Conventional manufacturing consisted of either job shops capable of variety but high cost, or transfer lines for high volume but limited to 1-2 parts. A flexible manufacturing system (FMS) integrates multiple machines via automated material handling controlled by a computer to manufacture various products. A manufacturing cell typically consists of 2-3 CNC machines plus a handling system. An FMS provides flexibility in machine functions, production, product mixing, routing, volumes and expansion through computer control of workstations, material storage and movement, and production monitoring. Reasons to implement FMS include increased efficiency and responsiveness compared to conventional systems. Careful planning is required to implement FMS successfully.

1. Conventional Manufacturing
Consisted of 2 varieties
1. Job Shop type systems were capable of
large variety of product, but at a high
cost.
2. Transfer lines could produce large
volumes of a product at a reasonable
cost, but were limited to the production
of one, two, or very few different parts.

2. What is FMS/FAS?
 A FMS/FAS is one manufacturing
machine, or multiple machines that are
integrated by an automated material
handling system, whose operation is
managed by a computerized control
system. An FMS can be reconfigured
by computer control to manufacture
various products.

3. What is a manufacturing Cell?
 A manufacturing cell usually consists of two
or three processing workstations (typically
CNC Machining or turning centers) plus a part
handling system.
The following two slides contain a CAD layout
and picture of the RIT Mfg Eng Tech Class of
2000’s manufacturing work cell.

4. Manufacturing Workcell

5. Flexibility in a FMS/FAS
 Machine flexibility
 Production flexibility
 Mix flexibility
 Product flexibility
 Routing flexibility
 Volume flexibility
 Expansion flexibility

6. Components of an FMS/FAS
 Workstations
 Material handling and storage system
 Computer control system
 People to manage and operate the
system

7. Types of Workstations
 Load/unload Stations
 Machining Stations
 Other Processing Stations
 Assembly
 Other Stations and Equipment (like
Inspection)

8. Layout Configurations for Material
Handling System
 In-line layout
 In-line Transfer
 Conveyor
 Rail guided vehicle
 Loop layout
 Conveyor system
 In-Floor towline carts

9. Layouts Continued
 Ladder layout
 Conveyor System
 Automated Guided Vehicle (AGV)
 Rail guided Vehicle
 Open field layout
 AGV
 In-line towline carts
 Robot-centered layout

10. Computer Control Systems
 Workstation
 Distribution of control instructions to
workstations
 Production control
 Traffic control
 Shuttle control
 Workpiece monitoring

11. Computer Controls (cont)
 Tool control
 Tool locations
 Tool life monitoring
 Performance monitoring and reporting
 Diagnostics

12. Why Implement a FMS/FAS?
 Increased machine utilization
 Fewer machines required
 Reduction in factory floor space
required
 Greater responsiveness to change
 Reduced inventory requirements
 Lower manufacturing lead times

13. Why Implement a FMS/FAS?
(continued)
 Reduced direct labor requirements and
higher labor productivity
 Opportunity for unattended production

14. FMS Implementation Issues
 Part family considerations
 Processing requirements
 Physical characteristics or workparts
 Production volume
 Scheduling and dispatching
 Machine loading
 Part routing

15. FMS Issues (cont)
 Part grouping
 Tool management
 Pallet and fixture allocation
 Requires management commitment and
planning
 Major invest of time and money