DEFINITION FMS consists of a group of processing work stations interconnected by means of an automated material handling and storage system and controlled by integrated computer control system. A flexible manufacturing system (FMS) is an arrangement of machines interconnected by a transport system. The transporter carries work to the machines on pallets or other interface units so that work-machine registration is accurate, rapid and automatic. A central computer controls both machines and transport system.
Flexibility in manufacturing means the ability to deal with slightly or greatly mixed parts, to allow variation in parts assembly and variations in process sequence, change the production volume and change the design of certain product being manufactured.
BASIC COMPONENTS OF FMS Workstations- They are typically CNC machine tools that perform machining operation on families of parts. Automated Material Handling and Storage system- They are used to transport work parts and subassembly parts between the processing stations, sometimes incorporating storage into function. Computer Control System- It is used to coordinate the activities of the processing stations and the material handling system in the FMS.
WORKSTATIONS Machining Centers Load and Unload stations Assembly Work stations Inspection Stations Forging Stations Sheet Metal Processing
FUNCTIONS OF AUTOMATED MATERIAL HANDLING AND STORAGE SYSTEM Random and independent movement of work parts between workstations Handling of a variety of work part configuration Temporary storage Convenient access for loading and unloading of work parts
FUNCTIONS OF COMPUTER CONTROL SYSTEM Control of each workstation Distribution of control instruction to work station Production control Shuttle control Work handling system and monitoring System Performance and reporting
TYPES OF FMS LAYOUT Progressive or Line type Loop type Ladder type Open Field type Robot Centered Type
TYPES OF FMS Sequential FMS Random FMS Dedicated FMS Engineered FMS Modular FMS
OBJECTIVES OF AN FMS Decreased Lead Times Increased Through put Increased machine utilization Improved Due Date Reliability Decreased Work in Progress Increased Quality
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 Consistent and better quality, due to the automated control Lower cost/unit of output, due to the greater productivity using the same number of workers Savings from the indirect labor, from reduced errors, rework, repairs and rejects
DISADVANTAGES OF FMS IMPLEMENTATION 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 positioning and precise timing necessary to process a component Sophisticated manufacturing systems
FORDS’ FLEXIBLE MANUFACTURING SYSTEM Ford has poured $4,400,000 into overhauling its Torrence Avenue plant in Chicago. The flexible manufacturing systems used in five of Ford Motor Company's plants will yield a $2.5 billion savings. By the year 2010, Ford will have converted 80 percent of its plants to flexible manufacturing.