UNIT 4

FLEXIBLE
MANUFACTURING SYSTEM
(FMS)

FLEXIBLE MANUFACTURING
SYSTEM (FMS)
A flexible manufacturing system (FMS) is a
highly automated GT machine cell consisting of a
group of processing workstations (usually CNC
machine tools), interconnected by an automated
material handling and storage system, and
controlled by a distributed computer system.
FMS
would
be
flexible
automated
manufacturing system.

Where FMS can apply?

FMS technology can be applied in situations similar to
those identified for group technology and cellular
manufacturing; specifically,
Presently, the plant either
(1) produces parts in batches or
(2) uses manned GT cells and management wants to automate.

It must be possible to group a portion of the parts made

in the plant into part families whose similarities permit
them to be processed on the machines in the FMS.
The parts or products made by the facility are in the midvolume, mid-variety production range. The approximate
production volume range is
5000-75,000 parts/yr.

Manual Vs. FMS

The differences between implementing a
manually operated machine cell and installing an
FMS are:
(1) FMS requires a significantly greater capital
investment because new equipment is being
installed rather than existing equipment being
rearranged and
(2) FMS is technologically more sophisticated for
the human resources who must make it work.

Benefits of FMS
The benefits that can be expected from an FMS
include:
1. Increased machine utilization
2. Fewer machines required
3. Reduction in factory floor space required
4. Greater responsiveness to change
5. Reduced inventory requirements
6. Lower manufacturing lead times
7. Reduced direct labor requirements and higher
labor productivity
8. Opportunity for unattended production

What makes it flexible?

Three
capabilities
that
a
manufacturing system must possess to
be flexible:
(1)The
ability
to
identify
and
distinguish among the different part
or product styles processed by the
system,
(2)Quick changeover of operating
instructions, and
(3)Quick changeover of physical setup

To qualify as being flexible, a

manufacturing system should satisfy
several criteria. The following are four
reasonable tests of flexibility in an
automated manufacturing system:
1. Part variety test
2. Schedule change test
3. Error recovery test
4. New part test

Types of FMS

Flexible manufacturing systems can

be distinguished according to the
kinds of operations they perform:
(1)processing operations or
(2)assembly operations
Two other ways to classify FMSs are
by:
(3)Number of machines and
(4)Level of flexibility

Number of Machines
1. Single Machine Cell (SMC)
2. Flexible manufacturing Cell (FMC)
3. Flexible manufacturing System
(FMS)

Level of Flexibility
Application seems most common with
FMCs and FMSs.
Two categories are distinguished here:
Dedicated FMS
Random-order FMS

FMS COMPONENTS
(1)Workstations,
(2)Material handling and storage
system, and
(3)Computer
control
system.
In
addition, even though an FMS is
highly automated,
(4)People are required to manage and
operate the system.

Workstations

Load/Unload Stations
Machining Stations
Other Processing Stations
Assembly
Other Stations and Equipment

Material Handling and Storage

System
Functions of the Handling System
1. Random, independent movement of
workparts between stations
2. Handle a variety of workpart
configurations
3. Temporary storage
4. Convenient access for loading and
unloading workparts
5. Compatible with computer control

Material Handling
Equipment
The material handling function in an
FMS is often shared between two
systems:
(1)Primary handling system and
(2)Secondary handling system.

FMS Layout
Configurations
(1)
(2)
(3)
(4)
(5)

In-line layout,
Loop layout,
Ladder layout.
Open field layout, and
Robot-cemered cell.

Computer Control
System

Workstation control
Distribution of control instructions to
workstations
Production control
Traffic control
Shuttle control
Workpiece monitoring
Tool control
Performance monitoring and reporting
Diagnostics

Human Resources
Functions typically performed by humans
include:
(1)Loading raw workparts into the system,
(2)Unloading finished parts (or assemblies) from
the system
(3)Changing and setting tools
(4)Equipment maintenance and repair
(5)NC part programming in a machining system,
(6)Programming and operating the computer
system, and
(7)Overall management of the system

FMS APPLICATIONS AND BENEFITS

FMS technology is most widely

applied in machining operations. Other
applications include sheet metal
pressworking, forging, and assembly.
Flexible Machining Systems.
FMS milling and drilling applications
is more mature today than for FMS
turning applications.

FMS BENEFITS

Increased machine utilization

Fewer machines required
Reduction in factory floor space required
Greater responsiveness to change
Reduced inventory requirements
Lower manufacturing lead times
Reduced direct labor requirements
Higher labor productivity
Opportunity for unattended production.

FMS PLANNING AND

IMPLEMENTATION ISSUES
FMS Planning and Design Issues
The initial phase of FMS planning
must consider the parts that will he
produced by the system.
Part family considerations
Processing requirements
Physical characteristics of the
workparts
Production volume

After
the
part
family,
production
volumes, and similar part issues have been
decided, design of the system can proceed.
Important factors that must be specified in
FMS design include
Types of workstations
Variations in process routings and FMS
layout
Material handling system
Work-in-process and storage capacity
Tooling
Pallet fixtures

FMS Operational Issues

Scheduling and dispatching

Machine loading
Part routing
Part grouping
Tool management
Pallet and fixture allocation

QUANTITATIVE ANALYSIS OF
FLEXIBLE
MANUFACTURING SYSTEMS
(1)Deterministic models,
(2)Queueing models,
(3)Discrete event simulation, and
(4)Other
approaches,
including
heuristics.

Bottleneck Model

AUTOMATED GUIDED VEHICLE

SYSTEMS
An
automated
guided
vehicle
system (AGVS) is a material handling
system
that
uses
independently
operated,
self-propelled
vehicles
guided along defined pathways. The
vehicles are powered by on-board
batteries that allow many hours of
operation (8-16 hr is typical) between
recharging.

Types of Vehicles and AGVS

Applications
Automated guided vehicles can be
divided into the following three
categories:
(1)Driverless trains
(2)Pallet trucks and
(3)Unit load carriers

Applications of AGVS

Driverless train operations

Storage and distribution
Assembly line applications
Flexible manufacturing systems
Office mail delivery and hospital
material transport

Vehicle Guidance
Technology
Three technologies that are used in
commercial
systems
for
vehicle
guidance:
(1)Imbedded guide wires,
(2)Paint strips and
(3)Self-guided vehicles.

Vehicle Management and

Safety
Traffic Control
Two methods of traffic control used in
commercial AGV systems are:
(1)On-board vehicle sensing and
(2)Zone control

Vehicle Dispatching
(1)On-board control panel
(2)Remote call stations, and
(3)Central computer control

Safety
Vehicle's acquisition distance
Obstacle detection sensor
Emergency bumper.