides an overview of flexible manufacturing systems (FMS). It defines FMS and identifies its key components: workstations, material handling systems, and computer control systems. It also describes different types of flexibility in FMS and provides examples of FMS applications. An operational problem is presented and solved to demonstrate how to determine the optimal parts to produce given constraints like due dates, machine hours, and tool availability.
Flexible Manufacturing System, Advantages and DIsadvantages of FMSRajivB10
A flexible manufacturing system (FMS) consists of numerically controlled machine tools and automated material handling equipment controlled by a central computer. An FMS allows for flexible production of many part types in any sequence using automated tool changing and material handling. Key components include machines, automated material handling systems, and a central controller. FMS aims to improve efficiency, reduce costs, and increase flexibility over traditional manufacturing methods.
Plant layout refers to the physical arrangement of equipment, machinery, workstations, and space in a manufacturing facility. The key types of layouts discussed are process layout, product layout, mixed layout, fixed layout, and group technology layout. Process layout groups similar processes together while product layout arranges machinery in a linear flow. Group technology layout clusters machines by part families to reduce setup times and material handling. Flexible manufacturing systems apply group technology and automation to allow production of different product styles simultaneously on the same system.
This document discusses flexible manufacturing systems (FMS) over five units. It introduces FMS, including its evolution and basic components. FMS combines computer controlled machine tools with automated material handling to improve manufacturing flexibility. The document then covers group technology, flexible manufacturing cells, FMS software, and provides examples of FMS layouts including progressive, loop, ladder, open field, and robot centered types. The goal of FMS is to efficiently produce variable mixes of parts in lower volumes with reduced setup times and costs.
The document discusses manufacturing systems and lean manufacturing. It defines a manufacturing system as a collection of integrated equipment and human resources that perform processing and assembly operations on raw materials. It describes the typical input-transformation-output process. Examples of manufacturing systems include single station cells, machine clusters, and automated assembly lines. The key components of manufacturing systems are production machines, material handling systems, computer systems, and human resources. Lean manufacturing aims to eliminate waste from the manufacturing system, such as overproduction, waiting, inventory, transportation, and over-processing. It was pioneered by Toyota to increase efficiency and reduce costs.
Flexible manufacturing system - Computer aided manufacturingsajan gohel
This document discusses flexible manufacturing systems (FMS). It defines an FMS as an automated machine cell consisting of a group of processing workstations interconnected with an automated material handling and storage system. The key components of an FMS are workstations, material handling/storage systems, computer control systems, and human resources. An FMS provides various types of flexibility including flexibility of product variety, production volume, delivery time, material handling, operations, expansion, and markets. The document then provides a brief history of FMS and classifications including single machine cells, flexible manufacturing cells, and flexible manufacturing systems.
Definition of Automation
Automated Manufacturing Systems
Types of Manufacturing Automation
Levels of Automation
Computerized Manufacturing Support Systems
Reasons for Automation
Automation Strategies-The USA Principle
Ten Strategies for Automation and Process Improvement
Automation Migration Strategy
Benefits of Automation
References
The document discusses different types of manufacturing system layouts and capacity management strategies. It describes three basic layout types - process, product, and fixed-position layouts. It also covers hybrid layouts like cellular manufacturing, flexible manufacturing systems, and mixed-model assembly lines. The document then discusses capacity planning strategies like capacity lead, capacity lag, and average capacity strategies to match production capacity with demand over time.
Just-in-Time (JIT) systems were developed by Toyota in response to low production levels in Japan compared to the US. The key principles of JIT developed by Toyota include eliminating waste, producing only necessary units in the required quantity at the required time, and having flexible resources and reliable suppliers. Taiichi Ohno at Toyota was a major inventor of JIT and focused on continuous improvement, small lot sizes, quick set-ups, and quality at the source to reduce waste and inventory in production.
Executive Directors Chat Leveraging AI for Diversity, Equity, and InclusionTechSoup
Let’s explore the intersection of technology and equity in the final session of our DEI series. Discover how AI tools, like ChatGPT, can be used to support and enhance your nonprofit's DEI initiatives. Participants will gain insights into practical AI applications and get tips for leveraging technology to advance their DEI goals.
This presentation includes basic of PCOS their pathology and treatment and also Ayurveda correlation of PCOS and Ayurvedic line of treatment mentioned in classics.
Strategies for Effective Upskilling is a presentation by Chinwendu Peace in a Your Skill Boost Masterclass organisation by the Excellence Foundation for South Sudan on 08th and 09th June 2024 from 1 PM to 3 PM on each day.
How to Manage Your Lost Opportunities in Odoo 17 CRMCeline George
Odoo 17 CRM allows us to track why we lose sales opportunities with "Lost Reasons." This helps analyze our sales process and identify areas for improvement. Here's how to configure lost reasons in Odoo 17 CRM
The simplified electron and muon model, Oscillating Spacetime: The Foundation...RitikBhardwaj56
Discover the Simplified Electron and Muon Model: A New Wave-Based Approach to Understanding Particles delves into a groundbreaking theory that presents electrons and muons as rotating soliton waves within oscillating spacetime. Geared towards students, researchers, and science buffs, this book breaks down complex ideas into simple explanations. It covers topics such as electron waves, temporal dynamics, and the implications of this model on particle physics. With clear illustrations and easy-to-follow explanations, readers will gain a new outlook on the universe's fundamental nature.
Exploiting Artificial Intelligence for Empowering Researchers and Faculty, In...Dr. Vinod Kumar Kanvaria
Exploiting Artificial Intelligence for Empowering Researchers and Faculty,
International FDP on Fundamentals of Research in Social Sciences
at Integral University, Lucknow, 06.06.2024
By Dr. Vinod Kumar Kanvaria
हिंदी वर्णमाला पीपीटी, hindi alphabet PPT presentation, hindi varnamala PPT, Hindi Varnamala pdf, हिंदी स्वर, हिंदी व्यंजन, sikhiye hindi varnmala, dr. mulla adam ali, hindi language and literature, hindi alphabet with drawing, hindi alphabet pdf, hindi varnamala for childrens, hindi language, hindi varnamala practice for kids, https://www.drmullaadamali.com
ISO/IEC 27001, ISO/IEC 42001, and GDPR: Best Practices for Implementation and...PECB
Denis is a dynamic and results-driven Chief Information Officer (CIO) with a distinguished career spanning information systems analysis and technical project management. With a proven track record of spearheading the design and delivery of cutting-edge Information Management solutions, he has consistently elevated business operations, streamlined reporting functions, and maximized process efficiency.
Certified as an ISO/IEC 27001: Information Security Management Systems (ISMS) Lead Implementer, Data Protection Officer, and Cyber Risks Analyst, Denis brings a heightened focus on data security, privacy, and cyber resilience to every endeavor.
His expertise extends across a diverse spectrum of reporting, database, and web development applications, underpinned by an exceptional grasp of data storage and virtualization technologies. His proficiency in application testing, database administration, and data cleansing ensures seamless execution of complex projects.
What sets Denis apart is his comprehensive understanding of Business and Systems Analysis technologies, honed through involvement in all phases of the Software Development Lifecycle (SDLC). From meticulous requirements gathering to precise analysis, innovative design, rigorous development, thorough testing, and successful implementation, he has consistently delivered exceptional results.
Throughout his career, he has taken on multifaceted roles, from leading technical project management teams to owning solutions that drive operational excellence. His conscientious and proactive approach is unwavering, whether he is working independently or collaboratively within a team. His ability to connect with colleagues on a personal level underscores his commitment to fostering a harmonious and productive workplace environment.
Date: May 29, 2024
Tags: Information Security, ISO/IEC 27001, ISO/IEC 42001, Artificial Intelligence, GDPR
-------------------------------------------------------------------------------
Find out more about ISO training and certification services
Training: ISO/IEC 27001 Information Security Management System - EN | PECB
ISO/IEC 42001 Artificial Intelligence Management System - EN | PECB
General Data Protection Regulation (GDPR) - Training Courses - EN | PECB
Webinars: https://pecb.com/webinars
Article: https://pecb.com/article
-------------------------------------------------------------------------------
For more information about PECB:
Website: https://pecb.com/
LinkedIn: https://www.linkedin.com/company/pecb/
Facebook: https://www.facebook.com/PECBInternational/
Slideshare: http://www.slideshare.net/PECBCERTIFICATION
ISO/IEC 27001, ISO/IEC 42001, and GDPR: Best Practices for Implementation and...
Fms (1)
1. Flexible Manufacturing System
• Introduction to FMS
• Features of FMS
• Operational problems in FMS
• Layout considerations
• Sequencing of Robot Moves
• FMS Scheduling and control
• Examples
• Deadlocking
• Flow system
• Complex control FMS
• General Shop-Floor Control Problem
2. Why do we need flexibility in manufacturing systems?
• Variety in products thus options for the consumers
• Optimizing the manufacturing cycle time
• Reduced production costs
• Overcoming internal changes like failure, breakdowns, limited
sources, etc.
• External changes such as change in product design and
production system.
3. Flexibility in Manufacturing System:
• ?
• Flexibility can be defined as collection of properties of a
manufacturing system that support changes in production
activities or capabilities (Carter,1986).
• Ability of the manufacturing system to respond effectively to
both internal and external changes by having built-in
redundancy of versatile equipments.
4. Various types of flexibility?
• Machine flexibility
– Capability of a machine to perform a variety of operations on a variety
of part types and sizes
• Routing flexibility
– Alternative machines, sequences or resources can be used for
manufacturing a part for changes resulting from equipment
breakdowns, tool breakages, controller failures, etc.
• Process flexibility
– Ability to absorb changes in the product mix by performing similar
operations, producing similar products or parts.
• Product flexibility
– Ability to change over to a new set of products economically and
quickly in response to markets
• Production flexibility
– Ability to produce a range of products without adding capital
equipment
• Expansion flexibility
– Ability to change a manufacturing system with a view to
accommodating a changed product envelope
6. Classification of the manufacturing system based on Volume-variety
considerations:
Transfer Line (High-Volume, Low-Variety Production system, H-L)
• Machines dedicated to manufacture of one or 2 product types.
• Nearly no flexibility
• Maximum utilization and high production volume
• Direct labor cost is minimal
• Low per unit cost
Stand Alone NC machines / Flexible Manufacturing module
(Low-Volume High-Variety Production system, L-H)
• Highest level of flexibility
• Low utilization and low production volume
• Very high per unit cost
Mid-Volume Mid-Variety Production systems, M-M
• Manufacturing Cell
• Flexible manufacturing system
• Special Manufacturing System
7. Manufacturing Cell
• Low to mid-volume, most of the parts are manufactured in batch mode
• Similar to an FMS, but no central control
• Most flexible in CIM category
• Lowest production rate in CIM systems
Flexible manufacturing system
• Actual M-M manufacturing system.
• Automated material-handling system, NC machines (flexible machines), automated tools and
pallet changer, auto-gauge systems, etc.
• Allows both sequential and random routing of a wide variety of parts.
• Higher production rate than manufacturing cell
• High degree of overlap between this and cell manufacturing system
• Higher flexibility than special manufacturing systems
Special Manufacturing System
• Least flexible category of CIM system
• Multispindle heads and low-level controller
• High production rate and low per unit cost
• Main difference: - Fixed-path material-handling system links the machines together.
- Sequence based dedicated machines.
8. What is FMS?
• “ an automated, mid-volume, mid-variety, central computer-
controlled manufacturing system”
• Activities covered: machining, sheet metal working, welding,
fabricating, assembly
• Physical components:
– Potentially independent NC machine tools capable of
performing multiple functions and having automated tool
interchange capabilities
– Automated material handling system to move parts
between machine tools and fixturing stations
– All the components are hierarchically computer controlled
– Equipment such as coordinate measuring machines and
part-washing devices
9.
10.
11.
12. A FMS consists of:
• Physical subsystem
-Workstations: NC machine tools, inspection equipment,
part-washing devices, load & unload area.
-Storage-retrieval systems
-Material handling systems
• Control subsystem
-Control hardware
-Control software
13. NC machine tools: The major building blocks of an FMS,
determine the degree of flexibility,
determine the capabilities.
Machining centers with numerical control of movements in up to five axes.
Spindle movement in x, y and z directions, rotation of table, and tilting of table.
14. Workholding and Tooling considerations
• Fixtures and pallets must be designed to minimize part-handling time
• Strategies required for storage/retrieval of different fixtures
• Integration with AS/RS and material handling system
• Machining centers are equipped with tool storage known as tool
magazine.
15. Control systems in FMS
• Work-order processing and part control system
– Part process planning module, part routing module, part setup module,
etc.
• Machine tool control system
– DNC transmitter control module, NC editor, machine monitor and
control module
• Tool management and control system
– To control the processing of parts and enhance the flexibility to
manufacturing variety of parts. Tool identification, tool setup, tool
routing, tool replacement strategies are accomplished by the system
• Traffic management control system
– Material handling and storage control system coordinates part routing,
fixtures, pallets and tool modules
16. • Quality control management system
• Capabilities include collection, storage, retrieval, and achieving of
work-piece inspection data.
• Maintenance control system (service control system)
• On-line help, alarms due to problems, etc.
• Management control system
• Provides the management status of output performance.
• Interfacing of these subsystems with the central computer
17. FMS Architecture
• An FMS is a complex network of equipment and processes that must be controlled via
a computer or network of computers.
• System is usually divided into a task-based hierarchy.
• One of the standard hierarchies that have evolved is the National Institute of Standards
and Technology (NIST) factory-control hierarchy.
• This hierarchy consists of five levels and is illustrated in Figures.
18. •The system consists of physical machining equipment at the lowest level of the system.
•Workstation equipment resides just above the process level and provides integration and
interface functions for the equipment.
• Pallet fixtures and programming elements are part of the workstation.
• Provides both man-machine interface as well as machine-part interface.
• Off-line programming such as APT for NC or AML for a robot resides at the this
level.
• The cell is the unit in the hierarchy where interaction between machines becomes part of
the system.
• Provides the interface between the machines and material-handling system.
• Responsible for sequencing and scheduling parts through the system .
• At the shop level, integration of multiple cells occurs as well as the planning and
management of inventory.
•The facility level is the place in the hierarchy where the master production schedule is
constructed and manufacturing resource planning is conducted.
• Ordering materials, planning inventories, and analyzing business plans are part of the
activities that affect the production system.
19. Operational Problems in FMS
• Part selection and tool management
• Fixture and pallet selection
• Machine grouping and loading, considering part and tool assignments
Part Selection
• Batching approach
- Part types are partitioned into separate sets called batches. The selected part
types in a particular batch are manufactured continuously until all the
production requirements are completed. Then processing the next batch,
removing all the tools, loading new tools for the new batch.
• Flexible approach
- When the production requirements of some part types are finished, space
becomes available in the tool magazine. New part types may be introduced
into the system for immediate and simultaneous processing if this input can
help increase utilization of the system. This requires more frequent tool
changes.
20. Part Selection (continue….)
Hwang’s Integer Programming model (Optimization approach )
Part types i = 1,2,…..,N
Cutting tool types c = 1,2,….,C
Tool magazine capacity t
bic = 1 if part type i requires tool c
0 otherwise
dc = number of tool slots required to hold cutting tool c in a magazine of each
machine
zi = 1 if part type i is selected in the batch
0 otherwise
yc = 1 if cutting tool c is loaded on a machine
0 otherwise
zi and yc are the decision variables. Consider the system of identical machines,
Maximize Σ zi
subject to Σ dc yc ≤ t
bizi ≤ yc all i, c
zi = 0 or 1 all i
yc= 0 or 1 all c
• Objective function max. the number of parts in a batch.
• Tool magazine capacity is the constraint for that machine type.
• By repeatedly solving the problem subsequent batches are formed, after deleting already
• selected part types from the model.
21. • Consider the following example of 8 parts and corresponding tools required given in
the tables. The tool magazine capacity is limited to 5 tool slots. Determine the
batches of the part types selected:
Part types and required tools:
Part Types P1 P2 P3 P4 P5 P6 P7 P8
Types of t1 t2 t3 t4 t1,t2 t3,t5 t6 t1,t2,t7
tools required
Tool types and required slots:
Tool types t1 t2 t3 t4 t5 t6 t7
No. of slots req. 1 1 1 1 1 2 2
Solution: Max f = z1+z2….+z8
subject to: y1 + y2 + y3 + y4 + y5 + 2*y6 + 2*y7 = < 5
z1 - y1 =< 0 , z2 – y2 =< 0, …….
The integer programming model results in the following batches of the part types
selected.
Batch 1: P1,P2, P3, P4, P5, P6
Batch 2: p7
Batch 3: p8
22. Stecke and Kim Extension of Hwang’s Model
Modified objective function of Hwang’s model by incorporating the number of tool slots
required for all operations for each part type as a coefficient. Here, the objective function aims
to select the part types with the largest number of required tools. This permits the consideration
of more toll overlaps. The modified model is
Maximize Σi (Σc bicdc )zi
Subject to Σc dcyc ≤ t
biczi ≤ yc all i,c
zi = 0 or 1 all i
Example yck = 0 or 1 all c
Part types and required tools:
Part Types P1 P2 P3 P4 P5 P6 P7 P8
Types of t1 t2 t3 t4 t1,t2 t3,t5 t6 t1,t2,t7
tools required
Tool types and required slots:
Tool types t1 t2 t3 t4 t5 t6 t7
No. of slots req. 1 1 1 1 1 2 2
Solution: Max f = z1 + z2 + z3 + z4 + 2*z5 + 2*z6 + 2*z7 + 4*z8
subject to: y1 + y2 + y3 + y4 + y5 + 2*y6 + 2*y7 = < 5
z1 - y1 =< 0 , z2 – y2 =< 0, ……. (same as previous constraints)
The integer programming model results in the following batches of the part types selected.
Batch 1: P1,P2, P3, P5, P8
Batch 2: P4, P6, P7
(Number of batches is reduced to 2, compared to 3 in the previous solution)
23. Tool Allocation Policies / Tool Management
Tool Allocation Strategies:
• Bulk exchange policy
• Tool migration policy
• Resident Tooling Policy
• Tool Sharing Policy
Resident tooling policy:
• Forms cluster different combinations of tools representing similar processing
requirements of parts.
• Formed clusters are made permanently available at various machines
• Benefits: Ease of tool condition monitoring
Easy identification of tools for replacement.
Example of the above policy:
Solution: Using similarity coefficients between tools and the Single linkage cluster analysis
approach, 2 tool groups have been obtained.
First: (t1, t2, t5, t6), (p1, p3, p5, p6, p10, p11, p13, p15)
Second: (t3, t4, t7, t8, t9), (p2, p4, p7, p8, p12, p14)
24. Fixture and Pallet Selection:
The approximate number of pallets required can be estimated:
Number of pallets = parts req. per shift * avg. pallet cycle time
Planned production time per shift *
no. of parts per pallet
Example:
Parts req. per shift = 20
Avg. pallet cycle time = 120
Planned production per shift = 480
No. of parts per pallet = 1
Solution: Number of pallets req.: (20 * 120) / (480 * 1)
=5
25. Layout Considerations
• Layout is one of the important design characteristics of FMS
design.
• The layout of machines to process part families in an FMS is
determined by the type of material handling equipment used.
26.
27. A model for the Single-Row Machine layout problem:
(based on Naghabat, 1974, Heragu, et al, 1988, Kusiak, 1990)
Objective:
Minimize the total cost of making the required trips between machines by
determining the non-overlapping optimal sequence of machines
m = number of machines
fij = frequency of trips between all pairs of machines (frequency matrix) for all (i, j),
i not equal to j.
cij = material-handling cost per unit distance between all pairs of machines for all (i,
j), i not equal to j.
li = length of the ith machine
dij = clearance between machines i and j.
xj = distance of jth machine from the vertical reference as shown in figure.
MinimizeZ = ∑ ∑c
m −1 m
ij f ij x i − x j
i =1 j = i +1
Subject to: x i − x j ≥ (l i + l j ) + d ij and j = i+1, …., m
1 for all i, i = 1, 2, …, m-1
2
xi ≥ 0 for all i = 1,…., m
28. A simple heuristic algorithm for circular and linear Single-Row machine
layouts:
Data required
•m = number of machines
•fij = frequency of trips between all pairs of machines (frequency matrix) for all (i, j), i not equal
to j.
•cij = material-handling cost per unit distance between all pairs of machines for all (i, j), i not
equal to j.
Step 1: From the frequency and cost matrices, determine the adjusted flow matrix as follows:
F = [ f ij ] = [ f ij cij ]
Step 2: Determine f i ' j ' = max[ f ij , for .all .i.and . j ].
Obtain the partial solution by connecting i’ and j’. Set f i' j' = f j 'i ' = −∞
Step 3: Determine f p 'q ' = max[ f i 'k , f j 'l : k = 1,2,..., m; l = 1,2,...m].
Step 3.1: Connect q’ to p’ and add q’ to the partial solution.
Step 3.2: Delete row p’ and column p’ from [ f ij ]
Step 3.3: if p’ = i’, set i’ = q’; otherwise, set j’ = q’.
Step 4: Repeat step 3 until all the machines are included in the solution.
29. Ex: Five machines in a FMS to be observed by an AGV. A linear single-row is
recommended because of AGV. The data on the frequency of AGV trips, material-handling
cost per unit distance, and clearance between the machines are given in the following
tables. Suggest a suitable layout.
Frequency of trips between pairs of machines: Cost Matrix:
1 2 3 4 5 1 2 3 4 5
1 0 20 70 50 30 1 0 2 7 5 3
2 20 0 10 40 15 2 2 0 1 4 2
3 70 10 0 18 21 3 7 1 0 1 2
4 50 40 18 0 35 4 5 4 1 0 3
5 30 15 21 35 0 5 3 2 2 3 0
The machine dimensions: Clearance Matrix:
Machines M1 M2 M3 M4 M5 1 2 3 4 5
Machine sizes 10*10 15*15 20*30 20*20 25*15 1 0 2 1 1 1
2 2 0 1 2 2
3 1 1 0 1 2
4 1 2 1 0 1
5 1 2 2 1 0
30. Solution:
Step 1: Determine the adjusted flow matrix (given below):
Step 2: Include machines 1 and 3 in the partial solution as they are connected.
Step 3: a) Add machine 4 to the partial solution, as it is connected to machine 1. Delete row 1
and column 1.
Step 3: b) Add machine 2 to the partial solution, as it is connected to machine 4. Delete row
and column 4 from the matrix.
Step 3: c) Add machine 5 to the partial solution.
Step 4: Because all the machines are connected, stop. The final sequence is 5, 2, 4, 1, 3. It is
obtained by arranging the adjusted flow weights in increasing order while retaining the
connectivity of the machines. Accordingly, the final layout considering the clearances between
the machine is as shown.
1 2 3 4 5
1 0 40 490 250 90
2 40 0 10 160 30
3 490 10 0 18 42
4 250 160 18 0 105
5 90 30 42 105 0
31. Sequencing of robot moves
Alternative sequences of robot moves in a two-machine robot moves.
fig (a): Robot picks up a part at I, moves to m/c M1, loads the part on m/c M1, waits at M1 until
the part has been processed, unloads the part from M1, moves to m/c M2, loads the part on M2,
waits at M2 until the part has been processed there, unloads the part from M2, moves to O,
drops the part at O and moves back to I.
Cycle time T1 for fig (a) = ε + δ + ε + 3δ + ε + δ + ε + a + ε + δ + ε + b
T1 = 6ε + 6δ + a + b
where,
a and b are processing time on Machine 1 and 2 respectively.
‘ε’ is the robot pick up/release time.
‘δ’ is the robot move time between M1 & M2
32. Sequencing of robot moves
Alternative sequences of robot moves in a two-machine robot moves.
fig (b): Robot picks up a part P1 at I, moves to m/c M1, loads the part on m/c M1, waits at M1
until the part has been processed, unloads the part from M1, moves to m/c M2, loads the part on
M2, moves back to I. Picks up another part P2 at /I, moves to M1, loads P2 on M1, if necessary
waits at M2 until the earlier part P1 has been processed, unloads P1, moves to O, drops P1 at O,
moves to M1, if necessary waits at M1 until part P2 has been processed, unloads P2, moves to
M2, loads P2 on M2, and moves to I.
Cycle time T2 for fig (b) = ε + δ + ε + 2δ + w1 + ε + δ + ε + 2δ + ε + δ + ε + δ + w2
T2 = 6ε + 8δ + w1 + w2
taking α = 4ε + 4δ and µ = 2ε + 4δ,
T2 = α + µ + w1 + w2
= α + µ + max{0, b - µ} + max{2ε + 4δ, a, b}
= α + max{µ, b, a} = 4ε + 4δ + max{2ε + 4δ, a, b}
where,
w1 = max{0, a - 4δ - 2ε - w2}
w2 = max{0, b - 4δ - 2ε}
33. Algorithm:Step 0: Calculate µ = 2ε + 4δ
Step 1: Calculate µ ≤ max {a, b}, then T2 is optimal. Calculate T2 and stop.
Otherwise go to step 2.
Step 2: If µ > max {a, b} and 2δ ≤ a + b, then T2 is optimal. Calculate T2 and stop.
Otherwise go to step 3.
Step 3: If µ > max {a, b} and 2δ > a + b, then T1 is optimal. Calculate T1 and stop.
Example: Determine the optimal cycle time and corresponding robot sequences in a two-
machine robotic cell with the following data:
Processing time of Machine M1 =11.00 min
Processing time of Machine M2 =09.00 min
Robot gripper pickup = 0.16 min
Robot gripper release time = 0.16 min
Robot move time between the two machines = 0.24 min
Solution:
Step 0: µ = 2ε + 4δ
µ = 2(0.16) + 4(0.24) = 1.28 min
Step 1: µ ≤ max {a, b}
1.28 ≤ max {11, 9}, i.e.1.28 < 11. Therefore, T2 is optimal.
T2 = α + max {µ, a, b}
T2 = [4ε + 4δ] + max {1.28, 11, 9} = [4(0.16) + 4(0.24)] + 11
T2 = 1.6 + 11 = 12.6 min
The optimal cycle time is 12.6 min and the optimal robot is given by fig (b) as shown in the
previous slide.
34. FMS Scheduling and Control
• Flexible manufacturing systems can differ significantly in complexity.
•Complexity is determined by:
•The number of machines and the number of parts resident in the system.
•The complexity of parts and control requirements of the specific equipment.
Example 1: The most simple FMS consists of a processing machine, a load/unload area, and
a material handler (a one-machine system is the most simple FMS that can be constructed).
Operation of this system consists of loading the part/parts that move down a conveyor to the
machine.
Once the part is loaded onto the machine, the robot is retracted to a "safe position" and the
machining begins.
For a single part is to be processed in the system, a minimum number of switches and
sensors required are:
Parts on the conveyor all have to be oriented in the same way.
Robot can pick up the part and deliver it to the NC machine in the same
orientation.
Proximity switch or micro-switch is required at the end of the conveyor to detect
when a part is resident, and on the machine for the same purpose.
A simple programmable logic controller can easily control this system.
35. The logic for the system is as follows:
1. If a part is resident at the end of the
conveyor (switch 1 is on) and no part is
on the NC machine (switch 2 is off),
then pick up the part on the conveyor
and move it to the NC machine and
retract the robot to a safe point (run
robot program I). After the program is
complete and switch 2 senses that the
part is correctly positioned, start the NC
machine (turn on relay M,). While the
machine is running, a switch signal
from the NC machine, switch #2, will
be ON.
2. If switch 11 is off and switch # 2 is on
(the NC machine has completed
processing a part), take the part off the
NC machine and move it to the output
bin (run robot program 2).
36. Add little complexity: Example 2
If the same system were to be used to process a variety of parts, several changes in the control
would be required.
•Either several robot programs for handling the parts would be necessary or a common
part pallet would be necessary for gripping the part.
•For simplicity, its assume that a common pallet is used to fixture all parts.
•Need to detect which part is resident at each station.
Part identification is usually performed by a bar-code reader or by using a set of switches that
each pallet will trigger.
Each pallet type (and sometimes each pallet) then can be identified by the combination of
switches that are active.
For instance, sixteen part types could be
identified using four 2-state switches (24). These
switches are numbered 31-34 (Diagram of Robot,
machine and conveyor).
Variety of different part programs have to be
executed to machine each different part type.
The PLC ladder logic indicates which program
should be run in CNC machine.
37. The system consists of two CNC
machines, a robot, a load station,
and an output bin. Parts enter the
system on a conveyor in a pre-
specified order that cannot be
altered once the parts are on the
conveyor.
Example 3: Single part routing
is assumed for this system.
The control logic for the system is summarized
as follows :
1. If a part is at the end of the conveyor (switch
1 is on) and no part is on machine 1 (switch
11 is off), move the part from the conveyor
to the machine (run robot program 1).
2. If a part is finished at machine 1 (switch 11
is on and switch 12 is off) and machine 2 is
empty (switch 21 is off), move the part from
machine 1 to machine 2.
3. If the part on machine 2 is complete (switch
21 is on and switch 22 is off), remove the
part from the machine and place it in the
output bin .
38. Example 4: Case-I. If two parts are allowed to
A two-machine enter the system in a random order
two-part FMS. (but 2nd part is processed after
finishing the 1st part):
Part identification is necessary.
If the parts are of different size,
different robot programs may be
required unless the parts are on a
common-size pallet fixture (assumed in
this case).
Two state switches are required on
each machine: one to detect if a part is
on the machine and one to determine
Case-II. If the parts are allowed to be mixed in the whether it is part 1 or 2.
system. Consider this case:
If all part 1's are in the system, the
Part 1 is in the system and at machine 1 and part 2 is at control of the system is the same as it
the load point on the conveyor. Then if , part 2 is moved was previously.
to machine 2 and processing begins, system "locks" or
"deadlocks." If all part 2's are in the system, a
Part 1 must be moved to machine 2, which is occupied similar control is required, changing
by part 2. When part 2 is complete, it must be moved to the routing from machine 1 to machine
machine 1, which is also occupied. 2 and vice versa.
39. Deadlocking
Deadlocking can occur in an operational FMSs. It can only be overcome by human intervention .
In order to eliminate dead-locking, one of two fixes are required:
1. A queuing station is required or,
2. Both/multiple parts are not allowed in the system at the same time.
In order to eliminate deadlocking by adding queueing stations:
• If n parts are allowed in the system, then n - 1 queueing stations will be required to
ensure that blocking does not occur.
• Part routing can significantly reduce this number, may be to zero.
For the system with a queueing station, logic is:
1. If part 1 is on machine 1 and part 2 is at the load position on the conveyor, then load a
part from the conveyor to machine 2.
2. If part 2 is on machine 2 and part 1 is on the load position on the conveyor, then load a
part from the conveyor to machine l.
40. The processing times are given as
part of the figure, gantt chart.
Assumed that 1 min of handling
time is required for each robot
operation. Also, assumed that parts
are batched in groups of 2, that is,
two part 1's are followed by two part
2's, and so on.
Gantt chart for the 2 m/c 2 part FMS: ‘1’ / ‘2’ indicates
that part 1 / part 2 is being processed, handled, or queued, Completion of five parts requires 44
respectively. time units given the control strategy
and the additional queueing station.
Indication of, when locking can
occur is that the network graph of
the system forms a closed graph.
Whenever a closed circuit of arcs
occurs on the network, a potential
for locking occurs.
When an additional queueing station
Network graph of a 2-machine 2-part FMS-system flow. is added to the system, the continuity
(a) Part 1 at machine 1 and part 2 at machine 2. of the circuit is broken.
(b) Part 1 at machine 1 and part 2 at machine 2 and a queue.
41. Flow Systems
FMSs are also designed to produce part families that produce a flow-system environment
rather than a job-shop environment.
A flow system constrains the flow and control of the system significantly.
• All parts must follow the same routing.
• The machines need not perform an operation on all parts, but all parts must visit all
machines.
The logic control of the system:
1. If a part is at the load station and machine 1 is idle, move the part to machine 1.
2. If a part is resident at machine m and complete and machine m + 1 is idle, move the part to
machine m + l.
3. If a part is at a machine and unprocessed, process that part.
4. If a part is at the last machine and complete, move it to the unload station.
Example. The 3 machine
system (figure), parts enter
the system at the load station
and are then moved to the
first NC machine by robot 1.
Robot 2 then moves the part
from machine 1 to machine
2, and so forth.
43. Part Routings
Robot handling times
Partial state table of the control for 3 m/c 5 part FMS
aL denotes that the robot is currently directed at the load station.
M1 = machine 1, M2 = machine 2 ; M3 = machine 3 .
bUnderlined entries indicate that the operation is complete.
c1,2 indicates that part 1, operation 2 is currently being performed at
that station.
44. General Shop-Floor Control Problem
A shop consists of several pieces of manufacturing
equipment that are used to process, transport, and store
items. An item can be a part, raw material, a tool, a fixture,
or any other object that moves through the shop.
The equipment includes NC machine tools, robots,
conveyors, automated guided vehicles, automated storage
systems, and so on. Set of other items might be required
(e.g., specific cutting tools or fixtures).
Between processing tasks, some or all of these items must
be transported between the different pieces of equipment.
Input/output diagram for the general
shop-floor control problem .
Figure shows the shop-floor control system (SFCS) as a black-box entity that receives inputs
from an external (business) system/s and generates the device-specific instructions necessary to
enact the individual manufacturing tasks.
Primary inputs to the SFCS are the production requirements, which describe the parts to be
manufactured, and the resources, which describe the shared resources (items) to be used by the
equipment within the shop.
45. A sample bracket.
Manufacturing
system to illustrate
control
General Shop-Floor Control Problem
Precedence graph for a sample bracket. Operation task and resource summary for bracket arranged by feature